1999 SUBARU LEGACY Service Repair Manual

24. Crossbar
A: REMOVAL
1) Loosen and remove TORX bolt T30 from the
top of each crossbar end support.
2) Rotate lower clamp on the bottom of each end
support downward approximately 90É.
B5M0576A
3) Remove crossbar.
B: INSTALLATION
1. FRONT CROSSBAR
NOTE:
Front crossbar has ªMAXIMUM LOAD 100LBS.
EVENLY DISTRIBUTEDº label on LH side.
1) Rotate lower clamp on the bottom of each end
support downward approximately 90É.
2) With the front direction arrow label on the top
right side of the crossbar pointing toward the front
of the vehicle, carefully place the crossbar across
the top of the vehicle so that the crossbar end
supports rest on the top of the roof rails approxi-
mately 127 mm (5 in) rearward from the joint
between the front roof rail support and the roof rail.
Length:
A: 127 mm (5 in)
B5M0577A
3) Rotate the lower clamp up to the bottom of the
roof rail and loose assemble the TORX bolt T30,
through the top of the end support and into the
threaded insert in the lower clamp on each end of
the crossbar.NOTE:
It may be necessary to squeeze the lower clamp
and the end support together to compress the pads
and gain a better alignment of the pieces while
trying to start the screw. Be careful not to cross
thread the screw in the insert.
4) Tighten TORX bolt T30.
Tightening torque:
3.7
±0.3 N´m (0.38±0.03 kg-m, 2.75±0.22
ft-lb)
B5M0578A
2. REAR CROSSBAR
NOTE:
Rear crossbar does not have the ªMAXIMUM
LOAD 100LBS. EVENLY DISTRIBUTEDº label.
1) Rotate lower clamp on the bottom of each end
support downward approximately 90É.
2) With the front direction arrow label on the top
right side of the crossbar pointing toward the front
of the vehicle, carefully place the crossbar across
the top of the vehicle so that the crossbar end
supports rest on the top of the roof rails approxi-
mately 127 mm (5 in) forward from the joint
between the rear roof rail support and the roof rail.
Length:
B: 127 mm (5 in)
B5M0579A
3) Rotate the lower clamp up to the bottom of the
roof rail and loose assemble the TORX bolt T30,
through the top of the end support and into the
threaded insert in the lower clamp on each end of
the crossbar.
65
[W24B2]5-1SERVICE PROCEDURE
24. Crossbar

NOTE:
It may be necessary to squeeze the lower clamp
and the end support together to compress the pads
and gain a better alignment of the pieces while
trying to start the screw. Be careful not to cross
thread the screw in the insert.
4) Tighten TORX bolt T30.
Tightening torque:
3.7
±0.3 N´m (0.38±0.03 kg-m, 2.75±0.22
ft-lb)
B5M0578A
66
5-1[W24B2]SERVICE PROCEDURE
24. Crossbar

1. Sunroof
Entry of water into compartment(1) Check roof panel and glass lid assembly for improper or
poor sealing.
(2) Check drain tube for clogging.
(3) Check sunroof frame seal and body for improper fit.
Booming noise(1) Check glass lid assembly and roof panel for improper
clearance.
(2) Check sun shade and roof trim for improper clearance.
Abnormal motor noise(1) Check motor for looseness.
(2) Check gears and bearings for wear.
(3) Check cable for wear.
(4) Check cable pipe for deformities.
Failure of sunroof to operate
(Motor operates properly.)(1) Check guide rail for foreign particles.
(2) Check guide rail for improper installation.
(3) Check parts for mutual interference.
(4) Check cable slider for improper clinching.
(5) Check cable for improper installation.
(6) Check clutch adjustment nut for improper tightness.
Motor does not rotate or rotates improperly.
(Use sunroof wrench to check operation.)(1) Check fuse for blowout.
(2) Check switch for improper function.
(3) Check motor for incorrect terminal voltage.
(4) Check relay for improper operation.
(5) Check poor grounding system.
(6) Check cords for discontinuity and terminals for poor con-
nections.
(7) Check limit switch for improper operation.
67
[K100]5-1DIAGNOSTICS
1. Sunroof

MEMO:
68
5-1DIAGNOSTICS

1. Door Alignment
B5M0051A
2
5-2[S100]SPECIFICATIONS AND SERVICE DATA
1. Door Alignment

1. Front Door
B5M0052B
(1) Gusset
(2) Weatherstrip (Outer)
(3) Stabilizer (Outer)
(4) Stabilizer (Inner)
(5) Protector
(6) Stopper
(7) Knock pin(8) Checker
(9) Sealing cover
(10) Door panel
(11) Lower hinge
(12) Upper hinge
(13) Door sash (Rear)
(14) Door sash (Front)Tightening torque: N´m (kg-m, ft-lb)
T1:
7.4±2.0 (0.75±0.2, 5.4±1.4)
T2:13±3 (1.3±0.3, 9.4±2.2)
T3:25±3 (2.5±0.3, 18.1±2.2)
T4:29±5 (3.0±0.5, 21.7±3.6)
3
[C100]5-2COMPONENT PARTS
1. Front Door

2. Rear Door
B5M0466B
(1) Weatherstrip (Outer)
(2) Stabilizer (Outer)
(3) Stabilizer (Inner)
(4) Stopper
(5) Knock pin
(6) Checker
(7) Seating cover(8) Door panel
(9) Lower hinge
(10) Upper hinge
(11) Door sash (Rear)
(12) Door sash (Front)
(13) Rear door catcherTightening torque: N´m (kg-m, ft-lb)
T1:
7.4±2.0 (0.75±0.2, 5.4±1.4)
T2:14±4 (1.4±0.4, 10.1±2.9)
T3:25±3 (2.5±0.3, 18.1±2.2)
T4:29±5 (3.0±0.5, 21.7±3.6)
T5:37±10 (3.8±1.0, 27.5±7.2)
4
5-2[C200]COMPONENT PARTS
2. Rear Door

3. Fixed Glass
B5M0502A
(1) Windshield glass
(2) Dam rubber
(3) Molding(4) Locate pin
(5) Fastener
(6) Garnish(7) Rear window glass
(8) Rear quarter glass
5
[C300]5-2COMPONENT PARTS
3. Fixed Glass