Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Power Sunroof

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See Figures 1 and 2

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Fig. Fig. 1: Exploded view of the power sunroof assembly-except Impreza, SVX and 1995-96 Legacy



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Fig. Fig. 2: Exploded view of the power sunroof assembly-1995-96 Legacy

The sunroof assembly is equipped with water drain tubes. It is important to keep these drain tubes open. So it is recommended to blow compressed air through the drain tubes at regular intervals, in order to keep the drain tubes clear.

REMOVAL & INSTALLATION



Except Impreza and SVX
SUNROOF LID ASSEMBLY

See Figure 3

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Fig. Fig. 3: Remove these nuts to remove the sunroof lid-except Impreza and SVX

  1. Completely close the sunroof glass. Completely open the sunshade. Remove the bracket cap and screws and detach the bracket cover.
  2.  
  3. Completely close the sunroof lid assembly and lift it up. Remove the 8 nuts, (6 nuts on 1995-96 Legacy) from the left and right ring bracket.
  4.  
  5. Working from inside the vehicle, slightly raise the sunroof lid assembly until it is disengaged from the link bracket. Hold both ends of the lid assembly and remove it at an angle.
  6.  

SUNSHADE
  1. Unhook the sunshade hooks. Move the sunroof lid assembly rearward.
  2.  
  3. Set the sunshade to the FORWARD position and remove the retaining nuts from both sides of the sunshade.
  4.  
  5. Installation is the reverse order of the removal procedure.
  6.  

SUNROOF FRAME

See Figure 4

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Fig. Fig. 4: Remove these nuts to remove the sunroof frame-except Impreza and SVX

  1. Remove the sunroof trim. Disconnect the front and rear drain tubes.
  2.  
  3. On 1995-96 Legacy, remove the sunroof switch, and the center and rear room lamps.
  4.  
  5. Remove the bolts which hold the sunroof frame and detach the sunroof frame.
  6.  
  7. Installation is the reverse order of the removal procedure.
  8.  

SUNROOF MOTOR

See Figure 5

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Fig. Fig. 5: Remove these screws and nut to remove the sunroof motor-except Impreza and SVX

  1. Disconnect the negative battery cable. Remove the roof trim.
  2.  
  3. Remove the sunroof motor nut and harness coupler and remove the sunroof motor.
  4.  
  5. Installation of the motor is the reverse order of the removal procedure.The sunroof is operated by a switch, which is usually located in the headliner. The system is consists of the sunroof switch, motor drive cables and circuit breaker and a relay. The sunroof can be closed manually, (should it be necessary) by removing the headliner plug, insert the handle and turn the gear to close the sunroof.
  6.  

Impreza and SVX

See Figure 6

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Fig. Fig. 6: Exploded view of the power sunroof assembly-Impreza and SVX

SUNROOF PANEL

See Figures 6 and 7

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Fig. Fig. 7: Detach the trim from the trim holder and remove from the sunroof panel-Impreza and SVX

  1. Open the sunroof approximately 1 / 3 of the way.
  2.  
  3. Remove the clips attached to the front side of the sunroof trim by pulling the trim from the inside of the compartment.
  4.  
  5. Move the trim forward and detach the trim from the holder.
  6.  
  7. Close the sunroof, remove the sunroof panel retaining nuts and remove the sunroof from the vehicle.
  8.  
  9. Installation is the reverse order of the removal procedure. Make sure the sunroof is free from slack and noise when opened and closed. Adjust as necessary.
  10.  

SUNROOF MOTOR AND RELAY

See Figure 6

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the rear quarter trim, pillar trim and roof trim
  4.  
  5. Disconnect the connector and remove the sunroof motor retaining screws. Pull out the motor and relay.
  6.  
  7. Installation is the reverse order of the removal procedure.
  8.  

SUNROOF FRAME

See Figures 6, 7, 8, 9, 10, 11 and 12

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Fig. Fig. 8: Loosen, but do not remove, these two mounting bolts near the motor-Impreza and SVX



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Fig. Fig. 9: Remove the two outside bolts, eight nuts and four adjusting nuts, then remove the sunroof frame-Impreza and SVX



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Fig. Fig. 10: Loosen the set bracket mounting bolt-Impreza and SVX



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Fig. Fig. 11: Insert the frame rear end slit to the two bolts temporary fitted to the roof brace-Impreza and SVX



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Fig. Fig. 12: Align the frame to the reference pin installed on the roof-Impreza and SVX

  1. Remove the rear quarter trim, pillar trim and roof trim.
  2.  
  3. Remove the sunroof panel as outlined in this section.
  4.  
  5. Disconnect the drain tubes.
  6.  
  7. Disconnect the connector between the body harness and the sunroof harness.
  8.  
  9. Loosen, but do not remove, the two mounting bolts near the motor.
  10.  
  11. Remove the two outside bolts, eight nuts and four adjusting nuts and remove the sunroof frame.
  12.  
  13. Loosen the set bracket mounting bolt.
  14.  

To install:

The sunroof trim reference pin must be fitted in the holder notch.

  1. Insert the frame rear end slit to the two bolts temporary fitted to the roof brace.
  2.  
  3. Align the frame to the reference pin installed on the roof.
  4.  
  5. Tighten the adjusting nut to set the frame to its highest position. Temporarily tighten the nuts and bolts.
  6.  
  7. Install the sunroof panel as outlined in this section.
  8.  
  9. Adjust the height by turning the adjusting screw. The difference in height between the roof panel and the sunroof panel should be 0-0.039 in. (0 -1.0mm)
  10.  
  11. Adjust the front, rear, right and left side partitions. The partitions clearance should be 0.021-0.25 in. (5.4-6.4mm).
  12.  
  13. Tighten the set bracket mounting bolts.
  14.  
  15. Tighten the all remaining bolts and nuts.
  16.  
  17. Install the drain tubes securely.
  18.  
  19. Install the roof trim.
  20.  
  21. Install the garnish and place the garnish joint at the rear center of the body.
  22.  
  23. Install the sunroof trim, pillar trim and rear quarter trim.
  24.  
  25. After complete assembly, check the following:

    The garnish must be free of waves.
     
    There must be no clearance between the garnish and the sunroof trim when the sunroof is fully closed.
     
    The sunroof must be free from slack and noise when it is fully opened and closed.
     

  26.  

ADJUSTMENTS



Except Impreza and SVX
HEIGHT ADJUSTMENT

See Figure 13

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Fig. Fig. 13: Height adjustment-except Impreza and SVX

  1. Place shim(s) between the link bracket and the lid assembly to align the sunroof with the roof panel.
  2.  
  3. The difference in the height between the roof and the main seal should be adjusted to within the 0.028-0.059 in. (0.7-1.5mm) range.
  4.  

HORIZONTAL ADJUSTMENT
  1. Loosen the 8 nuts which hold the sunroof lid assembly.
  2.  
  3. Move the sunroof lid assembly to either side, along the oblong hole at the stay location, until proper adjustment is reached. Then tighten the nuts.
  4.  
  5. Check to see if the deflector is positioned at a proper height. The height of the deflector cannot be adjusted. Repair or replace the deflector if it is deformed or damaged.
  6.  

SUNROOF CLOSING FORCE CHECK

See Figure 14

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Fig. Fig. 14: Sunroof closing force check-all except Impreza and SVX

  1. After installing all removed parts, using a second person, have them hold the switch to close the sunroof while measuring the force required to stop the sunroof with a suitable spring scale.
  2.  
  3. Read the force on the scale as soon as the glass stops moving, then immediately release the switch and spring scale. The closing force should be 44-55 lbs. (20-25 kg).
  4.  
  5. If the force required to stop the sunroof is not within specifications, adjust it, by turning the sunroof motor clutch adjusting nut (using the handle furnished by the manufacturer). Turn the nut clockwise to increase the force and counterclockwise to decrease the force.
  6.  
  7. After the proper adjustment has been made, install a new lockwasher and bend it against the flat of the adjusting nut.
  8.  

Impreza and SVX
HEIGHT ADJUSTMENT

See Figure 15

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Fig. Fig. 15: Height adjustment-Impreza and SVX

  1. Adjust the height by turning the adjusting screw. The difference in height between the roof panel and the sunroof panel should be 0-0.039 in. (0-1.0mm)
  2.  

HORIZONTAL ADJUSTMENT

See Figure 16

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Fig. Fig. 16: Horizontal adjustment-Impreza and SVX

  1. Loosen the 8 nuts which hold the sunroof lid assembly.
  2.  
  3. Adjust the front, rear, right and left side partitions. The partitions clearance should be 0.021-0.25 in. (5.4-6.4mm).
  4.  

 
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