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Subaru 2003 LEGACY Service Manual

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2003 LEGACY SERVICE MANUAL

BODY SECTION

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
HVAC SYSTEM (DIAGNOSTICS)
AIRBAG SYSTEM
AIRBAG SYSTEM (DIAGNOSTICS)
SEAT BELT SYSTEM
LIGHTING SYSTEM
WIPER AND WASHER SYSTEMS
ENTERTAINMENT
COMMUNICATION SYSTEM
GLASS/WINDOWS/MIRRORS
BODY STRUCTURE
INSTRUMENTATION/DRIVER INFO
SEATS
SECURITY AND LOCKS
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
EXTERIOR/INTERIOR TRIM
EXTERIOR BODY PANELS
EXTERIOR/INTERIOR TRIM
AC
AC
AB
AB
SB
LI
WW
ET
COM
GW
BS
IDI
SE
SL
SR
EI
EB
EI
G2300GE7

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Summary of Contents for Subaru 2003 LEGACY

  • Page 1: Body Section

    2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION HVAC SYSTEM (HEATER, VENTILATOR AND A/C) HVAC SYSTEM (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) This service manual has been prepared to provide SUBARU service personnel SEAT BELT SYSTEM with the necessary information and data for the correct maintenance and repair of SUBARU vehicles.
  • Page 2 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) G2300GE7...

  • Page 3: Table Of Contents

    SECURITY AND LOCKS Page General Description ..................2 Door Lock Control System ................8 Keyless Entry System ................11 Front Inner Remote ...................19 Front Outer Handle ...................20 Front Door Latch Assembly...............21 Front Door Lock Actuator ................22 Rear Inner Remote..................23 Rear Outer Handle ..................24 Rear Door Latch Assembly ...............25 Rear Door Lock Actuator................26 Rear Gate Outer Handle ................27...

  • Page 4: General Description

    GENERAL DESCRIPTION SECURITY AND LOCKS 1. General Description A: SPECIFICATIONS B: COMPONENT 1. DOOR LOCK ASSEMBLY FRONT ( 1 ) ( 3 ) ( 7 ) ( 2 ) ( 6 ) ( 8 ) ( 5 ) ( 4 ) REAR ( 6 ) ( 1 )
  • Page 5 GENERAL DESCRIPTION SECURITY AND LOCKS 2. TRUNK LID AND REAR GATE LOCK TRUNK REAR GATE ( 6 ) ( 1 ) ( 4 ) ( 5 ) ( 1 ) ( 2 ) ( 3 ) ( 2 ) ( 8 ) ( 7 ) ( 3 ) SL-00115...
  • Page 6 GENERAL DESCRIPTION SECURITY AND LOCKS 3. HOOD LOCK AND REMOTE OPENERS ( 4 ) ( 5 ) WAGON ( 3 ) ( 4 ) ( 5 ) SEDAN ( 3 ) ( 2 ) ( 6 ) HOOD ( 3 ) ( 1 ) SL-00116 (1) Hood lock ASSY...
  • Page 7 GENERAL DESCRIPTION SECURITY AND LOCKS 4. IMMOBILIZER SYSTEM ( 2 ) ( 1 ) ( 4 ) ( 3 ) IM-00040 (1) Antenna (3) Immobilizer control module (IMM ECM) (2) Immobilizer indicator light (LED bulb) (4) Transponder NOTE: IMM ECM location for RHD model is symmetrically opposite. SL-5...
  • Page 8 GENERAL DESCRIPTION SECURITY AND LOCKS 5. KEYLESS ENTRY SYSTEM ( 2 ) ( 1 ) ( 3 ) SL-00117 (1) Keyless entry control module (2) Rear gate latch switch (Wagon) (3) Door switch SL-6...
  • Page 9 GENERAL DESCRIPTION SECURITY AND LOCKS C: CAUTION • Connect connectors and hoses securely during reassembly. • Before disassembling or reassembling parts, • After reassembly, ensure all functional parts always disconnect battery ground cable. When operate smoothly. repairing radio, control module, etc. which are •...

  • Page 10: Door Lock Control System

    DOOR LOCK CONTROL SYSTEM SECURITY AND LOCKS 2. Door Lock Control System A: SCHEMATIC <Ref. to WI-240, SCHEMATIC, Keyless Entry System.> B: INSPECTION 1. SYMPTOM CHART Symptom Repair order Reference Door lock control system does not 1. Check the fuse. <Ref.
  • Page 11 DOOR LOCK CONTROL SYSTEM SECURITY AND LOCKS 3. CHECK POWER SUPPLY AND GROUND CIRCUIT Step Value CHECK POWER SUPPLY. 10 V Go to step 2. Check the harness 1) Disconnect the keyless entry control mod- for open circuits or ule harness connector. shorts between 2) Measure the voltage between the harness the keyless entry...
  • Page 12 DOOR LOCK CONTROL SYSTEM SECURITY AND LOCKS Step Value CHECK DOOR LOCK SWITCH. 1 MΩ Check the harness Replace the door Measure the resistance between the door lock for open circuits or lock switch (actua- switch terminals when moving the door lock shorts between tor).

  • Page 13: Keyless Entry System

    KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 3. Keyless Entry System A: SCHEMATIC <Ref. to WI-240, SCHEMATIC, Keyless Entry System.> B: ELECTRICAL SPECIFICATION 10 9 18 17 16 15 14 13 12 11 SL-00118 Content Terminal No. Measuring condition Key warning switch 1 (INPUT) Battery voltage is present when inserting the key into the ignition switch.
  • Page 14 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS C: INSPECTION 1. SYMPTOM CHART Symptom Repair order Reference None of the functions of the keyless 1. Check the transmitter battery. <Ref. to SL-13, CHECK TRANSMITTER BAT- entry system operate. TERY, INSPECTION, Keyless Entry System.> 2.
  • Page 15 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 2. CHECK TRANSMITTER BATTERY Step Value CHECK TRANSMITTER BATTERY. The transmitter Replace the trans- 1) Remove the battery from the transmitter. battery is OK. Fur- mitter battery. <Ref. to SL-39, REMOVAL, Keyless Trans- ther inspection is mitter.>...
  • Page 16 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 5. CHECK REGISTRATION CONNECTOR CIRCUIT Step Value REGISTRATION CONNECTOR INPUT VOLT- 10 V Go to step 2. Repair harness, AGE INSPECTION and (or) connec- 1) Turn ignition switch ON. tor. 2) Disconnect registration connector. 3) Measure voltage between keyless entry control module harness connector and chassis ground.
  • Page 17 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 6. CHECK DOOR SWITCH Step Value CHECK DOOR SWITCH CIRCUIT. Go to step 2. Go to step 3. Measure the voltage between the keyless entry control module harness connector termi- nal and chassis ground. Connector &...
  • Page 18 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 7. CHECK KEY WARNING SWITCH Step Value CHECK FUSE. The fuse is not blown. Go to step 2. Replace the fuse Remove and visually check fuse No. 6 (in the with a new one. main fuse box).
  • Page 19 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 8. CHECK HAZARD LIGHT OPERATION Step Value CHECK HAZARD LIGHT OPERATION. Hazard light blinks. Go to step 2. Check hazard light Make sure the hazard light blinks when hazard circuit. switch is turned ON. Does hazard light brink? CHECK OUTPUT SIGNAL.
  • Page 20 KEYLESS ENTRY SYSTEM SECURITY AND LOCKS 10.CHECK IGNITION SWITCH ILLUMINATION CIRCUIT Step Value CHECK IGNITION SWITCH ILLUMINATION 10 V Go to step 2. Check harness for POWER SUPPLY. open circuit or 1) Disconnect the ignition switch illumination shorts between harness connector. the ignition switch 2) Measure voltage between the ignition illumination and...

  • Page 21: Front Inner Remote

    FRONT INNER REMOTE SECURITY AND LOCKS 4. Front Inner Remote A: REMOVAL 1) Remove the door trim. <Ref. to EI-30, REMOV- AL, Front Door Trim.> 2) Remove the sealing cover. <Ref. to EB-13, RE- MOVAL, Front Sealing Cover.> 3) Remove the two rod joints. 4) Remove the screw, and detach the front inner remote.

  • Page 22: Front Outer Handle

    FRONT OUTER HANDLE SECURITY AND LOCKS 5. Front Outer Handle A: REMOVAL 1) Remove the front door latch assembly. <Ref. to SL-21, REMOVAL, Front Door Latch Assembly.> 2) Remove the two bolts. Remove the front outer handle (A). ( A ) SL-00073 CAUTION: Do not use excessive force to remove the door...

  • Page 23: Front Door Latch Assembly

    FRONT DOOR LATCH ASSEMBLY SECURITY AND LOCKS 6. Front Door Latch Assembly A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove the front door trim. <Ref. to EI-30, RE- MOVAL, Front Door Trim.> 3) Remove the sealing cover. <Ref. to EB-13, RE- MOVAL, Front Sealing Cover.>...

  • Page 24: Front Door Lock Actuator

    FRONT DOOR LOCK ACTUATOR SECURITY AND LOCKS 7. Front Door Lock Actuator A: REMOVAL 1) Remove the front door latch assembly. <Ref. to SL-21, REMOVAL, Front Door Latch Assembly.> 2) Remove the bolt. Remove the front door lock ac- tuator. SL-00075 B: INSTALLATION Install in the reverse order of removal.

  • Page 25: Rear Inner Remote

    REAR INNER REMOTE SECURITY AND LOCKS 8. Rear Inner Remote A: REMOVAL 1) Remove the rear door trim. <Ref. to EI-31, RE- MOVAL, Rear Door Trim.> 2) Remove the sealing cover. <Ref. to EB-16, RE- MOVAL, Rear Sealing Cover.> 3) Remove the two rod joints. 4) Remove the screw, and detach the inner remote.

  • Page 26: Rear Outer Handle

    REAR OUTER HANDLE SECURITY AND LOCKS 9. Rear Outer Handle A: REMOVAL 1) Remove the rear door trim. <Ref. to EI-31, RE- MOVAL, Rear Door Trim.> 2) Remove the sealing cover. <Ref. to EB-16, RE- MOVAL, Rear Sealing Cover.> 3) Remove the rear inner remote. <Ref. to SL-23, REMOVAL, Rear Inner Remote.>...

  • Page 27: Rear Door Latch Assembly

    REAR DOOR LATCH ASSEMBLY SECURITY AND LOCKS 10.Rear Door Latch Assembly A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove the rear door trim. <Ref. to EI-31, RE- MOVAL, Rear Door Trim.> 3) Remove the sealing cover. <Ref. to EB-16, RE- MOVAL, Rear Sealing Cover.>...

  • Page 28: Rear Door Lock Actuator

    REAR DOOR LOCK ACTUATOR SECURITY AND LOCKS 11.Rear Door Lock Actuator A: REMOVAL 1) Remove the rear door latch assembly. <Ref. to SL-25, REMOVAL, Rear Door Latch Assembly.> 2) Remove the bolt. Remove the rear door lock ac- tuator. SL-00080 B: INSTALLATION Install in the reverse order of removal.

  • Page 29: Rear Gate Outer Handle

    REAR GATE OUTER HANDLE SECURITY AND LOCKS 12.Rear Gate Outer Handle A: REMOVAL 1) Remove the rear gate lower trim. <Ref. to EI-44, REMOVAL, Rear Gate Trim.> 2) Remove the rear gate latch rod. 3) Remove the nut holding the rear gate outer han- dle, and then remove the rear gate outer handle.

  • Page 30: Rear Gate Latch Assembly

    REAR GATE LATCH ASSEMBLY SECURITY AND LOCKS 13.Rear Gate Latch Assembly A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove the rear gate lower trim. <Ref. to EI-44, REMOVAL, Rear Gate Trim.> 3) Remove the rear gate key cylinder rod. 4) Remove the rear gate outer handle.

  • Page 31: Rear Gate Latch Lock Actuator

    REAR GATE LATCH LOCK ACTUATOR SECURITY AND LOCKS 14.Rear Gate Latch Lock Actua- A: REMOVAL 1) Remove the rear gate latch assembly. <Ref. to SL-28, REMOVAL, Rear Gate Latch Assembly.> 2) Remove the rear gate lock actuator. SL-00083 B: INSTALLATION Install in the reverse order of removal.

  • Page 32: Trunk Lid Lock Assembly

    TRUNK LID LOCK ASSEMBLY SECURITY AND LOCKS 15.Trunk Lid Lock Assembly A: REMOVAL 1) Remove the trunk lid key cylinder rod. 2) Remove the lock assembly cover (A). 3) Remove the nut while holding the lock assembly. Remove the lock assembly (B). ( B ) ( A ) SL-00084...

  • Page 33: Front Hood Lock Assembly

    FRONT HOOD LOCK ASSEMBLY SECURITY AND LOCKS 16.Front Hood Lock Assembly A: REMOVAL 1) Open the hood. 2) Remove the bolt. Remove the hood lock assem- bly. 3) Remove the release cable from the lock assem- bly. SL-00087 B: INSTALLATION Install in the reverse order of removal.

  • Page 34: Remote Openers

    REMOTE OPENERS SECURITY AND LOCKS 17.Remote Openers 6) Remove the cable from the striker. A: REMOVAL 1. HOOD OPENER 1) Remove the release cable from the hood lock. ( 1 ) 2) Remove the bolt. Remove the opener lever. ( 2 ) SL-00120 (1) Striker (2) Cable...
  • Page 35 REMOTE OPENERS SECURITY AND LOCKS 6) Rotate the fuel lock inside the quarter panel to left and remove. SL-00092 B: INSTALLATION 1. HOOD OPENER Install in the reverse order of removal. 2. TRUNK LID OPENER Install in the reverse order of removal. 3.

  • Page 36: Ignition Key Lock

    IGNITION KEY LOCK SECURITY AND LOCKS 18.Ignition Key Lock A: REPLACEMENT 1) Disconnect ground cable from battery. 2) Remove the steering column. <Ref. to PS-28, REMOVAL, Tilt Steering Column.> 3) Secure the steering column in a vise. Remove the bolt with a drill. SL-00093 4) Remove the ignition key lock.

  • Page 37: Key Lock Cylinders

    KEY LOCK CYLINDERS SECURITY AND LOCKS 19.Key Lock Cylinders A: REPLACEMENT 1. FRONT DOOR 1) Remove the front outer handle. <Ref. to SL-20, REMOVAL, Front Outer Handle.> 2) Remove the rod clamp. Replace the key cylin- der. SL-00095 2. TRUNK LID 1) Remove the trunk trim.

  • Page 38: Immobilizer Control Module

    IMMOBILIZER CONTROL MODULE SECURITY AND LOCKS 20.Immobilizer Control Module A: REMOVAL NOTE: The following positions for removal and installation are for LHD models. The positions for RHD models are symmetrically opposite. 1) Disconnect ground cable from battery. 2) Remove instrument panel lower cover. <Ref. to EI-35, REMOVAL, Instrument Panel Assembly.>...

  • Page 39: Immobilizer Antenna

    IMMOBILIZER ANTENNA SECURITY AND LOCKS 21.Immobilizer Antenna A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove instrument panel lower cover. <Ref. to EI-35, REMOVAL, Instrument Panel Assembly.> 3) Remove screws, separate upper column cover and lower column cover. SL-00122 4) Disconnect immobilizer antenna connector (A) from immobilizer control module.

  • Page 40: Keyless Entry Control Module

    KEYLESS ENTRY CONTROL MODULE SECURITY AND LOCKS 22.Keyless Entry Control Mod- A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove glove box. <Ref. to EI-32, REMOVAL, Glove Box.> 3) Remove nut, then remove keyless entry control module (B) and the other electrical control module (A) while disconnecting connector.

  • Page 41: Keyless Transmitter

    KEYLESS TRANSMITTER SECURITY AND LOCKS 23.Keyless Transmitter C: INSPECTION A: REMOVAL 1. TRANSMITTER BATTERY 1) Measure voltage between battery (+) terminal 1. TRANSMITTER BATTERY and (–) terminal. Remove battery from transmitter. NOTE: NOTE: • Battery discharge occurs during measurement. To prevent static electricity damage to transmitter Complete measurement within 5 seconds.
  • Page 42 KEYLESS TRANSMITTER SECURITY AND LOCKS MEMO: SL-40...

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