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Subaru LEGACY 2004 Service Manual

Subaru LEGACY 2004 Service Manual

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2004 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 (AUTO A/C)

(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

AC

AC(diag)

AB

AB(diag)

SB

LI

WW

ET

COM

GW

BS

IDI

SE

SL

SR

EI

EB

G2320GE7

Table of Contents

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Table of Contents

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Summary of Contents for Subaru LEGACY 2004

Page 1: Body Section
AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 2 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 3: Table Of Contents
HVAC SYSTEM (HEATER, VENTILATOR AND A/C) Page General Description ..................2 Refrigerant Pressure with Manifold Gauge Set.........19 Refrigerant Recovery Procedure...............20 Refrigerant Charging Procedure ...............21 Refrigerant Leak Check ................24 Compressor Oil ..................25 Blower Motor Unit Assembly ..............26 Blower Motor .....................27 Power Transistor (Auto A/C Model) ............28 Blower Resistor (Manual A/C Model) ............29 Heater Core....................30 Control Unit (Manual A/C Model) ..............31...
Page 4: General Description
General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 1. General Description A: SPECIFICATION 1. HEATER SYSTEM Item Specification On condition • Mode selector switch: HEAT • Temperature control switch: FULL HOT 5.2 kW (4,471 kcal/h, • Temperature difference between hot water Heating capacity 17,743 BTU/h) or more and inlet air: 65!C (149!F)
Page 5 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) Motor type Magnet H4 model: 90 W Power consumption Condenser fan (Sub fan) H6 model: 160 W H4 model: 300 mm (11.8 in) Fan outer diameter H6 model: 320 mm (12.6 in) Motor type Magnet H4 model: 90 W...
Page 6 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) Type Corrugated fin (Sub cool type) Core face area 0.186 m (2.002 sq ft) Condenser Core thickness 16 mm (0.63 in) Radiation area 5.49 m (59.09 sq ft) Receiver drier Effective inner capacity 250 cm (15.26 cu in) Expansion valve...
Page 7 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) B: COMPONENT 1. HEATER COOLING UNIT • Auto A/C model (10) (12) (11) (13) (14) (15) (16) (17) AC-00906 Foot duct (RH) Mix actuator (15) Foot duct (LH) Evaporator center Mode actuator (16) Unit ASSY Pipe cover...
Page 8 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • Manual A/C model (11) (13) (12) (10) (14) (15) (16) AC-00907 Foot duct (RH) Clip (15) Unit ASSY Thermo amplifier Air mix door linkage (16) Drain hose Pipe cover (10) Mode actuator &...
Page 9 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 2. BLOWER MOTOR UNIT AC-00908 & Upper case Control unit (Auto A/C model) Tightening torque: N m (kgf-m, ft-lb) Intake door actuator Power transistor (Auto A/C model) T: 7.5 (0.76, 5.5) Filter (Auto A/C model) Blower resistor (Manual A/C model) Filter cover...
Page 10: Control Panel
General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 3. CONTROL PANEL • Auto A/C model AC-00909 For integrated audio For Mclntosh audio Temperature control dial Board Heater control base Control panel assembly AC-8...
Page 11 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • Manual A/C model (10) AC-00910 Dial Heater control panel Valve A/C switch Heater control base Fan switch ASSY FRESH/RECIRC switch Temperature control cable (10) Switch base Rear window defogger switch AC-9...
Page 12 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 4. AIR CONDITIONING UNIT AC-00911 & Condenser Compressor Tightening torque: N m (kgf-m, ft-lb) Hose (High-pressure) O-ring T1: 7.5 (0.76, 5.5) Hose (Low-pressure) Clamp T2: 10 (1.0, 7.4) Bracket Tube T3: 5 (0.5, 3.7) AC-10...
Page 13 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 5. COMPRESSOR • H4 model AC-00760 & Idler pulley bracket Compressor Tightening torque: N m (kgf-m, ft-lb) Idler pulley adjuster Compressor lower bracket T1: 23.0 (2.35, 17.0) Idler pulley V-Belt T2: 28.9 (2.95, 21.3) Compressor upper bracket T3: 36 (3.7, 26.6) AC-11...
Page 14 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • H6 model AC-00912 & Compressor upper bracket Tightening torque: N m (kgf-m, ft-lb) Compressor T1: 28.9 (2.95, 21.3) Compressor lower bracket T2: 36 (3.7, 26.6) AC-12...
Page 15 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 6. HEATER DUCT AC-00913 Front defroster nozzle Side ventilation duct (RH) Rear heater duct (LH) Side ventilation duct (LH) Center ventilation duct Rear heater duct (RH) AC-13...
Page 16 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) C: CAUTION If the refrigerant gets into your eye, avoid rubbing your eyes with your hands. Wash your eye with 1. HFC-134a A/C SYSTEM plenty of water, and receive medical treatment from an eye doctor.
Page 17 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) • Apply compressor oil to O-rings to avoid sticking, Apply compressor oil to the bead of tube. before installation. • Use a torque wrench to tighten the O-ring fittings. Over-tightening will result in damage of O-ring and tube end distortion.
Page 18 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) D: PREPARATION TOOL CAUTION: When working on vehicles with HFC-134a system, only use HFC-134a specified tools and parts. Do not mix with those of CFC-12. If HFC-134a and CFC-12 refrigerant or compressor oil is mixed, it will result in poor lubrication and the compressor itself may be destroyed.
Page 19 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) ILLUSTRATION Tools and Equipment Refrigerant recovery system A REFRIGERANT RECOVERY SYSTEM is used for the recovery and reuse of A/C system refrigerant after contaminants and moisture have been removed from the refrigerant. AC-00014 Syringe A graduated plastic SYRINGE will be needed to add oil back into the...
Page 20 General Description HVAC SYSTEM (HEATER, VENTILATOR AND A/C) ILLUSTRATION Tools and Equipment Temperature gauge A Pocket THERMOMETER is available at either a industrial hardware store or a refrigerant suppliers. AC-00018 Electronic leak detector An ELECTRONIC LEAK DETECTOR can be available at either a spe- cialty tool supplier or an A/C equipment supplier.
Page 21: Refrigerant Pressure With Manifold Gauge Set
Refrigerant Pressure with Manifold Gauge Set HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 2. Refrigerant Pressure with Manifold Gauge Set A: PROCEDURE 1) Place the vehicle in the shade and windless condition. 2) Connect the manifold gauge set. 3) Open the front windows and close all doors. 4) Open the front hood.
Page 22: Refrigerant Recovery Procedure
Refrigerant Recovery Procedure HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 3. Refrigerant Recovery Proce- 4) Install the low-/high-pressure hoses to the ser- vice ports on the low-/high-pressure sides of the dure vehicle respectively. A: PROCEDURE CAUTION: • During operation, be sure to wear protective goggles and protective gloves.
Page 23: Refrigerant Charging Procedure
Refrigerant Charging Procedure HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 4. Refrigerant Charging Proce- 4) Carefully open the valves on the low-/high-pres- sure sides to activate the vacuum pump. dure A: PROCEDURE CAUTION: • During operation, be sure to wear protective goggles and protective gloves.
Page 24 Refrigerant Charging Procedure HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 7) Note the low-pressure gauge reading. 12) Confirm that all the 3 hoses are tightly connect- ed to the manifold gauge set. AC-00027 AC-00030 8) Leave it at least 5 minutes, and then check the low-pressure gauge reading for any changes.
Page 25 Refrigerant Charging Procedure HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 17) After confirming that there are no leaks with the 23) While reading the low-pressure gauge, careful- leak test, charge the required amount of refrigerant. ly open the low-pressure valve with the refrigerant source connected and the service hose purged.
Page 26: Refrigerant Leak Check
Refrigerant Leak Check HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 5. Refrigerant Leak Check CAUTION: Carefully check the external surface of hoses A: INSPECTION and tubes at approx. 25 mm (0.98 in) per sec- 1) Operate the A/C system for approx. 10 minutes, ond.
Page 27: Compressor Oil
Compressor Oil HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 6. Compressor Oil A: PROCEDURE NOTE: Before making repairs, perform the oil return oper- ation to return the compressor oil in circulation with the refrigerant to the compressor. 1) Increase the engine to 1,500 rpm. 2) Turn ON the A/C switch.
Page 28: Blower Motor Unit Assembly
Blower Motor Unit Assembly HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 7. Blower Motor Unit Assembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Disconnect the connectors of A/C control mod- ule, intake door actuator, blower motor, power tran- sistor and blower resistor.
Page 29: Blower Motor
Blower Motor HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 8. Blower Motor A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box lower cover. <Ref. to EI- 51, REMOVAL, Glove Box.> 3) Disconnect the connector of blower motor. 4) Loosen the screw to remove blower motor.
Page 30: Power Transistor (Auto A/C Model)
Power Transistor (Auto A/C Model) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 9. Power Transistor (Auto A/C Model) A: REMOVAL 1) Remove the glove box lower cover on passen- ger side. <Ref. to EI-51, REMOVAL, Glove Box.> 2) Disconnect the power transistor connector. 3) Remove two screws, and then remove the pow- er transistor.
Page 31: Blower Resistor (Manual A/C Model)
Blower Resistor (Manual A/C Model) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 10.Blower Resistor (Manual A/C Model) A: REMOVAL 1) Remove the glove box lower cover on passen- ger side. <Ref. to EI-51, REMOVAL, Glove Box.> 2) Disconnect the blower resistor connector. 3) Remove two screws, and then remove the blow- er resistor.
Page 32: Heater Core
Heater Core HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 11.Heater Core A: REMOVAL 1) Remove the heater and cooling unit. <Ref. to AC-36, REMOVAL, Heater and Cooling Unit.> 2) Remove the screws and remove the heater core cover and pipe clamp. AC-00917 3) Remove the heater core.
Page 33: Control Unit (Manual A/C Model)
Control Unit (Manual A/C Model) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 12.Control Unit (Manual A/C Model) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the control wires. AC-00918 4) Remove the integrated panel.
Page 34: Control Unit (Auto A/C Model)
Control Unit (Auto A/C Model) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 13.Control Unit (Auto A/C Model) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the screw, disconnect the connector and remove the control unit.
Page 35: Compressor
Compressor HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 14.Compressor 7) Remove the bolt and remove the low-pressure hose and high-pressure hose. A: INSPECTION 1. MAGNETIC CLUTCH CLEARANCE Check the clearance of entire circumference around the drive plate and pulley. Standard: 0.45 0.15 mm (0.0177 0.0059 in) 2.
Page 36 Compressor HVAC SYSTEM (HEATER, VENTILATOR AND A/C) C: INSTALLATION 1) Install in the reverse order of removal. 2) Replace the O-rings on low-/high-pressure hos- es with new ones, then apply compressor oil. 3) When replacing the compressor, adjust amount of compressor oil. <Ref. to AC-25, PROCEDURE, Compressor Oil.>...
Page 37: Condenser
Condenser HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 15.Condenser • If the condenser is replaced, add an appropri- ate amount of compressor oil to the compres- A: REMOVAL sor. <Ref. AC-25, REPLACEMENT, 1) Using the refrigerant recovery system, dis- Compressor Oil.> charge refrigerant.
Page 38: Heater And Cooling Unit
Heater and Cooling Unit HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 16.Heater and Cooling Unit A: REMOVAL 1) Disconnect the ground cable from battery. 2) Using the refrigerant recovery system, dis- charge refrigerant. <Ref. to AC-20, PROCEDURE, Refrigerant Recovery Procedure.> 3) Drain coolant from the radiator. 4) Remove the bolts securing expansion valve and pipe in engine compartment.
Page 39: Evaporator
Evaporator HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 17.Evaporator 5) Remove the bolt which holds the pipe to evapo- rator. A: REMOVAL 1) Remove the blower motor unit assembly. <Ref. to AC-26, REMOVAL, Blower Motor Unit Assem- bly.> 2) Disconnect the connector, remove the screw and then remove the air-mix door actuator and mode door actuator.
Page 40: Hose And Tube
Hose and Tube HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 18.Hose and Tube B: INSTALLATION CAUTION: A: REMOVAL • When disconnecting or connecting the hos- CAUTION: es, do not apply excessive force to them. Con- • When disconnecting/connecting hoses, do firm that no torsion and excessive tension is not apply an excessive force to them.
Page 41: Relay And Fuse
Relay and Fuse HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 19.Relay and Fuse B: INSPECTION A: LOCATION AC-00641 AC-00787 (3) — (4): Continuity exists (1) — (2): Continuity does not exist (1) Joint box While applying battery voltage to the terminal be- (2) Main fuse box tween (3) and (4), check continuity between (1) and (2).
Page 42: Pressure Switch (Triple Pressure Switch)
Pressure Switch (Triple Pressure Switch) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 20.Pressure Switch (Triple Pressure Switch) A: INSPECTION 1) Connect the manifold gauge to the service valve on the high-pressure side. 2) Remove the pressure switch harness connector. Using a circuit tester, inspect the ON-OFF operation of pressure switch.
Page 43: Ambient Sensor (Auto A/C Model)
Ambient Sensor (Auto A/C Model) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 21.Ambient Sensor (Auto A/C Model) A: REMOVAL 1) Open the front hood. 2) Disconnect the ground cable from battery. 3) Disconnect the ambient sensor connector. 4) Remove the ambient sensor from the radiator lower panel.
Page 44: Sunload Sensor (Auto A/C Model)
Sunload Sensor (Auto A/C Model) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 22.Sunload Sensor (Auto A/C Model) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector and remove the sun- load sensor. AC-00930 CAUTION: Be careful not to damage the interior trims when removing the sensor.
Page 45: In-Vehicle Sensor (Auto A/C Model)
In-Vehicle Sensor (Auto A/C Model) HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 23.In-Vehicle Sensor (Auto A/C Model) A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. <Ref. to EI-50, REMOVAL, Instrument Panel Lower Cov- er.>...
Page 46: Air Vent Grille
Air Vent Grille HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 24.Air Vent Grille A: REMOVAL 1. CENTER GRILLE 1) Disconnect the ground cable from battery. 2) Remove the three pawls and connector to re- move center air vent grill. AC-00931 2. SIDE GRILLE Remove the two pawls to remove side air vent grill.
Page 47: Heater Duct
Heater Duct HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 25.Heater Duct A: REMOVAL 1. FRONT HEATER DUCT 1) Remove the instrument panel lower cover. <Ref. to EI-50, REMOVAL, Instrument Panel Lower Cov- er.> 2) Remove the screws and detach the front heater duct (A).
Page 48: Heater Vent Duct
Heater Vent Duct HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 26.Heater Vent Duct A: REMOVAL 1) Remove the instrument panel. <Ref. to EI-50, REMOVAL, Instrument Panel Lower Cover.> 2) Remove the screws and detach the center vent duct (A). 3) Remove the screws and detach the center vent duct (B).
Page 49: Heater Cock Solenoid Valve
Heater Cock Solenoid Valve HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 27.Heater Cock Solenoid Valve A: REMOVAL 1) Drain the engine coolant. <Ref. to CO(H4SO 2.0)-13, DRAINING OF ENGINE COOLANT, RE- PLACEMENT, Engine Coolant.> 2) Disconnect the harness connector (A) of the heater cock solenoid valve.
Page 50: General Diagnostic Table
General Diagnostic Table HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 28.General Diagnostic Table A: INSPECTION Symptom Repair order Fuse Blower motor relay Blower motor Doesn’t operate. Blower motor Blower motor resistor Blower switch Wire harness Noise Blower motor Refrigerant Fuse Air conditioning relay Magnet clutch Doesn’t operate.
Page 51 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 52 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 53 HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) AC(diag) Page Basic Diagnostic Procedure ................2 General Description ..................3 Electrical Component Location ..............5 Auto A/C Control Module I/O Signal............8 Diagnostic Chart for Self-Diagnosis ............10 Diagnostics for A/C System Malfunction ...........15 Diagnostic Procedure for Actuators ............24 Diagnostic Procedure for Sensors ............30 Diagnostics with Phenomenon..............38...
Page 54: Basic Diagnostic Procedure
Basic Diagnostic Procedure HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 1. Basic Diagnostic Procedure A: PROCEDURE Step Check START INSPECTIONS. Does the self-diagnosis oper- Go to step 2. <Ref. to AC(diag)- 1) Perform the pre-inspection. <Ref. to ate? 15, A/C OR SELF- AC(diag)-3, INSPECTION, General Descrip- DIAGNOSIS SYS- tion.>...
Page 55: General Description
General Description HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 2. General Description NOTE: Be careful not to let the paper get sucked into the A: CAUTION port. 1) Never connect the battery in reverse polarity. • Auto A/C control module may be destroyed in- stantly.
Page 56: Control Switches
General Description HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 5. CONTROL SWITCHES Start and warm-up the engine completely. 1) Inspection using switches Point to check Switch operation Judgment standard Setting temperature display goes out. • Blower fan: OFF OFF switch Press the OFF switch. •...
Page 57: Electrical Component Location
Electrical Component Location HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 3. Electrical Component Location A: LOCATION 1. ENGINE COMPARTMENT AC-00896 A/C compressor Pressure switch Ambient sensor A/C relay AC(diag)-5...
Page 58: Passenger Compartment
Electrical Component Location HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) AC-00813 AC-00815 AC-00814 AC-00816 2. PASSENGER COMPARTMENT AC-00897 Evaporator sensor Blower motor Mode door actuator Air mix door actuator Sunload sensor In-vehicle sensor Auto A/C control module Intake door actuator AC(diag)-6...
Page 59 Electrical Component Location HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) AC-00898 AC-00900 AC-00899 AC(diag)-7...
Page 60: Auto A/C Control Module I/O Signal
Auto A/C Control Module I/O Signal HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 4. Auto A/C Control Module I/O Signal A: ELECTRICAL SPECIFICATION 16 15 14 13 12 11 20 19 18 17 16 15 14 13 12 11 To A: B282 To B: B283 AC-00735 AC(diag)-8...
Page 61 Auto A/C Control Module I/O Signal HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Terminal No. Remarks Measuring conditions Standard value Battery power supply Ignition switch: OFF Battery voltage ACC power supply Ignition switch: ACC Battery voltage Mode door: FACE position Mode door actuator position sig- Mode door: DEF position Air mix door: Maximum cool position Air mix door actuator position sig-...
Page 62: Diagnostic Chart For Self-Diagnosis
Diagnostic Chart for Self-Diagnosis HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 5. Diagnostic Chart for Self-Diagnosis A: OPERATION PUSH AUTO/TEMP AUTO MODE PUSH AUTO/TEMP AUTO MODE AC-00901 LHD model RHD model Defroster switch A/C switch OFF switch Rear window defogger switch Fan switch Temperature control dial (AUTO switch) Air flow control switch...
Page 63 Diagnostic Chart for Self-Diagnosis HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 1. A/C CONTROL PANEL SELF-DIAGNOSIS Step Check SET SELF-DIAGNOSIS MODE BY OPERAT- Does the self-diagnosis mode Go to step 2. <Ref. to AC(diag)- ING A/C CONTROL PANEL. operate? 15, A/C OR SELF- 1) Turn the ignition switch to OFF.
Page 64 Diagnostic Chart for Self-Diagnosis HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 2. SWITCH CHECK TABLE PUSH AUTO/TEMP AUTO MODE (11) (10) (12) (3) (4) PUSH AUTO/TEMP AUTO MODE (12) (11) (10) AC-00902 LHD model RHD model Switch Display screen Switch Display screen A/C switch FAN switch (+) AUTO switch...
Page 65 Diagnostic Chart for Self-Diagnosis HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 3. A/C CONTROL SYSTEM SELF-DIAGNOSIS Step Check SET SELF-DIAGNOSIS MODE BY OPERAT- Does the self-diagnosis mode Go to step 2. <Ref. to AC(diag)- ING A/C CONTROL PANEL. operate? 15, A/C OR SELF- 1) Turn the ignition switch to OFF.
Page 66 Diagnostic Chart for Self-Diagnosis HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 4. SENSOR CHECK TABLE NOTE: When the sunload sensor check is conducted indoors or in the shade, open circuit might be indicated. Always check the sunload sensor at the place where the sun shines directly on it. Display screen (Malfunction at SENSOR Trouble contents...
Page 67: Diagnostics For A/C System Malfunction
Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 6. Diagnostics for A/C System Malfunction A: A/C OR SELF-DIAGNOSIS SYSTEMS DO NOT OPERATE TROUBLE SYMPTOM: • “Set” temperature is not indicated on the display, switch LEDs are faulty and switches do not operate. •...
Page 68 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK FUSE. Is the fuse blown-out? Replace the fuse. Go to step 2. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 8 from main fuse box. 3) Check the condition of fuse.
Page 69 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK AUTO A/C CONTROL MODULE Is the resistance less than 5 Go to step 10. Repair the har- GROUND CIRCUIT. ness for ground Measure the resistance in harness between line.
Page 70: Wiring Diagram
Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) B: BLOWER FAN DOES NOT ROTATE. TROUBLE SYMPTOM: • Blower motor does not rotate. • Blower motor does not rotate in “HI”. WIRING DIAGRAM: BATTERY F/B NO. 27 SBF-4 SBF-1 F/B NO.
Page 71 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK FUSE. Is any fuse blown-out? Replace the fuse. Go to step 2. 1) Remove the fuse No. 22, 27 and 28 from fuse & relay box. 2) Check the condition of fuse. CHECK POWER SUPPLY FOR BLOWER Is the voltage more than 10 V? Go to step 3.
Page 72 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) C: COMPARTMENT TEMPERATURE DOES NOT CHANGE, OR A/C SYSTEM DOES NOT RESPOND PROMPTLY. WIRING DIAGRAM: IGNITION SWITCH BATTERY F/B No.22 SBF-7 SBF-1 B33 B35 B135 B360 B361 B136 THROUGH JOINT THROUGH JOINT CONNECTOR CONNECTOR...
Page 73 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK FUSE. Is the fuse blown-out? Replace the fuse. Go to step 2. 1) Turn the ignition switch to OFF. 2) Remove the fuse No. 22 from fuse & relay box.
Page 74 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK A/C ON SIGNAL. Is the voltage more than 5.5 V? Go to step 9. Go to step 8. 1) Turn the ignition switch to OFF. 2) Connect the A/C relay and all disconnected connectors.
Page 75 Diagnostics for A/C System Malfunction HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK POWER SUPPLY FOR MAGNET Is the voltage more than 10 V? Go to step 12. Check the harness CLUTCH. for open or short 1) Stop the engine and turn the A/C switch to circuit between A/ OFF.
Page 76: Diagnostic Procedure For Actuators
Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 7. Diagnostic Procedure for Actuators A: INTAKE DOOR ACTUATOR TROUBLE SYMPTOM: FRESH/RECIRC mode is not changed. WIRING DIAGRAM: IGNITION SWITCH BATTERY F/B No.22 SBF-7 SBF-1 INTAKE DOOR ACTUATOR AUTO A/C B283 CONTROL MODULE B283 1 2 3 4 5 6 7 8 9 10...
Page 77 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK POWER SUPPLY FOR INTAKE Is the voltage 7 V (at normal Go to step 2. Check the harness DOOR ACTUATOR. temperature)? for open or short 1) Turn the ignition switch to OFF. circuit between 2) Disconnect the intake door actuator con- intake door actua-...
Page 78 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) B: MODE DOOR ACTUATOR TROUBLE SYMPTOM: Air flow outlet is not changed. WIRING DIAGRAM: AUTO A/C B282 B283 CONTROL MODULE MODE DOOR ACTUATOR B282 B283 5 6 7 5 6 7 8 9 10 1 2 3 4 5 9 10 11 12 13 14 15 16...
Page 79 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK POWER SUPPLY FOR MODE DOOR Is the voltage approx. 5 V? Go to step 2. Replace the auto ACTUATOR POSITION SENSOR. A/C control mod- 1) Turn the ignition switch to OFF. ule.
Page 80 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) C: AIR MIX DOOR ACTUATOR TROUBLE SYMPTOM: Outlet air temperature does not change. WIRING DIAGRAM: AUTO A/C B282 B283 CONTROL MODULE B235 AIR MIX DOOR ACTUATOR B235 B282 B283 3 4 5 5 6 7 5 6 7 8 9 10...
Page 81 Diagnostic Procedure for Actuators HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK POWER SUPPLY FOR AIR MIX Is the voltage approx. 5 V? Go to step 2. Replace the auto DOOR ACTUATOR POSITION SWITCH. A/C control mod- 1) Turn the ignition switch to OFF. ule.
Page 82: Diagnostic Procedure For Sensors
Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 8. Diagnostic Procedure for Sensors A: AMBIENT SENSOR TROUBLE SYMPTOM: Fan speed is not switched when the fan speed control dial is in AUTO position. WIRING DIAGRAM: AMBIENT SENSOR F108 THROUGH JOINT CONNECTOR B361 BODY INTEGRATED UNIT...
Page 83 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK AMBIENT SENSOR. Is the resistance approx. 2.2 Go to step 2. Replace the ambi- 1) Turn the ignition switch to OFF. k# at 25!C (77!F)? ent sensor. 2) Disconnect the connector from ambient sensor.
Page 84 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) B: IN-VEHICLE SENSOR TROUBLE SYMPTOM: Blower fan speed, outlet port and inlet port do not change after turning the AUTO switch to ON. WIRING DIAGRAM: IN-VEHICLE SENSOR AUTO A/C A: B282 CONTROL MODULE A: B282 1 2 3 4...
Page 85 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK IN-VEHICLE SENSOR. Is the resistance approx. 2.7 Go to step 2. Replace the in- 1) Turn the ignition switch to OFF. k# at 20!C (68!F)? vehicle sensor. 2) Remove the driver’s side lower cover. 3) Disconnect the connector from in-vehicle sensor.
Page 86 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) C: EVAPORATOR SENSOR WIRING DIAGRAM: AUTO A/C B282 CONTROL MODULE B282 5 6 7 9 10 11 12 13 14 15 16 AC-00831 AC(diag)-34...
Page 87 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK EVAPORATOR SENSOR Is the resistance approx. 3.3 Go to step 2. Replace the evap- 1) Turn the ignition switch to OFF. k# at 20!C (68!F)? orator sensor. 2) Remove the glove box. 3) Disconnect the connector from evaporator sensor.
Page 88 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) D: SUNLOAD SENSOR TROUBLE SYMPTOM: • Sensor identifies that sunlight is at maximum. Then, A/C system is controlled to COOL side. • Sensor identifies that sunlight is at minimum. Then, A/C system is controlled to HOT side. NOTE: When the sunload sensor check is conducted indoors or in the shade, open circuit might be indicated.
Page 89 Diagnostic Procedure for Sensors HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) Step Check CHECK POWER SUPPLY VOLTAGE FOR Is the voltage approx. 5 V? Go to step 4. Go to step 2. SUNLOAD SENSOR. 1) Turn the ignition switch to OFF. 2) Disconnect the connector from sunload sensor.
Page 90: Diagnostics With Phenomenon
Diagnostics with Phenomenon HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS) 9. Diagnostics with Phenomenon A: INSPECTION Symptom Problem parts • Fuse (M/B No. 8, F/B No. 22, 31) • Connector (Poor contact) • Ground • Auto A/C control module A/C system fails to operate. •...
Page 91 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 92 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 93 AIRBAG SYSTEM Page General Description ..................2 Airbag Connector ..................9 Inspection Locations After a Collision ............12 Driver’s Airbag Module................14 Passenger’s Airbag Module ..............15 Side Airbag Module...................16 Curtain Airbag Module ................18 Airbag Control Module ................20 Side Airbag Sensor ...................21 Curtain Airbag Sensor................22 Roll Connector ..................23 Front Sub Sensor ..................24 Disposal of Airbag Module (Deployment Processing On Vehicle) ....25...
Page 94: General Description
General Description AIRBAG SYSTEM 1. General Description 4. CURTAIN AIRBAG MODULE • Sedan model A: COMPONENT 1. DRIVER’S AIRBAG MODULE AB-00625 (A) Bolt AB-00752 (B) Clip Tightening torque: • Wagon model 10 N m (1.0 kgf-m, 7.2 ft-lb) 2. PASSENGER’S AIRBAG MODULE AB-00626 (A) Bolt AB-00753...
Page 95 General Description AIRBAG SYSTEM 6. FRONT SUB SENSOR 9. STEERING ROLL CONNECTOR AB-00643 AB-00756 Tightening torque: 13 N m (1.32 kgf-m, 9.6 ft-lb) 7. SIDE AIRBAG SENSOR AB-00644 Tightening torque: 7.4 N m (0.75 kgf-m, 5.5 ft-lb) 8. CURTAIN AIRBAG SENSOR AB-00645 Tightening torque: 7.4 N...
Page 96 General Description AIRBAG SYSTEM 10.AIRBAG HARNESS AB-00757 Airbag main harness Airbag rear harness B: CAUTION • If sensors, airbag module, airbag control module, pretensioner and harness are deformed or dam- • When servicing a vehicle, be sure to turn the ig- aged, replace them with new parts.
Page 97 General Description AIRBAG SYSTEM • When checking the airbag system, be sure to • Do not drop the airbag modules, subject them to use a digital circuit tester. Use of an analog circuit high temperature over 93"C (199"F), or let water, tester may cause the airbag to activate erroneous- oil or grease get on them;...
Page 98 General Description AIRBAG SYSTEM • Do not allow water or oil to come in contact with • When painting or performing sheet metal work the connector terminals. Do not touch the connec- on the side of the vehicle, including the side sill, tor terminals.
Page 99 General Description AIRBAG SYSTEM • When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result.
Page 100: Special Tool
General Description AIRBAG SYSTEM C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FC030 DEPLOYMENT • Used for deploying side airbag module. ADAPTER A • Used for deploying curtain airbag module. • Used with DEPLOYMENT TOOL (98299PA030). ST98299FC030 98299SA030 DEPLOYMENT •...
Page 101: Airbag Connector
Airbag Connector AIRBAG SYSTEM 2. Airbag Connector 2. DRIVER’S AIRBAG MODULE AND PRE- TENSIONER A: PROCEDURE 1) How to disconnect: 1. POWER SUPPLY (1) Using a flat tip screwdriver, pry the push lock upward to unlock. 1) How to disconnect: (1) Move the slide lock (A) in the direction of ar- row.
Page 102 Airbag Connector AIRBAG SYSTEM 3. DRIVER’S AIRBAG (BETWEEN AIRBAG 4. SIDE AIRBAG AND CURTAIN AIRBAG MAIN HARNESS AND ROLL CONNECTOR), 1) How to disconnect: PASSENGER’S AIRBAG (1) Push the lock arm (A). (2) With the lock arm (A) pushed in, move the 1) How to disconnect: slide lock (B) in the direction of arrow.
Page 103 Airbag Connector AIRBAG SYSTEM 2) How to connect: Holding the connector, and push it in carefully until a connecting sound is heard. CAUTION: • The outer side (A) moves back, and so do not put your hand on the outer part. •...
Page 104: Inspection Locations After A Collision
Inspection Locations After a Collision AIRBAG SYSTEM 3. Inspection Locations After a 2) When installing a new driver’s airbag module, check for the following, and replace the damaged Collision parts with new parts. • The steering wheel is in the way, making it diffi- A: REPLACEMENT cult to install the airbag module.
Page 105 Inspection Locations After a Collision AIRBAG SYSTEM • Mounting bracket is cracked or deformed. 9. STEERING SHAFT • Connector is scratched, cracked or deformed. Check for the following, and replace the damaged • Airbag is deployed. parts with new parts. •...
Page 106: Driver's Airbag Module
Driver’s Airbag Module AIRBAG SYSTEM 4. Driver’s Airbag Module B: INSTALLATION CAUTION: A: REMOVAL • Refer to “CAUTION” of General Description CAUTION: before handling the airbag module. <Ref. to AB- Refer to “CAUTION” of General Description be- 4, CAUTION, General Description.> fore handling the airbag module.
Page 107: Passenger's Airbag Module
Passenger’s Airbag Module AIRBAG SYSTEM 5. Passenger’s Airbag Module C: INSPECTION CAUTION: A: REMOVAL Refer to “CAUTION” of General Description be- CAUTION: fore handling the airbag module. <Ref. to AB-4, Refer to “CAUTION” of “General Description” CAUTION, General Description.> before handling the airbag module. <Ref. to AB- Check for the following, and replace damaged 4, CAUTION, General Description.>...
Page 108: Side Airbag Module
Side Airbag Module AIRBAG SYSTEM 6. Side Airbag Module 7) Remove the side airbag module (A) from back- rest frame assembly. A: REMOVAL CAUTION: Refer to “CAUTION” of General Description be- fore handling the airbag module. <Ref. to AB-4, CAUTION, General Description.> NOTE: Remove the passenger’s side by referring to driv- er’s side.
Page 109 Side Airbag Module AIRBAG SYSTEM B: INSTALLATION 5) Install the side airbag harness to slide rail IN (A), and then secure the connector to the bracket on CAUTION: back side of seat cushion assembly. Refer to “CAUTION” of General Description be- fore handling the airbag module.
Page 110: Curtain Airbag Module
Curtain Airbag Module AIRBAG SYSTEM 7. Curtain Airbag Module • Sedan model A: REMOVAL CAUTION: Refer to “CAUTION” of General Description be- fore handling the airbag module. <Ref. to AB-4, CAUTION, General Description.> 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work.
Page 111 Curtain Airbag Module AIRBAG SYSTEM • Wagon model Tightening torque: Refer to “COMPONENT” of “General Descrip- tion”. <Ref. to AB-2, CURTAIN AIRBAG MOD- ULE, COMPONENT, General Description.> C: INSPECTION CAUTION: Refer to “CAUTION” of General Description be- fore handling the airbag module. <Ref. to AB-4, CAUTION, General Description.>...
Page 112: Airbag Control Module
Airbag Control Module AIRBAG SYSTEM 8. Airbag Control Module Tightening torque: Refer to “COMPONENT” of “General Descrip- A: REMOVAL tion”. <Ref. to AB-2, AIRBAG CONTROL MODULE, COMPONENT, General Descrip- CAUTION: tion.> • Do not disassemble the airbag control mod- C: INSPECTION ule.
Page 113: Side Airbag Sensor
Side Airbag Sensor AIRBAG SYSTEM 9. Side Airbag Sensor A: REMOVAL 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work. 3) Remove the center pillar lower trim. <Ref. to EI- 60, REMOVAL, Lower Inner Trim.>...
Page 114: Curtain Airbag Sensor
Curtain Airbag Sensor AIRBAG SYSTEM 10.Curtain Airbag Sensor A: REMOVAL 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work. 3) Remove the rear seat. <Ref. to SE-14, REMOV- AL, Rear Seat.>...
Page 115: Roll Connector
Roll Connector AIRBAG SYSTEM 11.Roll Connector A: REMOVAL 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work. 3) Remove the driver’s airbag module. <Ref. to AB- 14, REMOVAL, Driver’s Airbag Module.>...
Page 116: Front Sub Sensor
Front Sub Sensor AIRBAG SYSTEM 12.Front Sub Sensor A: REMOVAL 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work. 3) Remove the front bumper face. <Ref. to EI-30, FRONT BUMPER FACE, REMOVAL, Front Bumper.>...
Page 117: Disposal Of Airbag Module (Deployment Processing On Vehicle)
(B) Deployment adapter E: • If circumstances do not permit the airbag (Tool number 98299SA030) module deployment, contact the SUBARU deal- 7) Connect the deployment adapter E (1) to airbag connector (AB7). 1. DRIVER’S AIRBAG MODULE 1) Turn the ignition switch to OFF.
Page 118 Disposal of Airbag Module (Deployment Processing On Vehicle) AIRBAG SYSTEM 8) Extend the wiring of deployment tool to the limit, 2) Disconnect the ground cable from battery and and make sure the vehicle is empty. Close all the wait for at least 20 seconds before starting work. windows, sunroof and rear gate completely.
Page 119 Disposal of Airbag Module (Deployment Processing On Vehicle) AIRBAG SYSTEM 7) Extend the wiring of deployment tool to the limit, 3. SIDE AIRBAG MODULE and make sure the vehicle is empty. Close all the 1) Turn the ignition switch to OFF. windows, sunroof and rear gate completely.
Page 120 Disposal of Airbag Module (Deployment Processing On Vehicle) AIRBAG SYSTEM • Deploy the side airbag one by one to discard. 12) Wrap the deployed airbag module in airtight vi- nyl bag, and discard it. AB-00652 AB-00043 8) Extend the wiring of deployment tool to the limit, and make sure the vehicle is empty.
Page 121 Disposal of Airbag Module (Deployment Processing On Vehicle) AIRBAG SYSTEM 8) Extend the wiring of deployment tool to the limit, CAUTION: and make sure the vehicle is empty. Close all the The deployment tool should be kept shorted windows, sunroof and rear gate completely. terminals until just before deployment of airbag module.
Page 122: Disposal Of Airbag Module (Deployment Processing After Removal From Vehicle)
• If circumstances do not permit the airbag module deployment, contact the SUBARU deal- 1. DRIVER’S AIRBAG MODULE 1) Turn the ignition switch to OFF. 2) Disconnect the ground cable from battery and wait for at least 20 seconds before starting work.
Page 123 Disposal of Airbag Module (Deployment Processing After Removal from Vehi- cle) AIRBAG SYSTEM 9) Install the airbag module with pad side facing up- 12) Connect the other cable of deployment tool to ward on a wheel with tire. the battery positive (+) terminal, and deploy the airbag module.
Page 124 Disposal of Airbag Module (Deployment Processing After Removal from Vehi- cle) AIRBAG SYSTEM 5) Bundle three automotive wire harnesses [each 10) Put three tires without wheels on the tire in- with a sectional area of 1.25 mm (0.00194 sq in) or stalled with the airbag module.
Page 125 Disposal of Airbag Module (Deployment Processing After Removal from Vehi- cle) AIRBAG SYSTEM 13) Wrap the deployed airbag module in airtight vi- CAUTION: nyl bag, and discard it. The deployment tool should be kept shorted terminals until just before deployment of airbag module.
Page 126 Disposal of Airbag Module (Deployment Processing After Removal from Vehi- cle) AIRBAG SYSTEM 11) Move the battery at least 5 m (16 ft) from tires, 3) Remove the roof trim. <Ref. to EI-67, REMOV- and secure the nearby area. Connect the deploy- AL, Roof Trim.>...
Page 127 Disposal of Airbag Module (Deployment Processing After Removal from Vehi- cle) AIRBAG SYSTEM 12) Move the battery at least 5 m (16 ft) from tires, CAUTION: and secure the nearby area. Connect the deploy- The deployment tool should be kept shorted ment tool alligator clip to the battery negative (#) terminals until just before deployment of airbag terminal.
Page 128 Disposal of Airbag Module (Deployment Processing After Removal from Vehi- cle) AIRBAG SYSTEM AB-36...
Page 129 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 130 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 131 AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) Page Basic Diagnostic Procedure ................2 Check List for Interview................3 General Description ..................4 Electrical Component Location ..............18 Airbag Control Module I/O Signal..............22 Airbag Connector ..................26 Airbag Warning Light Illumination Pattern..........29 Read Diagnostic Trouble Code (DTC) ............30 Inspection Mode..................31 Clear Memory Mode..................32 Airbag Warning Light Failure..............33 List of Diagnostic Trouble Code (DTC) .............37...
Page 132: Basic Diagnostic Procedure
Basic Diagnostic Procedure AIRBAG SYSTEM (DIAGNOSTICS) 1. Basic Diagnostic Procedure A: PROCEDURE Step Check READ DTC. Is the normal code detected? Finish the diagno- Go to step 2. <Ref. to AB(diag)-30, Read Diagnostic Trouble sis. Code (DTC).> READ DTC. Is DTC displayed? Go to step 3.
Page 133: Check List For Interview
Check List for Interview AIRBAG SYSTEM (DIAGNOSTICS) 2. Check List for Interview A: CHECK Customer’s Name Inspector’s Name Date Vehicle Brought In Registration No. Odometer Reading V.I.N. miles Date Problem Occurred Registration Year J Fine J Cloudy J Rainy J Snowy J Other: Weather !C (!F)
Page 134: General Description
General Description AIRBAG SYSTEM (DIAGNOSTICS) 3. General Description • When checking, use a test harness (1). Do not directly apply the tester probe to any connector ter- A: CAUTION minal of the airbag. • When servicing a vehicle, be sure to turn the ig- nition switch to OFF, disconnect the ground cable from battery, and wait for more than 20 seconds before starting work.
Page 135 General Description AIRBAG SYSTEM (DIAGNOSTICS) • If any damage, opening or rust is found on the • The airbag module cannot be used again if once airbag system wire harness, do not attempt to re- deployed. pair using soldering equipment. Be sure to replace the faulty harness with a new genuine part.
Page 136 General Description AIRBAG SYSTEM (DIAGNOSTICS) • The removed front seat with an airbag module must be kept at least 200 mm (8 in) away from walls and other objects. AB-00128 (1) 200 mm (8 in) or more • When painting or performing sheet metal work on the front part of the vehicle, including the front wheel apron, front fender and front side frame, re- move the front sub sensors and wire harness of the...
Page 137 General Description AIRBAG SYSTEM (DIAGNOSTICS) • When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of each other. If the airbag inflates for some reason when it is placed with its pad side facing downward or under any object, a serious accident may result.
Page 138 General Description AIRBAG SYSTEM (DIAGNOSTICS) B: INSPECTION Measure the battery voltage and check electrolyte. Standard voltage: 12 V Specific gravity: Above 1.260 C: PREPARATION TOOL CAUTION: To check the voltage and resistance of airbag system component, be sure to use the specified test harness.
Page 139 General Description AIRBAG SYSTEM (DIAGNOSTICS) • TEST HARNESS H ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FA030 TEST HARNESS H Used when measuring voltage and resistance of front sub-sensor. ST98299FA030 3 4 5 6 AB-00720 AB(diag)-9...
Page 140 General Description AIRBAG SYSTEM (DIAGNOSTICS) • TEST HARNESS R ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299FE030 TEST HARNESS R Used when measuring voltage and resistance of airbag control module. ST98299FE030 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 5 6 7...
Page 141 General Description AIRBAG SYSTEM (DIAGNOSTICS) • TEST HARNESS N ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA000 TEST HARNESS N Used when measuring voltage and resistance of driver’s airbag module and seat belt preten- sioner. ST98299SA000 AB-00675 AB(diag)-11...
Page 142 General Description AIRBAG SYSTEM (DIAGNOSTICS) • TEST HARNESS P ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA020 TEST HARNESS P Used when measuring voltage and resistance of driver’s airbag module harness and passenger airbag module harness. ST98299SA020 AB-00679 AB(diag)-12...
Page 143 General Description AIRBAG SYSTEM (DIAGNOSTICS) • TEST HARNESS Q ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299SA040 TEST HARNESS Q Used when measuring voltage and resistance of driver’s airbag module. ST98299SA040 AB-00678 AB(diag)-13...
Page 144 General Description AIRBAG SYSTEM (DIAGNOSTICS) • TEST HARNESS U ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299AG000 TEST HARNESS U Used when measuring voltage and resistance of airbag control module. ST98299AG000 AB(diag)-14...
Page 145 General Description AIRBAG SYSTEM (DIAGNOSTICS) 8 12 1 2 3 4 5 6 2 3 4 5 6 7 8 9 7 8 9 10 11 12 13 14 11 12 13 14 15 16 17 18 19 20 58 57 56 55 54 53 1 2 3 5 6 7 1 2 3 4 5 6 7 8...
Page 146 General Description AIRBAG SYSTEM (DIAGNOSTICS) • TEST HARNESS V ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299AG010 TEST HARNESS V Used when measuring voltage and resistance of side airbag sensor and curtain airbag sensor. ST98299AG010 4 5 6 7 8 1 2 3 4 4 3 2 1 AB-00677 AB(diag)-16...
Page 147 General Description AIRBAG SYSTEM (DIAGNOSTICS) • AIRBAG RESISTOR ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 98299PA040 AIRBAG RESISTOR Used in replacement of airbag module for which resistance value is same as airbag module. ST98299PA040 AB-00433 AB(diag)-17...
Page 148: Electrical Component Location
Electrical Component Location AIRBAG SYSTEM (DIAGNOSTICS) 4. Electrical Component Location A: LOCATION 1. LHD MODEL (11) (13) AB32 AB23 AB21 AB13 (15) AB39 AB19 AB10 AB31 (17) AB20 AB17 AB18 AB38 AB25 (18) AB33 AB24 AB40 (16) AB37 AB16 AB26 AB23 AB34 (14)
Page 149 Electrical Component Location AIRBAG SYSTEM (DIAGNOSTICS) Connector (AB1) (AB2) (AB7) (AB9) (AB10) (AB13) (AB16) (AB17) (AB18) (AB19) (AB20) (AB21) Color Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Black Male/Female Female Female Male Female Male Female Female Male Male Female...
Page 150 Electrical Component Location AIRBAG SYSTEM (DIAGNOSTICS) 2. RHD MODEL (10) (12) (14) AB28 AB34 AB26 AB16 AB37 (16) AB24 AB40 AB33 (18) AB25 AB38 AB18 AB17 AB20 (17) AB31 AB10 AB19 AB39 (15) AB13 AB21 AB23 (13) AB32 (11) AB-00680 Front sub-sensor (LH) Driver’s airbag inflator (13)
Page 151 Electrical Component Location AIRBAG SYSTEM (DIAGNOSTICS) Connector (AB1) (AB2) (AB7) (AB9) (AB10) (AB13) (AB16) (AB17) (AB18) (AB19) (AB20) (AB21) Color Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Black Male/Female Female Female Male Female Male Female Female Male Male Female...
Page 152: Airbag Control Module I/O Signal
Airbag Control Module I/O Signal AIRBAG SYSTEM (DIAGNOSTICS) 5. Airbag Control Module I/O Signal A: WIRING DIAGRAM TO POWER SUPPLY ROUTING FB-36 FB-41 FB-39 FB-32 F/B FUSE NO.5 F/B FUSE NO.25 F/B FUSE NO.12 F/B FUSE NO.4 (IG) (IG) (IG) (IG) COMBINATION METER...
Page 153 Airbag Control Module I/O Signal AIRBAG SYSTEM (DIAGNOSTICS) FRONT SUB SENSOR LH FRONT SUB SENSOR RH AB16 AB13 AIRBAG CONTROL MODULE STEERING ROLL CONNECTOR AB37 AB38 AB10 GAB-2 GAB-1 INFLATOR INFLATOR (PASSENGER SIDE) (DRIVER SIDE) AB13 (YELLOW) (YELLOW) AB38 AB38 AB37 (YELLOW) AB16...
Page 154 Airbag Control Module I/O Signal AIRBAG SYSTEM (DIAGNOSTICS) AB18 AIRBAG CONTROL MODULE WITH CURTAIN AIRBAG WITHOUT CURTAIN AIRBAG AB26 AB28 AB24 AB34 AB33 AB25 AB40 PRETENSIONER RH SIDE AIRBAG INFLATOR CURTAIN INFLATOR SENSOR RH AIRBAG (CURTAIN RH) (SIDE RH) SENSOR RH AB26 (YELLOW) AB28...
Page 155 Airbag Control Module I/O Signal AIRBAG SYSTEM (DIAGNOSTICS) AB17 AIRBAG CONTROL MODULE WITH CURTAIN AIRBAG WITHOUT CURTAIN AIRBAG AB21 AB23 AB19 AB32 AB31 AB20 AB39 PRETENSIONER LH SIDE AIRBAG INFLATOR CURTAIN INFLATOR SENSOR LH AIRBAG (CURTAIN LH) (SIDE LH) SENSOR LH AB21 (YELLOW) AB23...
Page 156: Airbag Connector
Airbag Connector AIRBAG SYSTEM (DIAGNOSTICS) 6. Airbag Connector 2. DRIVER’S AIRBAG MODULE AND PRE- TENSIONER A: PROCEDURE 1) How to disconnect: 1. POWER SUPPLY (1) Using a flat tip screwdriver, pry the push lock upward to unlock. 1) How to disconnect: (1) Move the slide lock (A) in the direction of ar- row.
Page 157 Airbag Connector AIRBAG SYSTEM (DIAGNOSTICS) 3. DRIVER’S AIRBAG (BETWEEN AIRBAG 4. SIDE AIRBAG AND CURTAIN AIRBAG MAIN HARNESS AND ROLL CONNECTOR), 1) How to disconnect: PASSENGER’S AIRBAG (1) Push the lock arm (A). (2) With the lock arm (A) pushed in, move the 1) How to disconnect: slide lock (B) in the direction of arrow.
Page 158 Airbag Connector AIRBAG SYSTEM (DIAGNOSTICS) 2) How to connect: Holding the connector, and push it in carefully until a connecting sound is heard. CAUTION: • Outer side (A) move back, and so do not put your hand on the outer part. •...
Page 159: Airbag Warning Light Illumination Pattern
Airbag Warning Light Illumination Pattern AIRBAG SYSTEM (DIAGNOSTICS) 7. Airbag Warning Light Illumi- nation Pattern A: INSPECTION Keep the ignition switch ON, and confirm that the airbag warning light remains off approx. 6 seconds after being turned on. AB-00135 (1) Airbag warning light (2) Approx.
Page 160: Read Diagnostic Trouble Code (Dtc)
Read Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTICS) 8. Read Diagnostic Trouble NOTE: The harness (yellow/black) of ground terminal is Code (DTC) wrapped by tapes with the harness (red, red/black) A: OPERATION of diagnosis connector. 4) Read the DTC by identifying the way airbag 1) Remove the instrument panel lower cover upper.
Page 161: Inspection Mode
Inspection Mode AIRBAG SYSTEM (DIAGNOSTICS) 9. Inspection Mode A: PROCEDURE Recreate the circumstance by referring to the con- ditions described in the checklist. AB(diag)-31...
Page 162: Clear Memory Mode
Clear Memory Mode AIRBAG SYSTEM (DIAGNOSTICS) 10.Clear Memory Mode A: OPERATION 1) Remove the instrument panel lower cover upper. <Ref. to EI-50, REMOVAL, Instrument Panel Low- er Cover.> 2) Turn the ignition switch to ON. 3) Connect one of the ground terminals to the diag- nosis connector terminal No.
Page 163: Airbag Warning Light Failure
Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTICS) 11.Airbag Warning Light Failure A: AIRBAG WARNING LIGHT REMAINS ON DETECTING CONDITION: • Airbag warning light failure • Airbag control module to airbag warning light circuit is shorted or open. • Grounding circuit is faulty. •...
Page 164 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK POOR CONTACT. Is there poor contact in con- Replace the airbag Go to step 2. 1) Turn the ignition switch OFF, disconnect the nector (AB6)? main harness with battery ground terminal, and wait more than 20 body harness or seconds.
Page 165 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTICS) B: AIRBAG WARNING LIGHT REMAINS OFF DETECTING CONDITION: • Fuse No. 5 (in fuse box) is blown. • Body harness circuit is open. • Airbag warning light is faulty. • Airbag main harness is faulty. •...
Page 166 Airbag Warning Light Failure AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK COMBINATION METER. Do warning lights other than Go to step 2. Repair the combi- Turn the ignition switch to ON, and confirm that the airbag turn on? nation meter warning lights equipped in the combination power supply.
Page 167: List Of Diagnostic Trouble Code (Dtc)
List of Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTICS) 12.List of Diagnostic Trouble Code (DTC) A: LIST Memory func- Content of diagnosis Reference tion • Airbag main harness circuit is open, shorted or <Ref. to AB(diag)-41, shorted to ground. DTC 11, Diagnostic •...
Page 168 List of Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTICS) Memory func- Content of diagnosis Reference tion • Front sub-sensor harness (LH) circuit is shorted. <Ref. to AB(diag)-58, • Front sub-sensor harness (LH) circuit is open. DTC 32, Diagnostic Experienced • Front sub-sensor (LH) is faulty. Chart with Trouble •...
Page 169 List of Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTICS) Memory func- Content of diagnosis Reference tion Curtain airbag sensor (RH) is faulty. <Ref. to AB(diag)-86, DTC 58, Diagnostic Experienced Chart with Trouble Code.> Curtain airbag sensor (LH) is faulty. <Ref. to AB(diag)-86, DTC 59, Diagnostic Experienced Chart with Trouble...
Page 170 List of Diagnostic Trouble Code (DTC) AIRBAG SYSTEM (DIAGNOSTICS) Memory func- Content of diagnosis Reference tion • Curtain airbag harness (RH) is faulty. <Ref. to AB(diag)-108, • Curtain airbag module (RH) is faulty. DTC 91, Diagnostic Experienced • Airbag control module is faulty. Chart with Trouble Code.>...
Page 171: Diagnostic Chart With Trouble Code
Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 13.Diagnostic Chart with Trouble Code A: DTC 11 DTC DETECTING CONDITION: • Airbag main harness circuit is open, shorted or shorted to ground. • Airbag module harness (Driver’s side) circuit is open, shorted or shorted to ground. •...
Page 172 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK DRIVER’S AIRBAG MODULE. Does the airbag warning light Replace the Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? driver’s airbag battery ground terminal, and wait more than 20 module.
Page 173 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG MAIN HARNESS (DRIV- Is the resistance more than 1 Replace the airbag Replace the airbag ER’S AIRBAG HARNESS). M"? control module. main harness with Measure the resistance between connector <Ref.
Page 174 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) B: DTC 12 DTC DETECTING CONDITION: • Airbag main harness circuit is open, shorted or shorted to ground. • Airbag module harness (Passenger’s side) circuit is open, shorted or shorted to ground. •...
Page 175 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK PASSENGER’S AIRBAG MODULE. Does the airbag warning light Replace the pas- Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? senger’s airbag battery ground terminal, and wait more than 20 module.
Page 176 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) C: DTC 15 DTC DETECTING CONDITION: • Airbag main harness circuit (Driver’s side) is shorted to power supply. • Airbag module harness circuit (Driver’s side) is shorted to power supply. • Roll connector is shorted to the power supply. •...
Page 177 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK DRIVER’S AIRBAG MODULE. Does the airbag warning light Replace the Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? driver’s airbag battery ground terminal, and wait more than 20 module.
Page 178 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) D: DTC 16 DTC DETECTING CONDITION: • Airbag main harness circuit (Passenger’s side) is shorted to power supply. • Airbag module harness circuit (Passenger’s side) is shorted to power supply. • Passenger’s airbag module is faulty. •...
Page 179 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK PASSENGER’S AIRBAG MODULE. Does the airbag warning light Replace the pas- Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? senger’s airbag battery ground terminal, and wait more than 20 module.
Page 180 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) F: DTC 22 WIRING DIAGRAM: AIRBAG CONTROL MODULE AB17 AB18 WITH CURTAIN AIRBAG 1 : 6 2 : 5 3 : 11 4 : 12 WITHOUT CURTAIN AIRBAG STEERING 1 : 2 ROLL CONNECTOR 2 : 1...
Page 181 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) G: DTC 23 DTC DETECTING CONDITION: (AB6), (AB17) and (AB18) are not connected properly to airbag control module. CAUTION: Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 182 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) H: DTC 24 DTC DETECTING CONDITION: • Airbag control module is faulty. • Airbag main harness circuit is open. • Fuse No. 25 (in joint box) is blown. • Body harness circuit is open. CAUTION: •...
Page 183 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG CONTROL MODULE. Is the voltage more than 10 V? Replace the airbag Go to step 2. 1) Turn the ignition switch OFF, disconnect the control module. battery ground terminal, and wait more than 20 <Ref.
Page 184 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) I: DTC 25 DTC DETECTING CONDITION: • Airbag control module is faulty. • Airbag main harness circuit is open. • Fuse No. 12 (in joint box) is blown. • Body harness circuit is open. CAUTION: •...
Page 185 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG CONTROL MODULE. Is the voltage more than 10 V? Replace the airbag Go to step 2. 1) Turn the ignition switch OFF, disconnect the control module. battery ground terminal, and wait more than 20 <Ref.
Page 186 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) J: DTC 31 DTC DETECTING CONDITION: • Front sub-sensor harness (RH) circuit is shorted. • Front sub-sensor harness (RH) circuit is open. • Front sub-sensor (RH) is faulty. • Airbag control module is faulty. CAUTION: •...
Page 187 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG MAIN HARNESS (FRONT Is the resistance less than 10 Go to step 2. Replace the airbag "? SUB-SENSOR HARNESS RH). main harness with 1) Turn the ignition switch OFF, disconnect the body harness.
Page 188 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) K: DTC 32 DTC DETECTING CONDITION: • Front sub-sensor harness (LH) circuit is shorted. • Front sub-sensor harness (LH) circuit is open. • Front sub-sensor (LH) is faulty. • Airbag control module is faulty. CAUTION: •...
Page 189 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG MAIN HARNESS (FRONT Is the resistance less than 10 Go to step 2. Replace the airbag "? SUB-SENSOR HARNESS LH). main harness with 1) Turn the ignition switch OFF, disconnect the body harness.
Page 190 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) N: DTC 41 DTC DETECTING CONDITION: • Side airbag harness (RH) is faulty. • Side airbag module (RH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 191 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 1. MODEL WITH CURTAIN AIRBAG Step Check CHECK SIDE AIRBAG MODULE. Does the airbag warning light Replace the front Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? seat with side air- battery ground terminal, and wait more than 20 bag module (RH).
Page 192 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG REAR HARNESS (SIDE Is the resistance more than 1 Replace the airbag Replace the airbag AIRBAG MODULE HARNESS RH). M"? control module. rear harness with Measure the resistance between connector <Ref.
Page 193 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 2. MODEL WITHOUT CURTAIN AIRBAG Step Check CHECK SIDE AIRBAG MODULE. Does the airbag warning light Replace the front Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? seat with side air- battery ground terminal, and wait more than 20 bag module (RH).
Page 194 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG REAR HARNESS (SIDE Is the resistance more than 1 Replace the airbag Replace the airbag AIRBAG MODULE HARNESS RH). M"? control module. rear harness with Measure the resistance between connector <Ref.
Page 195 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) O: DTC 42 DTC DETECTING CONDITION: • Side airbag harness (LH) is faulty. • Side airbag module (LH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 196 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 1. MODEL WITH CURTAIN AIRBAG Step Check CHECK SIDE AIRBAG MODULE. Does the airbag warning light Replace the front Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? seat with side air- battery ground terminal, and wait more than 20 bag module (LH).
Page 197 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG REAR HARNESS (SIDE Is the resistance more than 1 Replace the airbag Replace the airbag AIRBAG MODULE HARNESS LH). M"? control module. rear harness with Measure the resistance between connector <Ref.
Page 198 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 2. MODEL WITHOUT CURTAIN AIRBAG Step Check CHECK SIDE AIRBAG MODULE. Does the airbag warning light Replace the front Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? seat with side air- battery ground terminal, and wait more than 20 bag module (LH).
Page 199 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG REAR HARNESS (SIDE Is the resistance more than 1 Replace the airbag Replace the airbag AIRBAG MODULE HARNESS LH). M"? control module. rear harness with Measure the resistance between connector <Ref.
Page 200 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) P: DTC 45 DTC DETECTING CONDITION: • Side airbag harness (RH) is shorted to power supply. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 201 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 1. MODEL WITH CURTAIN AIRBAG Step Check CHECK SIDE AIRBAG MODULE. Does the airbag warning light Replace the front Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? seat with side air- battery ground terminal, and wait more than 20 bag module (RH).
Page 202 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 2. MODEL WITHOUT CURTAIN AIRBAG Step Check CHECK SIDE AIRBAG MODULE. Does the airbag warning light Replace the front Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? seat with side air- battery ground terminal, and wait more than 20 bag module (RH).
Page 203 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Q: DTC 46 DTC DETECTING CONDITION: • Side airbag harness (LH) is shorted to power supply. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 204 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 1. MODEL WITH CURTAIN AIRBAG Step Check CHECK SIDE AIRBAG MODULE. Does the airbag warning light Replace the side Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? airbag module battery ground terminal, and wait more than 20 (LH) with front...
Page 205 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 2. MODEL WITHOUT CURTAIN AIRBAG Step Check CHECK SIDE AIRBAG MODULE. Does the airbag warning light Replace the side Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? airbag module battery ground terminal, and wait more than 20 (LH) with front...
Page 206 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) R: DTC 51 DTC DETECTING CONDITION: • Side airbag sensor (RH) is faulty. • Side airbag harness (RH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 207 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 1. MODEL WITH CURTAIN AIRBAG Step Check CHECK AIRBAG REAR HARNESS (SIDE Is the resistance less than 10 Go to step 2. Replace the airbag "? AIRBAG SENSOR HARNESS RH). rear harness with 1) Turn the ignition switch OFF, disconnect the body harness.
Page 208 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 2. MODEL WITHOUT CURTAIN AIRBAG Step Check CHECK AIRBAG REAR HARNESS (SIDE Is the resistance less than 10 Go to step 2. Replace the airbag "? AIRBAG SENSOR HARNESS RH). rear harness with 1) Turn the ignition switch OFF, disconnect the body harness.
Page 209 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) S: DTC 52 DTC DETECTING CONDITION: • Side airbag sensor (LH) is faulty. • Side airbag harness (LH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 210 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 1. MODEL WITH CURTAIN AIRBAG Step Check CHECK AIRBAG REAR HARNESS (SIDE Is the resistance less than 10 Go to step 2. Replace the airbag "? AIRBAG SENSOR HARNESS LH). rear harness with 1) Turn the ignition switch OFF, disconnect the body harness.
Page 211 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 2. MODEL WITHOUT CURTAIN AIRBAG Step Check CHECK AIRBAG REAR HARNESS (SIDE Is the resistance less than 10 Go to step 2. Replace the airbag "? AIRBAG SENSOR HARNESS LH). rear harness with 1) Turn the ignition switch OFF, disconnect the body harness.
Page 212 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) T: DTC 53 DTC DETECTING CONDITION: Side airbag sensor (RH) is faulty. When DTC 53 is displayed, the circuit within the side airbag sensor (RH) is faulty. Replace the side airbag sensor (RH). <Ref. to AB-21, Side Airbag Sensor.> U: DTC 54 DTC DETECTING CONDITION: Side airbag sensor (LH) is faulty.
Page 213 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) W: DTC 56 DTC DETECTING CONDITION: • Curtain airbag sensor (RH) is faulty. • Curtain airbag harness (RH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 214 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG REAR HARNESS (CUR- Is the resistance less than 10 Go to step 2. Replace the airbag "? TAIN AIRBAG SENSOR HARNESS RH). rear harness with 1) Turn the ignition switch OFF, disconnect the body harness.
Page 215 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) X: DTC 57 DTC DETECTING CONDITION: • Curtain airbag sensor (LH) is faulty. • Curtain airbag harness (LH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 216 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG REAR HARNESS (CUR- Is the resistance less than 10 Go to step 2. Replace the airbag "? TAIN AIRBAG SENSOR HARNESS LH). rear harness with 1) Turn the ignition switch OFF, disconnect the body harness.
Page 217 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AA:DTC 61 DTC DETECTING CONDITION: • Seat belt pretensioner (RH) circuit is open, shorted or shorted to ground. • Airbag control module is faulty. • Pretensioner is faulty. • Pretensioner harness is faulty. CAUTION: •...
Page 218 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 1. MODEL WITH CURTAIN AIRBAG Step Check CHECK SEAT BELT PRETENSIONER. Does the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? belt pretensioner battery ground terminal, and wait more than 20 (RH).
Page 219 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 2. MODEL WITHOUT CURTAIN AIRBAG Step Check CHECK SEAT BELT PRETENSIONER. Does the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? belt pretensioner battery ground terminal, and wait more than 20 (RH).
Page 220 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AB:DTC 62 DTC DETECTING CONDITION: • Seat belt pretensioner (LH) circuit is open, shorted or shorted to ground. • Airbag control module is faulty. • Pretensioner is faulty. • Pretensioner harness is faulty. CAUTION: •...
Page 221 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 1. MODEL WITH CURTAIN AIRBAG Step Check CHECK SEAT BELT PRETENSIONER. Does the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? belt pretensioner battery ground terminal, and wait more than 20 (LH).
Page 222 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 2. MODEL WITHOUT CURTAIN AIRBAG Step Check CHECK SEAT BELT PRETENSIONER. Does the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? belt pretensioner battery ground terminal, and wait more than 20 (LH).
Page 223 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AC:DTC 65 DTC DETECTING CONDITION: • Seat belt pretensioner (RH) circuit is shorted to power supply. • Pretensioner is faulty. • Pretensioner harness is faulty. • Airbag control module is faulty. CAUTION: •...
Page 224 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 1. MODEL WITH CURTAIN AIRBAG Step Check CHECK SEAT BELT PRETENSIONER. Does the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? belt pretensioner battery ground terminal, and wait more than 20 (RH).
Page 225 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 2. MODEL WITHOUT CURTAIN AIRBAG Step Check CHECK SEAT BELT PRETENSIONER. Does the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? belt pretensioner battery ground terminal, and wait more than 20 (RH).
Page 226 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AD:DTC 66 DTC DETECTING CONDITION: • Seat belt pretensioner (LH) circuit is shorted to power supply. • Pretensioner is faulty. • Pretensioner harness is faulty. • Airbag control module is faulty. CAUTION: •...
Page 227 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 1. MODEL WITH CURTAIN AIRBAG Step Check CHECK SEAT BELT PRETENSIONER. Does the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? belt pretensioner battery ground terminal, and wait more than 20 (LH).
Page 228 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) 2. MODEL WITHOUT CURTAIN AIRBAG Step Check CHECK SEAT BELT PRETENSIONER. Does the airbag warning light Replace the seat Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? belt pretensioner battery ground terminal, and wait more than 20 (LH).
Page 229 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AE:DTC 71 DTC DETECTING CONDITION: • Airbag main harness circuit is open, shorted or shorted to ground. • Airbag module harness (Driver’s side) circuit is open, shorted or shorted to ground. • Roll connector circuit is open, shorted or shorted to ground. •...
Page 230 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK DRIVER’S AIRBAG MODULE. Does the airbag warning light Replace the Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? driver’s airbag battery ground terminal, and wait more than 20 module.
Page 231 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK AIRBAG MAIN HARNESS (DRIV- Is the resistance more than 1 Replace the airbag Replace the airbag ER’S AIRBAG HARNESS). M"? control module. main harness with Measure the resistance between connector <Ref.
Page 232 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AF:DTC 72 DTC DETECTING CONDITION: • Airbag main harness circuit is open, shorted or shorted to ground. • Airbag module harness (Passenger’s side) circuit is open, shorted or shorted to ground. • Passenger’s airbag module is faulty. •...
Page 233 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK PASSENGER’S AIRBAG MODULE. Does the airbag warning light Replace the pas- Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? senger airbag battery ground terminal, and wait more than 20 module.
Page 234 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AG:DTC 75 DTC DETECTING CONDITION: • Airbag main harness circuit (Driver’s side) is shorted to power supply. • Airbag module harness circuit (Driver’s side) is shorted to power supply. • Roll connector is shorted to the power supply. •...
Page 235 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK DRIVER’S AIRBAG MODULE. Does the airbag warning light Replace the Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? driver’s airbag battery ground terminal, and wait more than 20 module.
Page 236 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AH:DTC 76 DTC DETECTING CONDITION: • Airbag main harness circuit (Passenger’s side) is shorted to power supply. • Airbag module harness circuit (Passenger’s side) is shorted to power supply. • Passenger’s airbag module is faulty. •...
Page 237 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK PASSENGER’S AIRBAG MODULE. Does the airbag warning light Replace the pas- Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? senger airbag battery ground terminal, and wait more than 20 module.
Page 238 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AI: DTC 91 DTC DETECTING CONDITION: • Curtain airbag harness (RH) is faulty. • Curtain airbag module (RH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 239 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK CURTAIN AIRBAG MODULE. Does the airbag warning light Replace the cur- Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? tain airbag mod- battery ground terminal, and wait more than 20 ule (RH).
Page 240 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AJ:DTC 92 DTC DETECTING CONDITION: • Curtain airbag harness (LH) is faulty. • Curtain airbag module (LH) is faulty. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 241 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK CURTAIN AIRBAG MODULE. Does the airbag warning light Replace the cur- Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? tain airbag mod- battery ground terminal, and wait more than 20 ule (LH).
Page 242 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AK:DTC 95 DTC DETECTING CONDITION: • Curtain airbag harness (RH) is shorted to power supply. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 243 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK CURTAIN AIRBAG MODULE. Does the airbag warning light Replace the cur- Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? tain airbag mod- battery ground terminal, and wait more than 20 ule (RH).
Page 244 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AL:DTC 96 DTC DETECTING CONDITION: • Curtain airbag harness (LH) is shorted to power supply. • Airbag control module is faulty. CAUTION: • Before diagnosing the airbag system, be sure to turn the ignition switch OFF, disconnect the ground terminal from battery, and wait more than 20 seconds before starting to work.
Page 245 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) Step Check CHECK SIDE AIRBAG MODULE. Does the airbag warning light Replace the cur- Go to step 2. 1) Turn the ignition switch OFF, disconnect the operate properly? tain airbag mod- battery ground terminal, and wait more than 20 ule (LH).
Page 246 Diagnostic Chart with Trouble Code AIRBAG SYSTEM (DIAGNOSTICS) AB(diag)-116...
Page 247 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 248 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 249 SEAT BELT SYSTEM Page General Description ..................2 Pretensioner Connector ................6 Inspection Locations After a Collision ............7 Seat Belt Warning System ................8 Front Seat Belt ..................12 Rear Seat Belt...................14 Disposal of Pretensioner ................17...
Page 250: General Description
General Description SEAT BELT SYSTEM 1. General Description A: COMPONENT 1. FRONT SEAT BELT SB-00178 Adjustable anchor ASSY Seat belt retractor Tightening torque: N m (kgf-m, ft-lb) Shoulder anchor Center pillar upper trim T1: 30 (3.1, 22) Outer seat belt ASSY Inner seat belt ASSY T2: 38 (3.9, 28) T3: 53 (5.4, 39)
Page 251 General Description SEAT BELT SYSTEM 2. REAR SEAT BELT (SEDAN MODEL) SB-00147 Outer seat belt RH ASSY Outer seat belt LH ASSY Tightening torque: N m (kgf-m, ft-lb) Shoulder seat belt CTR ASSY Center seat belt LH ASSY T: 30 (3.1, 22) SB-3...
Page 252 General Description SEAT BELT SYSTEM 3. REAR SEAT BELT (WAGON MODEL) SB-00148 Outer seat belt RH ASSY Center seat belt LH ASSY Tightening torque: N m (kgf-m, ft-lb) Shoulder seat belt CTR ASSY Outer belt guide RH T1: 30 (3.1, 22) Outer seat belt LH ASSY Outer belt guide LH T2: 53 (5.4, 39.1)
Page 253 General Description SEAT BELT SYSTEM B: CAUTION • Do not disassemble or attempt to repair the pre- tensioner. If it is dented, cracked or deformed, re- • Before starting service, turn the ignition switch to place it with a new one. OFF, disconnect the battery ground cable and wait •...
Page 254: Pretensioner Connector
Pretensioner Connector SEAT BELT SYSTEM 2. Pretensioner Connector A: REMOVAL 1) Using a flat tip screwdriver, pry the push lock up- ward to unlock. AB-00478 2) Pull out the connector to disconnect it from re- tractor assembly. AB-00479 B: INSTALLATION Connect the connector in the reverse order of dis- connection.
Page 255: Inspection Locations After A Collision
Inspection Locations After a Collision SEAT BELT SYSTEM 3. Inspection Locations After a Collision A: INSPECTION Check for the following, and replace with new parts if necessary. • Center pillar lower garnish is discolored or cracked. • Wire harness and connector are damaged. SB-7...
Page 256: Seat Belt Warning System
TION, Subaru Select Monitor.> CHECK BODY INTEGRATED UNIT. Is the data of “Driver’s Seat Go to step 4. Check the harness 1) Connect the Subaru Select Monitor to data SW input” “OFF”? between body inte- link connector. grated unit and 2) Turn the ignition switch to ON (engine chassis ground.
Page 257 ABS or VDC warning light, but this indicates no malfunction. When diagno- sis is finished, perform the ABS or VDC memo- ry clearance procedure. <Ref. to ABS(diag)-15, OPERATION, Subaru Select Monitor.> <Ref. to VDC(diag)-16, OPERATION, Subaru Select Monitor.> CHECK SEAT BELT WARNING SYSTEM.
Page 258 Check CHECK VEHICLE SPEED SIGNAL. Is DTC displayed? Perform the diag- Go to step 3. Check DTC of ABS or VDC using Subaru nosis according to Select Monitor. <Ref. to ABS(diag)-15, OPER- DTC. ATION, Subaru Select Monitor.> <Ref. to VDC(diag)-16, OPERATION, Subaru Select Monitor.>...
Page 259 ABS or VDC warning light, but this indicates no malfunction. When diagno- sis is finished, perform the ABS or VDC memo- ry clearance procedure. <Ref. to ABS(diag)-15, OPERATION, Subaru Select Monitor.> <Ref. to VDC(diag)-16, OPERATION, Subaru Select Monitor.> CHECK SEAT BELT WARNING SYSTEM.
Page 260: Front Seat Belt
Front Seat Belt SEAT BELT SYSTEM 5. Front Seat Belt 8) Disconnect the pretensioner connector (A), and remove the bolt, and then remove the seat belt re- A: REMOVAL tractor. 1. OUTER SEAT BELT ASSEMBLY 1) Turn the ignition switch to OFF, disconnect the battery ground cable from battery, and wait for more than 20 seconds before starting work.
Page 261 Front Seat Belt SEAT BELT SYSTEM B: INSTALLATION 1. OUTER SEAT BELT ASSEMBLY Install in the reverse order of removal. CAUTION: • The parts of driver and passenger sides are not identical. Before installation, make sure that the correct part is used. •...
Page 262: Rear Seat Belt
Rear Seat Belt SEAT BELT SYSTEM 6. Rear Seat Belt 3) Remove the rear quarter trim. <Ref. to EI-63, REMOVAL, Rear Quarter Trim.> A: REMOVAL 4) Remove the rear shelf trim. <Ref. to EI-70, RE- MOVAL, Rear Shelf Trim.> 1. OUTER SEAT BELT RH ASSEMBLY AND 5) Remove the bolt to remove shoulder seat belt LH ASSEMBLY (SEDAN MODEL) assembly.
Page 263 Rear Seat Belt SEAT BELT SYSTEM 4. OUTER SEAT BELT RH ASSEMBLY AND 3) Remove the clips, and then lower the roof trim end. LH ASSEMBLY (WAGON MODEL) 1) Remove the luggage floor box. <Ref. to EI-74, REMOVAL, Luggage Floor Box.> 2) Remove the rear seat cushion and backrest shoulder.
Page 264 Rear Seat Belt SEAT BELT SYSTEM B: INSTALLATION • During installation, make sure that the seat belts are not twisted. 1. OUTER SEAT BELT RH ASSEMBLY AND • After installation, make sure that the seat LH ASSEMBLY (SEDAN MODEL) belts are smoothly extended and wound. Install in the reverse order of removal.
Page 265: Disposal Of Pretensioner
• Wrap the deployed pretensioner in an airtight vi- nyl bag, and then discard it. • If circumstances do not permit the pretensioner deployment, contact the SUBARU dealer. B: PROCEDURE 1. DEPLOYING OF PRETENSIONER WHILE INSTALLED IN VEHICLE 1) Fold the backrest all the way forward, and then move the front seat all the way forward.
Page 266 Disposal of Pretensioner SEAT BELT SYSTEM 4) Cut off the seat belt as close to retractor as pos- CAUTION: sible. • After deployment, the pretensioner is espe- cially hot, leave it unattended for 40 minutes or longer, and then discard it. •...
Page 267 Disposal of Pretensioner SEAT BELT SYSTEM 9) Put three tires without wheels on the tire in- 12) Wrap the deployed pretensioner in airtight vinyl stalled with pretensioner. Put on an additional tire bag, and discard it. with a wheel on top, and then fasten them tight with a rope.
Page 268 Disposal of Pretensioner SEAT BELT SYSTEM SB-20...
Page 269 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 270 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 271 LIGHTING SYSTEM Page General Description ..................2 Headlight and Tail Light System ..............3 Front Fog Light System................4 Rear Fog Light System ................5 Turn Signal Light and Hazard Light System..........6 Back-up Light System .................7 Stop Light System ..................8 Room Light System..................9 Combination Switch (Light) ...............10 Headlight Beam Leveler System...............12 Combination Base Switch Assembly............13 Headlight Assembly ..................14...
Page 272: General Description
General Description LIGHTING SYSTEM 1. General Description A: SPECIFICATION Halogen type low beam 12 V — 55 W Headlight Halogen type high beam 12 V — 60 W Front turn signal light 12 V — 21 W Clearance/parking light 12 V — 5 W Front fog light 12 V —...
Page 273: Headlight And Tail Light System
Headlight and Tail Light System LIGHTING SYSTEM 2. Headlight and Tail Light Sys- 3. TAIL AND ILLUMINATION RELAY Measure the resistance between tail and illumina- tion relay terminals when connecting terminal No. 4 A: WIRING DIAGRAM to battery positive terminal and terminal No. 3 to battery ground terminal.
Page 274: Front Fog Light System
Front Fog Light System LIGHTING SYSTEM 3. Front Fog Light System A: WIRING DIAGRAM 1. FRONT FOG LIGHT <Ref. to WI-267, WIRING DIAGRAM, Front Fog Light System.> B: INSPECTION 1. FRONT FOG LIGHT SWITCH Measure the resistance between front fog light switch terminals.
Page 275: Rear Fog Light System
Rear Fog Light System LIGHTING SYSTEM 4. Rear Fog Light System A: WIRING DIAGRAM 1. REAR FOG LIGHT <Ref. to WI-279, WIRING DIAGRAM, Rear Fog Light System.> B: INSPECTION 1. REAR FOG LIGHT SWITCH Measure the rear fog light switch resistance be- tween terminals.
Page 276: Turn Signal Light And Hazard Light System
Turn Signal Light and Hazard Light System LIGHTING SYSTEM 5. Turn Signal Light and Hazard Light System A: WIRING DIAGRAM 1. TURN SIGNAL LIGHT AND HAZARD LIGHT SYSTEM <Ref. to WI-282, WIRING DIAGRAM, Turn Signal Light and Hazard Light System.> B: INSPECTION 1.
Page 277: Back-Up Light System
Back-up Light System LIGHTING SYSTEM 6. Back-up Light System battery positive terminal and terminal No. 3 to bat- tery ground terminal. A: WIRING DIAGRAM 1. BACK-UP LIGHT <Ref. to WI-257, WIRING DIAGRAM, Back-up Light System.> B: INSPECTION 1. BACK-UP LIGHT SWITCH (MT MODEL) Measure the resistance between back-up light switch terminals.
Page 278: Stop Light System
Stop Light System LIGHTING SYSTEM 7. Stop Light System A: WIRING DIAGRAM 1. STOP LIGHT <Ref. to WI-281, WIRING DIAGRAM, Stop Light System.> B: INSPECTION 1. STOP LIGHT SWITCH Measure the resistance between stop light switch terminals. LI-00265 (1) Model without cruise control (2) Model with cruise control Switch position Terminal No.
Page 279: Room Light System
Room Light System LIGHTING SYSTEM 8. Room Light System 3. TRUNK ROOM LIGHT SWITCH Measure the resistance between trunk room light A: WIRING DIAGRAM switch terminals. 1. INTERIOR LIGHT <Ref. to WI-271, WIRING DIAGRAM, Interior Light System.> B: INSPECTION 1. DOOR SWITCH Measure the resistance between door switch termi- nals.
Page 280: Combination Switch (Light)
Combination Switch (Light) LIGHTING SYSTEM 9. Combination Switch (Light) 6) Remove the screws which secure switch, then remove the combination switch. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. <Ref. to EI-56, REMOVAL, Instrument Panel Assembly.> 3) Remove the screws and remove the steering column cover (upper and lower).
Page 281: Front Fog Light
Combination Switch (Light) LIGHTING SYSTEM • EK model 4. FRONT FOG LIGHT • LHD model/EK model Switch position Terminal No. Standard — More than 1 M! Switch position Terminal No. Standard Less than 1 ! Tail 14 and 16 — More than 1 M! Less than 1 ! Head...
Page 282: Headlight Beam Leveler System
Headlight Beam Leveler System LIGHTING SYSTEM 10.Headlight Beam Leveler Sys- A: WIRING DIAGRAM 1. HEADLIGHT BEAM LEVELER SYSTEM <Ref. to WI-243, WIRING DIAGRAM, Headlight Beam Leveler System.> B: INSPECTION 1. HEADLIGHT BEAM LEVELER ACTUA- 1) Turn on the headlights. 2) Confirm the headlight beam level is lowered by changing the switch position to 0 "...
Page 283: Combination Base Switch Assembly
Combination Base Switch Assembly LIGHTING SYSTEM 11.Combination Base Switch 2. PARKING SWITCH Assembly Measure the resistance between parking switch terminals. A: REMOVAL 1) Remove the driver’s airbag module. <Ref. to AB- 14, REMOVAL, Driver’s Airbag Module.> 2) Remove the steering wheel. <Ref. to PS-20, RE- MOVAL, Steering Wheel.>...
Page 284: Headlight Assembly
Headlight Assembly LIGHTING SYSTEM 12.Headlight Assembly 1) Remove the headlight assembly. <Ref. to LI-14, REMOVAL, Headlight Assembly.> A: REMOVAL 2) Remove the eight screws. 1) Disconnect the ground cable from battery. 2) Remove the air intake duct. (When removing the headlight RH) LI-00327 3) Remove headlight side bracket.
Page 285 Headlight Assembly LIGHTING SYSTEM CAUTION: CAUTION: Avoid heating one specific point of the seal por- Completely remove the packing not to leave tion and heating the headlight assembly to any chips behind. 100$C (212$F) or more. LI-00060 (A) Packing D: ASSEMBLY 1) Cut the tip of packing (A) at an angle of 45$.
Page 286 Headlight Assembly LIGHTING SYSTEM 4) Match the positions of the lens and headlight as- sembly, and then insert the lens into the headlight assembly. CAUTION: Remove the turn signal light bulb and clear- ance/parking light bulb before removing the lens. 5) Secure the hook, and then install the clip and screw.
Page 287 Headlight Assembly LIGHTING SYSTEM LI-00324 Vehicle center Bulb center marking 3 m (10 ft) Illustration above shows the illumination pattern for LHD model. Illumination pattern for RHD model is sym- metrically opposite. H mm (in) h mm (in) W mm (in) Sedan Wagon at 3 m (10 ft)
Page 288: Headlight Bulb
Headlight Bulb LIGHTING SYSTEM 13.Headlight Bulb 7) Remove the light bulb retaining spring (A) to re- move bulb. A: REMOVAL 1. HIGH BEAM AND LOW BEAM CAUTION: • Because the halogen bulb operates at a high temperature, dirt and oil on the bulb surface re- duces the bulb’s service life.
Page 289: Front Turn Signal Light Bulb
Front Turn Signal Light Bulb LIGHTING SYSTEM 14.Front Turn Signal Light Bulb A: REMOVAL 1) When removing the turn signal light bulb, fully turn the steering wheels to opposite direction from desired turn signal light bulb. LI-00311 (1) Turn the steering wheel fully. (2) Mud guard (3) Front turn signal light 2) Turn the mud guard inward.
Page 290: Clearance/Parking Light Bulb
Clearance/Parking Light Bulb LIGHTING SYSTEM 15.Clearance/Parking Light Bulb A: REMOVAL 1) Remove the air intake duct. (When removing the clearance light/parking light bulb RH). LI-00273 2) Remove the battery cover. (When removing the clearance light/parking light bulb LH) 3) Tilt the washer tank filler neck. (When removing the clearance/parking light bulb) 4) Remove the headlight low beam back cover (B).
Page 291: Front Fog Light Assembly
Front Fog Light Assembly LIGHTING SYSTEM 16.Front Fog Light Assembly 2. OUTBACK MODEL 1) Disconnect the ground cable from battery. A: REMOVAL 2) Remove the two clips, and then turn over the 1. EXCEPT FOR OUTBACK MODEL lower mud guard. 1) Disconnect the ground cable from battery.
Page 292: Front Fog Light Bulb
Front Fog Light Bulb LIGHTING SYSTEM 17.Front Fog Light Bulb A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disengage the two clips, and then turn over the lower mud guard. LI-00288 3) Disconnect the harness connector. 4) Remove the back cover. LI-00291 5) Remove the spring retainer then detach the fog light bulb.
Page 293: Rear Fog Light
Rear Fog Light LIGHTING SYSTEM 18.Rear Fog Light A: REMOVAL NOTE: Rear fog light is installed to rear combination light of driver’s side for sedan and rear gate garnish of driver’s side for wagon. 1. SEDAN MODEL Remove the rear combination light. <Ref. to LI-25, REMOVAL, Rear Combination Light Assembly.>...
Page 294: Side Turn Signal Light Assembly
Side Turn Signal Light Assembly LIGHTING SYSTEM 19.Side Turn Signal Light As- sembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the scalp caps. <Ref. to GW-17, RE- PLACEMENT, Scalp Cap.> 3) Remove the mirror. <Ref. to GW-19, REPLACE- MENT, Outer Mirror.>...
Page 295: Rear Combination Light Assembly
Rear Combination Light Assembly LIGHTING SYSTEM 20.Rear Combination Light As- 4) Remove the two bolts, and then detach the rear combination light by pulling it to the rear side of ve- sembly hicle. A: REMOVAL 1. SEDAN MODEL 1) Disconnect the ground cable from battery. 2) Remove the trunk room side trim.
Page 296: Tail/Stop Light Bulb
Tail/Stop Light Bulb LIGHTING SYSTEM 21.Tail/Stop Light Bulb A: REMOVAL 1. SEDAN MODEL 1) Remove the trunk side trim cover. 2) Turn the socket and remove the bulb. LI-00297 Model without rear fog light (A) Tail light (B) Stop light Model with rear fog light (A) Tail/stop light (B) Rear fog light (Driver’s side only)
Page 297: Rear Turn Signal Light Bulb
Rear Turn Signal Light Bulb LIGHTING SYSTEM 22.Rear Turn Signal Light Bulb A: REMOVAL 1. SEDAN MODEL 1) Remove the trunk side trim cover. 2) Turn the socket and remove the bulb. LI-00299 2. WAGON MODEL 1) Remove the rear combination light assembly. <Ref.
Page 298: Back-Up Light Assembly
Back-up Light Assembly LIGHTING SYSTEM 23.Back-up Light Assembly A: REMOVAL NOTE: In case of model with rear fog light, back-up light is installed to only passenger’s side. 1. SEDAN MODEL Remove the rear combination light. <Ref. to LI-25, REMOVAL, Rear Combination Light Assembly.> 2.
Page 299: Back-Up Light Bulb
Back-up Light Bulb LIGHTING SYSTEM 24.Back-up Light Bulb A: REMOVAL 1. SEDAN MODEL 1) Remove the bulb inspection cover of trunk side trim. 2) Turn the socket and remove the bulb. LI-00304 2. WAGON MODEL 1) Remove the bulb inspection cover of rear gate trim.
Page 300: Rear Fog Light Bulb
Rear Fog Light Bulb LIGHTING SYSTEM 25.Rear Fog Light Bulb A: REMOVAL 1. SEDAN MODEL 1) Remove the bulb inspection cover of trunk side trim. 2) Turn the socket and remove the bulb. LI-00302 2. WAGON MODEL 1) Remove the rear fog light assembly. <Ref. to LI- 23, REMOVAL, Rear Fog Light.>...
Page 301: License Plate Light Assembly
License Plate Light Assembly LIGHTING SYSTEM 26.License Plate Light Assembly A: REMOVAL 1. SEDAN MODEL 1) Remove the trunk lid garnish. <Ref. to EI-75, REMOVAL, Trunk Lid Garnish.> 2) Remove the trunk lid trim. <Ref. to EI-71, TRUNK LID TRIM, REMOVAL, Trunk Room Trim.> 3) Turn and remove the bulb socket (A).
Page 302: License Plate Light
License Plate Light LIGHTING SYSTEM 27.License Plate Light A: REMOVAL 1. SEDAN MODEL 1) Remove the trunk lid trim. <Ref. to EI-71, TRUNK LID TRIM, REMOVAL, Trunk Room Trim.> 2) Turn and remove the bulb socket (A). LI-00307 3) Remove the bulb. 2.
Page 303: High-Mounted Stop Light
High-mounted Stop Light LIGHTING SYSTEM 28.High-mounted Stop Light 5) Disengage three claws and remove the lens (A). A: REMOVAL 1. SEDAN MODEL 1) Disconnect the ground cable from battery. 2) Push the high-mounted stop light backward of the vehicle (1), raise the rear portion of it (2) and re- move the clips to remove it.
Page 304: Spot Map Light
Spot Map Light LIGHTING SYSTEM 29.Spot Map Light 2. SPOT MAP LIGHT SWITCH Measure the resistance between spot map light A: REMOVAL switch terminals. 1) Disconnect the ground cable from battery. 2) Remove the lens (A) and spot map light mount- Switch position Terminal No.
Page 305: Room Light
Room Light LIGHTING SYSTEM 30.Room Light 2. ROOM LIGHT SWITCH Measure the resistance between room light switch A: REMOVAL terminals. 1) Disconnect the ground cable from battery. 2) Remove the lens (A) and mounting screws (B). 3 2 1 LI-00257 LI-00315 Switch position Terminal No.
Page 306: Luggage Room Light
Luggage Room Light LIGHTING SYSTEM 31.Luggage Room Light A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove luggage room light body (A). LI-00258 3) Disconnect the harness connector and remove the lens. B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1.
Page 307: Trunk Room Light
Trunk Room Light LIGHTING SYSTEM 32.Trunk Room Light Trunk lid position Terminal No. Standard A: REMOVAL Close More than 1 M! 1 and 3 1.5%0.5 ! Open 1) Disconnect the ground cable from battery. 2) Turn the trunk room light counterclockwise to 60$ to remove it and disconnect the harness con- nector.
Page 308: Glove Box Light
Glove Box Light LIGHTING SYSTEM 33.Glove Box Light A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Disconnect the harness connector. 4) Remove the glove box light. LI-00323 B: INSTALLATION Install in the reverse order of removal.
Page 309: Door Step Light
Door Step Light LIGHTING SYSTEM 34.Door Step Light A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the lens (A), and then remove the door step light bulb. LI-00266 3) Remove the front door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.>...
Page 310: Ignition Switch Illumination
Ignition Switch Illumination LIGHTING SYSTEM 35.Ignition Switch Illumination 5) Turn the ignition switch illumination connector to left and remove it. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the screws and detach the upper col- umn cover and lower column cover. LI-00343 (A) Ignition switch illumination connector (B) Ignition switch illumination...
Page 311 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 312 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 313 WIPER AND WASHER SYSTEMS Page General Description ..................2 Wiper and Washer System .................7 Combination Switch (Wiper)................8 Wiper Blade....................13 Washer Tank and Motor................16 Front Wiper Arm..................17 Front Wiper Motor and Link...............18 Front Washer Nozzle ................20 Rear Wiper Arm ..................21 Rear Wiper Motor..................22 Rear Washer .....................24...
Page 314: General Description
General Description WIPER AND WASHER SYSTEMS 1. General Description A: SPECIFICATION Front wiper motor Input 12 V — 72 W or less Rear wiper motor Input 12 V — 42 W or less Pump type Centrifugal Front washer motor Input 12 V —...
Page 315 General Description WIPER AND WASHER SYSTEMS • RHD model WW-00222 Tightening torque: N m (kgf-m, ft-lb) Wiper rubber Wiper link ASSY T1: 6.0 (0.61, 4.4) Wiper blade ASSY Wiper motor ASSY T2: 20 (2.0, 14.5) Wiper arm WW-3...
Page 316 General Description WIPER AND WASHER SYSTEMS 2. REAR WIPER (SEDAN MODEL) WW-00166 Tightening torque: N m (kgf-m, ft-lb) Wiper rubber Nozzle & hose ASSY T1: 7.5 (0.76, 5.5) Wiper blade ASSY T2: 8.0 (0.82, 5.9) Wiper arm Wiper motor ASSY Wiper arm cover Cushion WW-4...
Page 317 General Description WIPER AND WASHER SYSTEMS 3. REAR WIPER (WAGON MODEL) WW-00167 Tightening torque: N m (kgf-m, ft-lb) Wiper rubber Wiper arm cover T1: 7.5 (0.77, 6.0) Wiper blade ASSY T2: 8.0 (0.82, 5.9) Wiper arm Wiper motor ASSY WW-5...
Page 318 General Description WIPER AND WASHER SYSTEMS 4. WASHER TANK WW-00168 Tightening torque: N m (kgf-m, ft-lb) Sedan model Wagon model T: 6.0 (0.61, 4.4) Washer nozzle Front washer motor Washer hose Rear washer motor Washer tank Grommet Washer tank cap Washer motor cover C: CAUTION •...
Page 319: Wiper And Washer System
Wiper and Washer System WIPER AND WASHER SYSTEMS 2. Wiper and Washer System A: WIRING DIAGRAM 1. WIPER AND WASHER (FRONT) LHD MODEL <Ref. to WI-324, LHD MODEL, WIRING DIAGRAM, Front Wiper and Washer System.> 2. WIPER AND WASHER (FRONT) RHD MODEL <Ref.
Page 320 Combination Switch (Wiper) WIPER AND WASHER SYSTEMS 3. Combination Switch (Wiper) C: INSPECTION A: REMOVAL 1. COMBINATION SWITCH 1) Disconnect the ground cable from battery. 1) Inspect the continuity between each connector 2) Remove the instrument panel lower cover. <Ref. terminal.
Page 321 Combination Switch (Wiper) WIPER AND WASHER SYSTEMS • KA model Switch position Terminal No. Standard Less than 1 " 3 and 12 Less than 1 " 3 and 12 Less than 1 " Front 3 and 11 Less than 1 " 2 and 11 Less than 1 "...
Page 322: Combination Switch (Wiper)
When the front wiper switch is operated, check <Ref. to SL-46, the input signal using Subaru Select Monitor. Body Integrated 1) Connect the Subaru Select Monitor to data Unit.> link connector. 2) Turn the ignition switch to ON. 3) Select {Body Integrated Unit} from the main menu.
Page 323 Check the rear Check the input from body integrated unit wiper switch. <Ref. using Subaru Select Monitor. to WW-8, 1) Connect the Subaru Select Monitor to data INSPECTION, link connector. Combination 2) Turn the ignition switch to ON. Switch (Wiper).>...
Page 324 Combination Switch (Wiper) WIPER AND WASHER SYSTEMS Step Check CHECK HARNESS BETWEEN BODY INTE- Is the resistance less than 10 Go to step 4. Repair the open "? GRATED UNIT AND REAR WIPER MOTOR. circuit of harness 1) Turn the ignition switch to OFF. between body inte- 2) Disconnect the harness connector of body grated unit and...
Page 325: Wiper Blade
Wiper Blade WIPER AND WASHER SYSTEMS 4. Wiper Blade C: DISASSEMBLY A: REMOVAL 1. METAL TYPE Pull side (A) of the wiper rubber stopper and re- CAUTION: move the rubber from blade assembly. When replacing wiper blades or etc., be sure to stand up the driver side wiper arm first, then passenger side wiper arm next.
Page 326 Wiper Blade WIPER AND WASHER SYSTEMS D: ASSEMBLY 2) Make sure the wiper rubber is securely fastened to the pull stopper (A). 1. METAL TYPE 1) Insert the wiper rubber onto blade so that the stopper is in the position shown in the figure. WW-00037 WW-00230 2.
Page 327 Wiper Blade WIPER AND WASHER SYSTEMS 3) Insert the wiper rubber into the claw (A). WW-00147 E: INSPECTION 1) When the wiper does not perform well, inspect the followings: • Make sure the movable part of the wiper blade assembly moves smoothly. •...
Page 328: Washer Tank And Motor
Washer Tank and Motor WIPER AND WASHER SYSTEMS 5. Washer Tank and Motor D: ASSEMBLY 1) Assemble in the reverse order of disassembly. A: REMOVAL 2) Confirm that water does not leak from installa- 1) Open the hood. tion area of motor. 2) Disconnect the ground cable from battery.
Page 329: Front Wiper Arm
Front Wiper Arm WIPER AND WASHER SYSTEMS 6. Front Wiper Arm C: ADJUSTMENT Operate the wiper once. Align the wiper blade to A: REMOVAL ceramic print point mark (A) of front window panel. CAUTION: When replacing wiper blades or etc., be sure to stand up the driver side wiper arm first, then passenger side wiper arm next.
Page 330: Front Wiper Motor And Link
Front Wiper Motor and Link WIPER AND WASHER SYSTEMS 7. Front Wiper Motor and Link • RHD model A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the cowl panel. <Ref. to EI-39, RE- MOVAL, Cowl Panel.> 3) Disconnect the connector of wiper motor assem- bly.
Page 331 Front Wiper Motor and Link WIPER AND WASHER SYSTEMS • RHD model WW-00210 4) Connect the battery and confirm that the wiper motor stops at automatic stop position after the wiper motor operates at low speed again. • LHD model WW-00221 •...
Page 332: Front Washer Nozzle
Front Washer Nozzle WIPER AND WASHER SYSTEMS 8. Front Washer Nozzle Injection angle should be adjusted with 0.5 mm (0.020 in) thickness steel scale. Use maximum A: REMOVAL thickness of 0.5 mm steel scale, because the injec- 1) Remove the front hood insulator. <Ref. to EB- tion slit width of washer nozzle is 0.6 mm (0.024 in).
Page 333: Rear Wiper Arm
Rear Wiper Arm WIPER AND WASHER SYSTEMS 9. Rear Wiper Arm C: ADJUSTMENT 1) Operate the rear wiper once. A: REMOVAL 2) Align the blade with the marking (A) of glass. 1. SEDAN MODEL 1) Detach the wiper arm cover (A). 2) Remove the nut (B) to remove wiper arm.
Page 334: Rear Wiper Motor
Rear Wiper Motor WIPER AND WASHER SYSTEMS 10.Rear Wiper Motor 5) Remove the bolts to remove wiper motor assem- bly (A). A: REMOVAL 1. SEDAN MODEL 1) Disconnect the ground cable from battery. 2) Remove the rear wiper arm. <Ref. to WW-21, SEDAN MODEL, REMOVAL, Rear Wiper Arm.>...
Page 335 Rear Wiper Motor WIPER AND WASHER SYSTEMS C: INSPECTION 1) Connect the battery to wiper motor connector and confirm that wiper motor operates. WW-00186 2) Connect the battery to terminals of connector, and remove the terminal connection with wiper mo- tor rotated, and stop the wiper motor through oper- ation.
Page 336: Rear Washer
Rear Washer WIPER AND WASHER SYSTEMS 11.Rear Washer NOTE: Injection position of rear washer nozzle is adjust- A: REMOVAL able only for sedan model. • Sedan model 1. SEDAN MODEL 1) Remove the rear wiper arm. <Ref. to WW-21, SEDAN MODEL, REMOVAL, Rear Wiper Arm.> 2) Remove the cap (A) and nut (B) from rear wiper shaft.
Page 337 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 338 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 339 ENTERTAINMENT Page General Description ..................2 Audio System ....................3 Front Accessory Power Supply Socket System ..........4 Audio ......................5 Front Speaker .....................6 Tweeter .......................7 Squawker ....................8 Rear Speaker ....................9 Woofer.......................10 Power Amplifier ..................11 Antenna.....................12 Antenna Amplifier..................13 Noise Suppressor..................14 Navigation Display ..................15 GPS Antenna ....................16 Navigation Body ..................17 Front Accessory Power Supply Socket .............18 Steering Satellite Switch ................19...
Page 340: General Description
General Description ENTERTAINMENT 1. General Description A: CAUTION • Before disassembling or reassembling parts, al- ways disconnect the battery ground cable. When replacing the audio, control unit, and other parts provided with memory functions, record the memo- ry contents before disconnecting the battery ground cable.
Page 341: Audio System
Audio System ENTERTAINMENT 2. Audio System A: WIRING DIAGRAM <Ref. to WI-116, WIRING DIAGRAM, Audio System.> B: INSPECTION Symptom Repair order No power coming in. (No display and no sound from speakers) (1) Check the fuse and power supply for audio. (2) Check the audio ground.
Page 342: Front Accessory Power Supply Socket System
Front Accessory Power Supply Socket System ENTERTAINMENT 3. Front Accessory Power Sup- ply Socket System A: WIRING DIAGRAM <Ref. to WI-242, WIRING DIAGRAM, Front Acces- sory Power Supply Socket System.> ET-4...
Page 343: Audio
Audio ENTERTAINMENT 4. Audio A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. <Ref. to EI-53, RE- MOVAL, Console Box.> 3) Remove the console front panel. <Ref. to EI-54, REMOVAL, Center Console.> 4) Remove the console side garnish. <Ref. to EI- 54, REMOVAL, Center Console.>...
Page 344: Front Speaker
Front Speaker ENTERTAINMENT 5. Front Speaker A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Remove the front speaker mounting screws. ET-00080 4) Disconnect the harness connector and remove front speaker.
Page 345: Tweeter
Tweeter ENTERTAINMENT 6. Tweeter A: REMOVAL 1. MODEL WITH TWEETER 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Remove the tweeter mounting screws. ET-00081 4) Disconnect the harness connector and remove tweeter.
Page 346: Squawker
Squawker ENTERTAINMENT 7. Squawker A: REMOVAL NOTE: Model with McIntosh audio system only. 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Remove the squawker mounting screws. ET-00083 4) Disconnect the harness connectors and remove squawker.
Page 347: Rear Speaker
Rear Speaker ENTERTAINMENT 8. Rear Speaker A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Remove the rear speaker mounting screws. ET-00084 4) Disconnect the harness connector and remove the rear speaker.
Page 348: Woofer
Woofer ENTERTAINMENT 9. Woofer 4) Remove the woofer bracket mounting clips (A) and screws, and then remove the woofer bracket. A: REMOVAL 1. SEDAN MODEL NOTE: Model with McIntosh audio system only. 1) Disconnect the ground cable from battery. 2) Remove the rear shelf trim. <Ref. to EI-70, RE- MOVAL, Rear Shelf Trim.>...
Page 349: Power Amplifier
Power Amplifier ENTERTAINMENT 10.Power Amplifier A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the passenger’s seat. <Ref. to SE-7, REMOVAL, Front Seat.> 3) Disconnect the harness connector. 4) Remove the nuts to remove power amplifier. ET-00029 B: INSTALLATION Install in the reverse order of removal.
Page 350: Antenna
Antenna ENTERTAINMENT 11.Antenna 3) Apply conductive silver composition (DUPONT No. 4817) on the broken portion with a drawing A: INSPECTION pen. Measure the resistance between antenna terminal and each antenna wire. If an antenna wire is OK, resistance will be less than 1 !.
Page 351: Antenna Amplifier
Antenna Amplifier ENTERTAINMENT 12.Antenna Amplifier C: INSPECTION Measure the resistance of antenna amplifier. A: REMOVAL • Sedan model 1. SEDAN MODEL (1)-a 1) Disconnect the ground cable from battery. (1)-b 2) Remove the rear quarter trim. <Ref. to EI-63, SEDAN MODEL (MODEL WITH CURTAIN AIR- BAG), REMOVAL, Rear Quarter Trim.>...
Page 352: Noise Suppressor
Noise Suppressor ENTERTAINMENT 13.Noise Suppressor A: REMOVAL 1. SEDAN MODEL 1) Disconnect the ground cable from battery. 2) Remove the rear quarter trim. <Ref. to EI-63, SEDAN MODEL (MODEL WITH CURTAIN AIR- BAG), REMOVAL, Rear Quarter Trim.> 3) Remove the curtain airbag module. <Ref. to AB- 18, REMOVAL, Curtain Airbag Module.>...
Page 353: Navigation Display
Navigation Display ENTERTAINMENT 14.Navigation Display A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the clips, and then remove the center upper panel. ET-00097 3) Remove the display mounting screws. ET-00098 4) Disconnect the harness connector, and then re- move the navigation display.
Page 354: Gps Antenna
GPS Antenna ENTERTAINMENT 15.GPS Antenna A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the combination meter. <Ref. to IDI-16, REMOVAL, Combination Meter Assembly.> 3) Remove the GPS antenna mounting screw, and then remove the GPS antenna. ET-00099 ET-00100 4) Remove the audio.
Page 355: Navigation Body
Navigation Body ENTERTAINMENT 16.Navigation Body A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the navigation body mounting screws in numerical order and pull it out. NOTE: To remove the screw (4) easier, move the naviga- tion body after removing the screw (3).
Page 356: Front Accessory Power Supply Socket
Front Accessory Power Supply Socket ENTERTAINMENT 17.Front Accessory Power Sup- ply Socket A: REMOVAL 1. FRONT 1) Disconnect the ground cable from battery. 2) Remove the console front panel. <Ref. to EI-54, REMOVAL, Center Console.> 3) Disconnect the harness connector, and remove the accessory power supply socket.
Page 357: Steering Satellite Switch
Steering Satellite Switch ENTERTAINMENT 18.Steering Satellite Switch A: REMOVAL 1) Disconnect the ground cable from battery. 2) Set the tire to the straight-ahead position. 3) Remove the airbag module. <Ref. to AB-14, RE- MOVAL, Driver’s Airbag Module.> WARNING: With the airbag module equipped, always refer to “Airbag System”...
Page 358 Steering Satellite Switch ENTERTAINMENT C: INSPECTION 2 3 4 6 7 8 CS-00306 Step Check Is the resistance approx. 22 !? Go to step 2. MUTE SWITCH CONTINUITY CHECK. Replace the satel- 1) Press the mute switch. lite switch. 2) Measure the resistance between satellite switch connector terminals.
Page 359 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 360 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 361 COMMUNICATION SYSTEM Page General Description ..................2 Horn System ....................3 Horn......................4 Horn Switch ....................5...
Page 362: General Description
General Description COMMUNICATION SYSTEM 1. General Description A: CAUTION • Before disassembling or reassembling parts, al- ways disconnect the battery ground cable from bat- tery. When replacing audio, control module, and other parts provided with memory functions, record memory contents before disconnecting the battery ground cable.
Page 363: Horn System
Horn System COMMUNICATION SYSTEM 2. Horn System A: WIRING DIAGRAM 1. HORN <Ref. to WI-245, WIRING DIAGRAM, Horn Sys- tem.> B: INSPECTION 1. HORN RELAY Measure the horn relay resistance between termi- nals (indicated in table below) when connecting the terminal No.
Page 364: Horn
Horn COMMUNICATION SYSTEM 3. Horn A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the two clips and turn up the lower mud guard RH. LI-00288 3) Remove the horn bracket mounting bolt (A). 4) Disconnect the harness connector and remove the horn assembly (B).
Page 365: Horn Switch
Horn Switch COMMUNICATION SYSTEM 4. Horn Switch A: REMOVAL WARNING: Before servicing, be sure to read the notes in AB section for proper handling of driver’s air- bag module. <Ref. to AB-4, CAUTION, General Description.> NOTE: Horn switch is a unit with the driver’s airbag mod- ule.
Page 366 Horn Switch COMMUNICATION SYSTEM COM-6...
Page 367 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 368 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 369 GLASS/WINDOWS/MIRRORS Page General Description ..................2 Power Window System ................8 Power Window Control Switch ..............9 Front Door Glass..................10 Front Regulator and Motor Assembly ............15 Remote Control Mirror System..............16 Scalp Cap....................17 Outer Mirror Assembly ................18 Outer Mirror....................19 Remote Control Mirror Switch ..............20 Rear Door Glass ..................22 Rear Regulator and Motor Assembly ............24 Windshield Glass ..................25...
Page 370: General Description
General Description GLASS/WINDOWS/MIRRORS 1. General Description A: COMPONENT 1. FIXED GLASS (SEDAN MODEL) GW-00331 Windshield glass Rearview mirror mount Six light glass Dam rubber Locating pin Bracket Molding Rear window glass Clip GW-2...
Page 371 General Description GLASS/WINDOWS/MIRRORS 2. FIXED GLASS (WAGON MODEL) GW-00314 Windshield glass Rearview mirror mount Rear quarter glass Dam rubber Locating pin Locating pin Molding Fastener Glass GW-3...
Page 372 General Description GLASS/WINDOWS/MIRRORS 3. FRONT DOOR GLASS (10) GW-00256 Glass Stabilizer (Inner) Tightening torque: N m (kgf-m, ft-lb) Door sash (Front) Regulator ASSY T1: 7.4 (0.75, 5.5) Door sash (Rear) Motor ASSY T2: 13.7 (1.4, 10.1) Weather strip Mirror gusset T3: 5.9 (0.60, 4.4) Stabilizer (Outer) (10)
Page 373 General Description GLASS/WINDOWS/MIRRORS 4. REAR DOOR GLASS GW-00257 Glass Stabilizer (Outer) Tightening torque: N m (kgf-m, ft-lb) Door sash (Front) Stabilizer (Inner) T1: 7.4 (0.75, 5.5) Door sash (Rear) Regulator ASSY T2: 13.7 (1.4, 10.1) Weather strip Motor ASSY GW-5...
Page 374 General Description GLASS/WINDOWS/MIRRORS 5. MIRROR GW-00258 Outer mirror Scalp cap Rearview mirror Mirror Side turn signal light Mount B: CAUTION • When electrical connectors are disconnected, always conduct an operational check after connecting them again. • Avoid impact and damage to the glass. GW-6...
Page 375 General Description GLASS/WINDOWS/MIRRORS C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 61299AE000 SPACER Used for adjusting the upper end position of front door glass. (Glass thickness: 5 mm (0.197 in)) ST61299AE000 61299AE010 SPACER Used for adjusting the upper end position of rear door glass.
Page 376: Power Window System
Power Window System GLASS/WINDOWS/MIRRORS 2. Power Window System A: WIRING DIAGRAM <Ref. to WI-294, Power Window System.> B: INSPECTION Symptom Repair order (1) Fuse (SBF-5) (2) Power window circuit breaker All power windows do not operate. (3) Power window relay (4) Wiring harness (5) Body integrated unit (1) Power window main switch...
Page 377: Power Window Control Switch
Power Window Control Switch GLASS/WINDOWS/MIRRORS 3. Power Window Control 2. SUB SWITCH Switch 1) Disconnect the ground cable from battery. 2) Remove the door trim. <Ref. to EI-48, REMOV- A: REMOVAL AL, Door Trim.> 3) Disconnect the connector. 1. MAIN SWITCH 4) Remove the screws from the reverse side of 1) Disconnect the ground cable from battery.
Page 378: Front Door Glass
Front Door Glass GLASS/WINDOWS/MIRRORS 4. Front Door Glass 6) Remove the stabilizer. A: REMOVAL 1) Remove the front door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 2) Remove the sealing cover. <Ref. to EB-20, RE- MOVAL, Front Sealing Cover.> 3) Remove the outer mirror assembly.
Page 379 Front Door Glass GLASS/WINDOWS/MIRRORS 11) Remove the door glass. sure of 25#5 N (2.5#0.5 kgf, 5.5#1.1 lb) to the glass, then secure it. A = A GW-00267 GW-00063 CAUTION: • Since the gear may be disengaged, do not (1) Fully closed position turn regulator in the closing direction after re- (2) Stabilizer moval of the glass.
Page 380 Front Door Glass GLASS/WINDOWS/MIRRORS 5) To adjust the upper end and lower end of center 6) Adjust so that the upper and lower ends of cen- pillar, loosen the stopper bolt (A) or nut (B) securing ter pillar are the same size. door sash, move the stopper position until the clearance between center pillar cover is equal.
Page 381 Front Door Glass GLASS/WINDOWS/MIRRORS 7) After adjusting the clearance between center pil- 9) For glass stroke adjustment, install the ST to lar, up and down the glass several times to check glass, close the door, and raise the glass with reg- glass contact to stopper when glass is fully closed.
Page 382 Front Door Glass GLASS/WINDOWS/MIRRORS 11) Make the same adjustment of two adjusting lower fitting part of gusset to prevent generation of bolts of rear sash. wind noise. ST 61299AE000 SPACER 15) During adjustment, loosen the other three (Glass thickness: 5 mm (0.197 clamping bolts.
Page 383: Front Regulator And Motor Assembly
Front Regulator and Motor Assembly GLASS/WINDOWS/MIRRORS 5. Front Regulator and Motor Assembly A: REMOVAL 1) Remove the door glass. <Ref. to GW-10, RE- MOVAL, Front Door Glass.> 2) Disconnect the motor connector. 3) Remove the four bolts and two nuts to remove regulator assembly.
Page 384: Remote Control Mirror System
Remote Control Mirror System GLASS/WINDOWS/MIRRORS 6. Remote Control Mirror System A: WIRING DIAGRAM <Ref. to WI-306, Remote Control Mirror System.> B: INSPECTION Symptom Repair order (1) Fuse (F/B No. 6) All function does not operate. (2) Mirror switch (3) Wiring harness (1) Mirror switch One side of the mirror motor does not operate.
Page 385: Scalp Cap
Scalp Cap GLASS/WINDOWS/MIRRORS 7. Scalp Cap A: REPLACEMENT 1) Remove the outer mirror. <Ref. to GW-19, RE- PLACEMENT, Outer Mirror.> 2) Press-in the upper side clips (A) from inside of door mirror. GW-00312 3) Pull the scalp cap frontward of door mirror, re- move the upper side clips (A) and lower side hooks (B), and then remove the scalp cap.
Page 386: Outer Mirror Assembly
Outer Mirror Assembly GLASS/WINDOWS/MIRRORS 8. Outer Mirror Assembly 2) Remove the door trim. <Ref. to EI-48, REMOV- AL, Door Trim.> A: REMOVAL 3) Disconnect the mirror connector. 1) Remove the mirror gusset cover. 4) Remove the screws to remove mirror assembly. : (1) GW-00278 GW-00277...
Page 387: Outer Mirror
Outer Mirror GLASS/WINDOWS/MIRRORS 9. Outer Mirror A: REPLACEMENT 1) Face the mirror upward. 2) Use a flat tip screwdriver to remove clip (A). 3) Lift the lower mirror up to remove hooks (B). GW-00279 4) Disconnect the mirror heater connector from the end of mirror.
Page 388: Remote Control Mirror Switch
Remote Control Mirror Switch GLASS/WINDOWS/MIRRORS 10.Remote Control Mirror Switch A: REMOVAL 1) Remove the instrument panel lower cover. <Ref. to EI-50, REMOVAL, Instrument Panel Lower Cov- er.> 2) Disconnect the connector. GW-00282 3) Remove the remote control mirror switch from instrument panel lower cover.
Page 389 Remote Control Mirror Switch GLASS/WINDOWS/MIRRORS C: INSPECTION 1. REMOTE CONTROL MIRROR SWITCH Move the remote control mirror switch to each position and check continuity between terminals. 7 6 5 4 3 2 1 16 15 13 12 11 10 GW-00283 •...
Page 390: Rear Door Glass
Rear Door Glass GLASS/WINDOWS/MIRRORS 11.Rear Door Glass 6) Operate the power window switch to move the glass to position shown in the figure, and then re- A: REMOVAL move the two nuts through service holes. 1) Remove the rear door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.>...
Page 391 Rear Door Glass GLASS/WINDOWS/MIRRORS B: INSTALLATION 2) Install the ST to glass and adjust the glass adhe- sion to the value shown. 1) Install in the reverse order of removal. ST 61299AE010 SPACER CAUTION: (Glass thickness: 4 mm (0.157 Make sure that glass stay is placed securely in in) for rear door glass) sash.
Page 392: Rear Regulator And Motor Assembly
Rear Regulator and Motor Assembly GLASS/WINDOWS/MIRRORS 12.Rear Regulator and Motor As- C: INSPECTION 1) Make sure that the power window motor rotates sembly properly when the battery voltage is applied to the A: REMOVAL terminals of motor connector. 2) Change polarity of battery connection to termi- 1) Remove the rear door glass.
Page 393: Windshield Glass
Windshield Glass GLASS/WINDOWS/MIRRORS 13.Windshield Glass • Because the locating pins are bonded to the cor- ners of glass, use piano wire to cut the pin. A: REMOVAL 1. USING WINDSHIELD GLASS KNIFE 1) Remove the cowl panel. <Ref. to EI-39, RE- MOVAL, Cowl Panel.>...
Page 394 Windshield Glass GLASS/WINDOWS/MIRRORS B: INSTALLATION 5) Adjust the glass position to make uniform clear- ance between body and glass in four corners. 1) Clean the external circumference of windshield glass with alcohol or white gasoline. 2) Remove the adhesive layer on the body using cutter knife to obtain smooth face of 2 mm (0.08 in) thick.
Page 395 Windshield Glass GLASS/WINDOWS/MIRRORS 9) Apply two types of primers to the adhesive layer Adhesive: of glass using sponge. Gurit-ESSEX Betaseal 1502 or equivalent Glass primer: Betawipe VP04604 Betaprime 5001 10) Apply primer to the adhesive layer of body. Painted surface primer: Betaprime 5402 NOTE: •...
Page 396: Rear Gate Glass
Rear Gate Glass GLASS/WINDOWS/MIRRORS 14.Rear Gate Glass NOTE: • When door is opened/closed after glass is bond- A: REMOVAL ed, always lower the door glass and then open/ 1) Remove the rear wiper motor. <Ref. to WW-22, close it carefully. REMOVAL, Rear Wiper Motor.>...
Page 397: Rear Window Glass
Rear Window Glass GLASS/WINDOWS/MIRRORS 15.Rear Window Glass 5) After curing of adhesive, pour the water on exter- nal surface of vehicle to check that there are no wa- A: REMOVAL ter leaks. 1) Disconnect the electrical connectors from rear NOTE: defogger terminal.
Page 398: Rear Window Defogger System
(4) Rear defogger condenser (5) Defogger wire (6) Wiring harness (7) Body integrated unit NOTE: Rear window defogger system can be customized on the touch panel in center display or Subaru Select Mon- itor. System name Initial setting Customize setting Repeat 15 min.
Page 399: Rear Window Defogger
15 minutes operation REMOVAL, Body Select Monitor. and 2 minutes stop? Integrated Unit.> 1) Connect the Subaru Select Monitor to data link connector. 2) Turn the ignition switch to ON. 3) Select {Body Integrated Unit} from «Main Menu». 4) Select {Current Data Display & Save}.
Page 400 Rear Window Defogger GLASS/WINDOWS/MIRRORS B: REPAIR 1) Clean the broken portion with alcohol or white gasoline. 2) Mask both side of wire with thin film. 3) Apply the conductive silver composition (DU- PONT No. 4817) to the broken portion. GW-00078 (1) Broken portion (2) Thin film (3) Broken wire...
Page 401: Rear Quarter Glass
Rear Quarter Glass GLASS/WINDOWS/MIRRORS 18.Rear Quarter Glass 2) Cut out the nozzle head and apply adhesive to the glass end surface as shown. A: REMOVAL Remove the glass in the same procedure as for windshield glass. <Ref. to GW-25, REMOVAL, Windshield Glass.>...
Page 402: Sun Roof Glass
Sun Roof Glass GLASS/WINDOWS/MIRRORS 19.Sun Roof Glass A: REMOVAL <Ref. to SR-6, REMOVAL, Glass Lid.> B: INSTALLATION <Ref. to SR-7, INSTALLATION, Glass Lid.> C: ADJUSTMENT <Ref. to SR-7, ADJUSTMENT, Glass Lid.> GW-34...
Page 403: Rearview Mirror
Rearview Mirror GLASS/WINDOWS/MIRRORS 20.Rearview Mirror A: REMOVAL NOTE: Never reuse the spring. Prepare a new spring be- fore removal. 1) Turn the mirror base 90% clockwise or counter- clockwise to remove it. GW-00046 2) Remove the spring from rearview mirror mount. CAUTION: Be careful not to damage the mirror surface.
Page 404: Wiper Deicer System
(5) Body integrated unit Refer to “Rear Window Defogger” for inspection. <Ref. to GW-31, INSPECTION, Rear Window Defogger.> NOTE: Wiper deicer system can be customized on the touch panel in center display or Subaru Select Monitor. System name Initial setting Customize setting Wiper deicer timer OFF after 15 min.
Page 405: Wiper Deicer Switch
Subaru Select ates continuously? REMOVAL, Body Monitor. Integrated Unit.> 1) Connect the Subaru Select Monitor to data link connector. 2) Turn the ignition switch to ON. 3) Select {Body Integrated Unit} from «Main Menu». 4) Select {Current Data Display & Save}.
Page 406 Wiper Deicer Switch GLASS/WINDOWS/MIRRORS GW-38...
Page 407 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 408 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 409: Body Structure
BODY STRUCTURE Page General Description ..................2...
Page 410 General Description BODY STRUCTURE 1. General Description A: SPECIFICATION Refer to “Body repair manual” for body structure, datum points and datum dimensions. <Ref. to Pub No. L0879GJ.> BS-2...
Page 411 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 412 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 413 INSTRUMENTATION/DRIVER INFO Page General Description ..................2 Combination Meter System .................3 Clock System ....................13 Combination Meter Assembly ..............16 Speedometer.....................18 Tachometer ....................19 Fuel Gauge ....................20 Water Temperature Gauge ...............21 Clock ......................22...
Page 414: General Description
General Description INSTRUMENTATION/DRIVER INFO 1. General Description A: SPECIFICATION Speedometer Tachometer Stepping motor type Water temperature gauge Fuel gauge Malfunction indicator light Oil pressure warning light ABS warning light Airbag warning light Seat belt warning light Door open warning light Brake fluid and parking brake warning light Low fuel warning light Charge warning light...
Page 415: Combination Meter System
Combination Meter System INSTRUMENTATION/DRIVER INFO 2. Combination Meter System A: WIRING DIAGRAM 1. COMBINATION METER <Ref. to WI-130, WIRING DIAGRAM, Combination Meter.> B: INSPECTION 1. SELF-DIAGNOSIS The self-diagnosis (checking of each meter, warn- ing light, indicator, illumination, LCD, buzzer sound) of combination meter can be performed in the following procedure.
Page 416 Combination Meter System INSTRUMENTATION/DRIVER INFO 2. LIST OF SELF-DIAGNOSIS MODE OPERATION Speedometer, Microcomputer AT select lever Odo/Trip indica- SPORT shift Illumination Buzzer (SPORT tachometer, fuel running type position indica- indicator (indicator nee- shift buzzer, gauge, water warning light, tor light dle, plate, ring, speed warning temperature...
Page 417 Combination Meter System INSTRUMENTATION/DRIVER INFO Speedometer, Microcomputer AT select lever Odo/Trip indica- SPORT shift Illumination Buzzer (SPORT tachometer, fuel running type position indica- indicator (indicator nee- shift buzzer, gauge, water warning light, tor light dle, plate, ring, speed warning temperature indicator light LCD) buzzer)
Page 418 Combination Meter System INSTRUMENTATION/DRIVER INFO • Illuminating order table Illuminating order Trip meter A/B 8888.8 00000 1111.1 22222 3333.3 44444 5555.5 66666 7777.7 88888 9999.9 Odo/trip meter 888888 000000 111111 222222 333333 444444 555555 666666 777777 888888 999999 SPORT shift Go back indicator to 1 and...
Page 419 Combination Meter System INSTRUMENTATION/DRIVER INFO 3. SYMPTOM CHART Symptom Repair order Reference Combination meter assembly does not operate. (1) Power supply <Ref. to IDI-8, CHECK (2) Ground circuit POWER SUPPLY AND (3) Combination meter GROUND CIRCUIT, INSPECTION, Combi- nation Meter System.> Speedometer does not operate.
Page 420 Combination Meter System INSTRUMENTATION/DRIVER INFO 4. CHECK POWER SUPPLY AND GROUND CIRCUIT Step Check CHECK POWER SUPPLY FOR COMBINA- Is the voltage more than 10 V? Go to step 2. Check the harness TION METER. for open or short 1) Remove the combination meter. <Ref. to between the igni- IDI-16, REMOVAL, Combination Meter tion switch and...
Page 421 Combination Meter System INSTRUMENTATION/DRIVER INFO 6. CHECK ENGINE CONTROL MODULE Step Check Is the voltage more than 0 #$ CHECK ECM SIGNAL. Go to step 2. Check the ECM. 1) Start the engine. 14 V? <Ref. to EN(H4SO 2) Measure the voltage between ECM con- 2.0)(diag)-2, Basic nector and engine ground.
Page 422 Combination Meter System INSTRUMENTATION/DRIVER INFO Step Check Is the resistance 1.0 — 3.0 " CHECK FUEL SUB LEVEL SENSOR. Go to step 4. Replace the fuel (FULL) or 61 — 63 " 1) Remove the fuel sub level sensor. <Ref. to sub level sensor.
Page 423 Combination Meter System INSTRUMENTATION/DRIVER INFO 8. CHECK ENGINE COOLANT TEMPERATURE SENSOR. Step Check CHECK COMMUNICATION ERROR DIS- Is the error code “Er xx” dis- Check the commu- Go to step 2. PLAY. played in odo/trip meter? nication circuit. 1) Set the ignition switch to ON. <Ref.
Page 424 Combination Meter System INSTRUMENTATION/DRIVER INFO 10.DTC DISPLAY MODE When DTC display mode is operated, {ECM}, {TCM}, {ABSCM/VDCCM} is displayed repeatedly in this order by pressing the odo/trip meter button. DTC is displayed in the following table according to type of control module, receiving DTC, DTC detected, No DTC.
Page 425: Clock System
Clock System INSTRUMENTATION/DRIVER INFO 3. Clock System A: WIRING DIAGRAM 1. CLOCK <Ref. to WI-129, WIRING DIAGRAM, Clock System.> B: INSPECTION 1. SYMPTOM CHART Symptom Repair order Reference No display is shown. (1) Power supply <Ref. to IDI-14, CHECK (2) Clock body POWER SUPPLY AND GROUND CIRCUIT, INSPECTION, Clock...
Page 426 Clock System INSTRUMENTATION/DRIVER INFO 2. CHECK POWER SUPPLY AND GROUND CIRCUIT Step Check CHECK CLOCK POWER SUPPLY. Is the voltage more than 10 V? Go to step 2. Check the harness 1) Disconnect the clock harness connector. for open or short 2) Measure the voltage between clock har- between fuse and ness connector and chassis ground.
Page 427 Clock System INSTRUMENTATION/DRIVER INFO 5. CHECK ACC OR IGNITION POWER SUPPLY Step Check CHECK ACC POWER SUPPLY. Is the voltage more than 10 V? Go to step 2. Check the open 1) Turn the ignition switch to OFF. circuit in harness 2) Disconnect the clock harness connector.
Page 428: Combination Meter Assembly
Combination Meter Assembly INSTRUMENTATION/DRIVER INFO 4. Combination Meter Assem- A: REMOVAL 1) Disconnect the ground cable from battery. 2) Set the tilt steering at the lowest position. 3) Remove the instrument panel under cover and lower cover of driver’s seat side. <Ref. to EI-56, REMOVAL, Instrument Panel Assembly.>...
Page 429 Combination Meter Assembly INSTRUMENTATION/DRIVER INFO C: DISASSEMBLY CAUTION: • Use gloves to avoid damage and getting fingerprints on the glass surface and meter surfaces. • Be careful not to apply excessive force to the trip knob. • Be sure not to touch the meter indicator needle. Remove the pawl (A), and then detach the meter glass assembly (B) and meter panel assembly (C) from meter case assembly (D).
Page 430: Speedometer
Speedometer INSTRUMENTATION/DRIVER INFO 5. Speedometer A: SPECIFICATION Since the meter case assembly cannot be disas- sembled, do not remove or inspect the speedome- ter alone. (Do not remove the cover on the back side.) IDI-18...
Page 431: Tachometer
Tachometer INSTRUMENTATION/DRIVER INFO 6. Tachometer A: SPECIFICATION Since the meter case assembly cannot be disas- sembled, do not remove or inspect the tachometer alone. (Do not remove the cover on the back side.) IDI-19...
Page 432: Fuel Gauge
Fuel Gauge INSTRUMENTATION/DRIVER INFO 7. Fuel Gauge A: SPECIFICATION Since the meter case assembly cannot be disas- sembled, do not remove or inspect the fuel gauge alone. (Do not remove the cover on the back side.) IDI-20...
Page 433: Water Temperature Gauge
Water Temperature Gauge INSTRUMENTATION/DRIVER INFO 8. Water Temperature Gauge A: SPECIFICATION Since the meter case assembly cannot be disas- sembled, do not remove or inspect the water tem- perature gauge alone. (Do not remove the cover on the back side.) IDI-21...
Page 434: Clock
Clock INSTRUMENTATION/DRIVER INFO 9. Clock A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the center air vent grille. <Ref. to AC- 44, REMOVAL, Air Vent Grille.> 3) Loosen the screws, and then remove the clock (B) from center air vent grille (A). IDI00103 B: INSTALLATION Install in the reverse order of removal.
Page 435 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 436 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 437 SEATS Page General Description ..................2 Front Seat ....................7 Rear Seat ....................14 Seat Heater System ..................19...
Page 438: General Description
General Description SEATS 1. General Description A: COMPONENT 1. FRONT SEAT (STANDARD SEAT) (10) (11) (12) (13) (19) (17) (14) (23) (18) (22) (16) (21) (15) (20) SE-00400 Backrest cover (12) Seat cushion cover (23) Inner belt Backrest pad (13) Seat cushion pad Backrest frame ASSY (14)
Page 439 General Description SEATS 2. FRONT SEAT (POWER SEAT) (10) (11) (12) (13) (18) (14) (17) (19) (16) (20) (15) SE-00401 Backrest cover (10) Hinge inner cover RH (19) Inner belt Backrest pad (11) Bolt cover inner (20) Seat rail ASSY Backrest frame ASSY (12) Seat cushion cover...
Page 440 General Description SEATS 3. REAR SEAT (SEDAN MODEL) (11) (10) SE-00422 Backrest Backrest pad ASSY Tightening torque: N m (kgf-m, ft-lb) Headrest Backrest cover ASSY T1: 10 (1.02, 7.38) Cushion Rear pad & cushion frame ASSY T2: 24.5 (2.5, 18.1) Armrest (10) Rear cushion cover...
Page 441 General Description SEATS 4. REAR SEAT (WAGON MODEL) (17) (18) (16) (12) (13) (15) (14) (11) (10) (19) SE-00402 Headrest (10) Hinge ASSY LH (19) Backrest shoulder LH Headrest bushing (11) Backrest pad LH Backrest cover RH (12) Backrest cover LH Tightening torque: N m (kgf-m, ft-lb) Backrest pad RH...
Page 442 General Description SEATS B: CAUTION When removing the front seat from a side airbag loaded vehicle, follow cautions given in the airbag section. <Ref. to AB-4, CAUTION, General Description.> C: PREPARATION TOOL 1. GENERAL TOOL TOOL NAME REMARKS Long nose pliers Used for removing the hog ring.
Page 443: Front Seat
Front Seat SEATS 2. Front Seat 8) Remove the two bolts at the front side of slide rail. A: REMOVAL 1) Disconnect the ground cable from battery, and wait for more than 20 seconds before starting work. CAUTION: The airbag system is fitted with a backup power source.
Page 444 Front Seat SEATS 3) Remove the hook (A) and detach reclining lever 7) Remove the two bolts from reclining hinge on cover. each side. SE-00404 4) Remove the screws (A) and clips (B), and then detach the seat hinge outer cover. SE-00408 8) Remove the clips and hooks, and then detach SE-00405...
Page 445 Front Seat SEATS 10) Remove the hooks at the rear side of backrest. 15) Remove the hooks (A), and then remove the seat cushion frame assembly. SE-00335 SE-00338 11) Remove the cover frame (A). 16) Remove the hog rings (A), and then remove the seat cushion cover from seat cushion pad.
Page 446 Front Seat SEATS 18) Remove the bolts, and then remove the slide 3) Disconnect the connector of reclining motor from rail. the back of seat cushion. SE-00383 4) Remove the screw (A) and clips (B), and then disconnect the seat switch connector to remove seat hinge outer cover.
Page 447 Front Seat SEATS 7) Remove the two bolts from the reclining hinge on 10) Remove the hooks at the rear side of backrest. each left and right side. SE-00335 NOTE: For the seat with side airbag, the airbag module in- stallation side is secured with hog rings (A).
Page 448 Front Seat SEATS 14) Remove the two bolts on each left and right 18) Remove the hooks (A), and then remove the side, and then remove the reclining motor assem- seat cushion from seat cushion frame. bly. SE-00391 SE-00388 19) Remove the hog rings (A), and then remove the 15) Remove the hog rings (A) on the front side of seat cushion cover from seat cushion pad.
Page 449 Front Seat SEATS • Secure the hog ring using hog ring pliers. • Install the hog rings to the specified points securely and make sure that no wrinkle or twist- ing on the backrest cover. Tightening torque: Refer to “COMPONENT” of “General Descrip- tion”.
Page 450: Rear Seat
Rear Seat SEATS 3. Rear Seat 4) Remove the bolts which secure the bottom of backrest. A: REMOVAL 1. SEDAN MODEL 1) Remove the two hooks while lifting up the rear seat cushion. SE-00344 5) Remove the anchor part on backrest side from the hook on body side (A) while lifting up the back- rest to detach it from vehicle.
Page 451 Rear Seat SEATS 3) Remove the hook (A) by pushing it backward NOTE: while lifting up the front side of seat cushion to de- The backrest cannot be detached when the hinge tach seat cushion. assembly side does not mate with the backrest pin position.
Page 452 Rear Seat SEATS Tightening torque: 5) Remove the hog rings (A) on the front side of backrest. Refer to “COMPONENT” of “General Descrip- tion”. <Ref. to SE-4, REAR SEAT (SEDAN MODEL), COMPONENT, General Descrip- tion.> 2. WAGON MODEL Install in the reverse order of removal. NOTE: •...
Page 453 Rear Seat SEATS 9) Remove the hook and hog ring, and then re- 2) Remove the hooks at the bottom of backrest as- move the headrest cover. sembly LH, and then turn over the backrest cover to remove the hog rings (A) and hooks (B). SE-00357 SE-00359 10) Remove the hog rings (A) on the rear side of...
Page 454 Rear Seat SEATS 10) Remove the hog rings (A), and then remove the NOTE: seat cushion cover. Armrest cannot be removed when backrest assem- bly RH side does not mate with armrest side pin po- sition. 6) After this operation, refer to the step 2) to disas- semble backrest assembly RH.
Page 455: Seat Heater System
Seat Heater System SEATS 4. Seat Heater System A: REMOVAL 1. SEAT HEATER UNIT 1) Remove the front seats. <Ref. to SE-7, REMOV- AL, Front Seat.> 2) Remove the backrest cover and seat cushion cover of front seat. <Ref. to SE-7, DISASSEMBLY, Front Seat.>...
Page 456 Seat Heater System SEATS SE-20...
Page 457 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 458 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 459 SECURITY AND LOCKS Page General Description ..................2 Door Lock Control System ................10 Keyless Entry System ................15 Front Inner Remote ...................28 Front Outer Handle ...................29 Front Door Latch and Door Lock Actuator Assembly........30 Front Door Lock Actuator ................31 Rear Inner Remote..................32 Rear Outer Handle ..................33 Rear Door Latch and Door Lock Actuator Assembly ........34 Rear Door Lock Actuator................35...
Page 460: General Description
General Description SECURITY AND LOCKS 1. General Description A: COMPONENT 1. DOOR LOCK ASSEMBLY • Model without double lock SL-00271 Front Rear Inner remote ASSY Key cylinder Tightening torque: N m (kgf-m, ft-lb) Front door latch & door lock actua- Striker T1: 6.5 (0.66, 4.8) tor ASSY...
Page 461 General Description SECURITY AND LOCKS • Model with double lock SL-00272 Front Rear Inner remote ASSY Rear door latch & door lock actua- Tightening torque: N m (kgf-m, ft-lb) tor ASSY Front door latch & door lock actua- T1: 6.5 (0.66, 4.8) tor ASSY Outer handle bracket T2: 7.5 (0.76, 5.5)
Page 462 General Description SECURITY AND LOCKS 2. TRUNK LID AND REAR GATE LOCK • Model without double lock SL-00309 Trunk Rear gate Cable Rear gate latch Tightening torque: N m (kgf-m, ft-lb) Striker T1: 7.5 (0.76, 5.5) Trunk lid lock ASSY T2: 25 (2.5, 18.4) Rear gate outer handle T3: 7.35 (0.75, 5.39)
Page 463 General Description SECURITY AND LOCKS • Model with double lock SL-00273 Trunk Rear gate Cable Rear gate latch ASSY Tightening torque: N m (kgf-m, ft-lb) Striker T1: 7.5 (0.76, 5.5) Trunk lid lock ASSY T2: 25 (2.5, 18.4) Rear gate outer handle T3: 7.35 (0.75, 5.39) Rear gate actuator T4: 18 (1.8, 13.3)
Page 464 General Description SECURITY AND LOCKS 3. FRONT HOOD LOCK AND REMOTE OPENERS SL-00275 Sedan model Wagon model Hood Front hood lock ASSY Cover Tightening torque: N m (kgf-m, ft-lb) Lever ASSY Pull handle ASSY T: 33 (3.36, 24.2) Lever ASSY bracket Striker Cable SL-6...
Page 465 General Description SECURITY AND LOCKS 4. IMMOBILIZER SYSTEM SL-00276 Antenna Immobilizer indicator light (LED Body integrated unit bulb) Transponder NOTE: Body integrated unit location for RHD model is symmetrically opposite. SL-7...
Page 466 General Description SECURITY AND LOCKS 5. KEYLESS ENTRY SYSTEM SL-00277 Keyless Entry Control Module Door switch Power window main switch Rear gate latch switch (Wagon) Body integrated unit B: CAUTION • Before disassembling or reassembling parts, al- ways disconnect the battery ground cable. When repairing the audio, control module, etc.
Page 467 General Description SECURITY AND LOCKS C: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925580000 PULLER Used for removing trim clip. ST-925580000 2. GENERAL TOOL TOOL NAME REMARKS Circuit tester Used for measuring resistance and voltage. Drill Used for replacing ignition key lock. SL-9...
Page 468: Door Lock Control System
Door Lock Control System SECURITY AND LOCKS 2. Door Lock Control System A: WIRING DIAGRAM 1. DOOR LOCK CONTROL <Ref. to WI-248, WIRING DIAGRAM, Keyless Entry System.> B: INSPECTION 1. SYMPTOM CHART Symptom Repair order Reference The door lock control system does 1.
Page 469 OK. integrated unit using Subaru Select Monitor. switch is moved to LOCK/ 1) Connect the Subaru Select Monitor to data UNLOCK? link connector. 2) Turn the ignition switch to ON. 3) Select {body integrated unit} from main menu.
Page 470 Door Lock Control System SECURITY AND LOCKS Step Check CHECK DOOR LOCK SWITCH CIRCUIT. Is the resistance less than 10 The door lock Go to step 4. Measure the resistance between the harness switch is OK. connector terminal and chassis ground when the door lock switch is moved to UNLOCK.
Page 471 Door Lock Control System SECURITY AND LOCKS Step Check CHECK POWER WINDOW MAIN SWITCH Is the voltage more than 10 V? Go to step 5. Replace the power OUTPUT SIGNAL. window main Measure the voltage between the harness con- switch. <Ref. to nector terminal of power window main switch GW-9, Power Win- and chassis ground when moving the door lock...
Page 472 Door Lock Control System SECURITY AND LOCKS 7. CHECK DOOR LOCK ACTUATOR (DOUBLE LOCK) AND CIRCUIT Step Check CHECK OUTPUT SIGNAL. Is the voltage more than 10 V? Go to step 2. Replace the body Measure the resistance between body inte- integrated unit.
Page 473: Keyless Entry System
Keyless Entry System SECURITY AND LOCKS 3. Keyless Entry System A: WIRING DIAGRAM 1. KEYLESS ENTRY <Ref. to WI-248, WIRING DIAGRAM, Keyless Entry System.> B: ELECTRICAL SPECIFICATION 1. KEYLESS ENTRY CONTROL UNIT 4 3 2 1 8 7 6 5 SL-00228 Remarks Terminal No.
Page 474 Keyless Entry System SECURITY AND LOCKS 2. BODY INTEGRATED UNIT SL-00229 Remarks Terminal No. Measuring conditions Ignition switch (ON) A1 (INPUT) Battery voltage is present when ignition switch is turned ON. Door and rear gate lock actuator (Model without double lock) Battery voltage is present when pressing the LOCK button of keyless Front double lock actuator RH, door A7 (OUTPUT)
Page 475 Keyless Entry System SECURITY AND LOCKS Remarks Terminal No. Measuring conditions Power supply Battery voltage is constantly present. Power supply Battery voltage is constantly present. Key warning switch C7 (INPUT) Battery voltage is present when inserting the key into ignition switch. Ground 0 V is constantly present.
Page 476 Keyless Entry System SECURITY AND LOCKS C: INSPECTION 1. SYMPTOM CHART Symptom Repair order Reference None of the functions of keyless entry 1. Check the keyless transmitter battery. <Ref. to SL-20, CHECK KEYLESS system operate. TRANSMITTER BATTERY AND FUNCTION, INSPECTION, Keyless Entry System.>...
Page 477 Keyless Entry System SECURITY AND LOCKS Symptom Repair order Reference Trunk lid unlock does not operate. 1. Check the keyless transmitter battery. <Ref. to SL-20, CHECK KEYLESS (Sedan model) TRANSMITTER BATTERY AND FUNCTION, INSPECTION, Keyless Entry System.> 2. Check the keyless entry control module. <Ref.
Page 478 Keyless Entry System SECURITY AND LOCKS 2. CHECK KEYLESS TRANSMITTER BATTERY AND FUNCTION Step Check CHECK KEYLESS TRANSMITTER BAT- Is the voltage more than 2 V? Go to step 2. Replace the key- TERY. less transmitter 1) Remove the battery from keyless transmit- battery.
Page 479 Go to step 2. Keyless entry con- (DTC) com. Malfunction” displayed? trol module is nor- 1) Connect the Subaru Select Monitor to data mal. link connector. 2) Turn the ignition switch to ON. 3) Select {Body integrated unit} from main menu.
Page 480 Keyless Entry System SECURITY AND LOCKS 5. CHECK BODY INTEGRATED UNIT POWER SUPPLY AND GROUND CIRCUIT Step Check CHECK POWER SUPPLY OF BODY INTE- Is the voltage more than 10 V? Go to step 2. Check the harness GRATED UNIT. for open or short 1) Disconnect the harness connector of body between body inte-...
Page 481 Keyless Entry System SECURITY AND LOCKS 7. CHECK DOOR SWITCH Step Check CHECK DOOR SWITCH CIRCUIT. Is the voltage 0 V when each Go to step 2. Go to step 3. Measure the voltage between the body inte- door or rear gate is opened? grated unit harness connector terminal and chassis ground.
Page 482 Keyless Entry System SECURITY AND LOCKS 8. CHECK KEY WARNING SWITCH Step Check CHECK FUSE. Is the fuse blown out? Replace the fuse Go to step 2. Remove and visually check the fuse No. 14 (in with a new one. the main fuse box).
Page 483 2) Disconnect the key warning switch harness ter LOCK/UNLOCK button? <Ref. to connector. LAN(diag)-2, Basic 3) Connect the Subaru Select Monitor to data Diagnostic Proce- link connector. dure.> 4) Turn the ignition switch to ON. 5) Select {Body integrated unit} from main menu.
Page 484 OK. body integrated module using Subaru Select switch is moved to LOCK/ Monitor. UNLOCK? 1) Connect the Subaru Select Monitor to data link connector. 2) Turn the ignition switch to ON. 3) Select {Body integrated unit} from main menu.
Page 485 Keyless Entry System SECURITY AND LOCKS 13.CHECK IGNITION SWITCH ILLUMINATION Step Check CHECK FUSE. Is the fuse blown out? Replace the fuse Go to step 2. Remove and visually check the fuse No. 14 (in with a new one. the main fuse box). CHECK POWER SUPPLY.
Page 486: Front Inner Remote
Front Inner Remote SECURITY AND LOCKS 4. Front Inner Remote A: REMOVAL 1) Remove the door trim. <Ref. to EI-48, REMOV- AL, Door Trim.> 2) Remove the back cover (1) of inner remote. 3) Remove the outer cable (2). 4) Remove the wire end ball (3). 5) Remove the screws (4), and detach the inner re- mote handle.
Page 487: Front Outer Handle
Front Outer Handle SECURITY AND LOCKS 5. Front Outer Handle CAUTION: Do not apply excessive force to remove the A: REMOVAL handle from door panel. Otherwise door panel may be deformed. 1. MODEL WITHOUT DOUBLE LOCK B: INSTALLATION 1) Raise the front door glass to the top position. Install in the reverse order of removal.
Page 488: Front Door Latch And Door Lock Actuator Assembly
Front Door Latch and Door Lock Actuator Assembly SECURITY AND LOCKS 6. Front Door Latch and Door Lock Actuator Assembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Remove the wires from front inner remote.
Page 489: Front Door Lock Actuator
Front Door Lock Actuator SECURITY AND LOCKS 7. Front Door Lock Actuator 2. Model with double lock A: REMOVAL 1) Remove the front door latch & door lock actuator assembly. <Ref. to SL-30, REMOVAL, Front Door Latch and Door Lock Actuator Assembly.> 6 5 4 3 2 1 2) Remove the pawl of front door latch security cov- er, and then remove the cover.
Page 490: Rear Inner Remote
Rear Inner Remote SECURITY AND LOCKS 8. Rear Inner Remote A: REMOVAL 1) Remove the rear door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 2) Remove the back cover (1) of inner remote. 3) Remove the outer cable (2). 4) Remove the wire end ball (3).
Page 491: Rear Outer Handle
Rear Outer Handle SECURITY AND LOCKS 9. Rear Outer Handle A: REMOVAL 1) Raise the rear door glass to the top position. 2) Remove the rear door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Remove the sealing cover. <Ref. to EB-24, RE- MOVAL, Rear Sealing Cover.>...
Page 492: Rear Door Latch And Door Lock Actuator Assembly
Rear Door Latch and Door Lock Actuator Assembly SECURITY AND LOCKS 10.Rear Door Latch and Door Lock Actuator Assembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Remove the wires from rear inner remote.
Page 493: Rear Door Lock Actuator
Rear Door Lock Actuator SECURITY AND LOCKS 11.Rear Door Lock Actuator 2. Model with double lock A: REMOVAL 1) Remove the rear door latch & door lock actuator assembly. <Ref. to SL-34, REMOVAL, Rear Door Latch and Door Lock Actuator Assembly.> 6 5 4 3 2 1 2) Remove the pawl of rear door latch security cov- er, and then remove the cover.
Page 494: Rear Gate Outer Handle
Rear Gate Outer Handle SECURITY AND LOCKS 12.Rear Gate Outer Handle A: REMOVAL 1) Remove the rear gate trim. <Ref. to EI-69, RE- MOVAL, Rear Gate Trim.> 2) Remove the rear gate garnish. <Ref. to EI-76, REMOVAL, Rear Gate Garnish.> 3) Remove the two nuts to take out the rear gate outer handle.
Page 495: Rear Gate Latch Assembly
Rear Gate Latch Assembly SECURITY AND LOCKS 13.Rear Gate Latch Assembly 5) Disconnect the each connector and rear gate handle cable. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear gate trim. <Ref. to EI-69, RE- MOVAL, Rear Gate Trim.>...
Page 496 Rear Gate Latch Assembly SECURITY AND LOCKS Replace the rear gate latch assembly if faulty. 3) Check the rear gate handle cable for deforma- tion. 4) Check the lever and rear gate handle cable for smooth operation. SL-38...
Page 497: Trunk Lid Lock Assembly
Trunk Lid Lock Assembly SECURITY AND LOCKS 14.Trunk Lid Lock Assembly 2) Connect the battery to trunk lid actuator termi- nals. A: REMOVAL 1. MODEL WITHOUT DOUBLE LOCK 1) Disconnect the connectors and detach the trunk opener cable. 2) Remove the two bolts to remove trunk lid lock assembly.
Page 498: Front Hood Lock Assembly
Front Hood Lock Assembly SECURITY AND LOCKS 15.Front Hood Lock Assembly A: REMOVAL 1) Open the front hood. 2) Remove the bolts, and then detach the front hood lock assembly. 3) Remove the release cable from lock assembly. SL-00287 B: INSTALLATION Install in the reverse order of removal.
Page 499: Remote Openers
Remote Openers SECURITY AND LOCKS 16.Remote Openers 6) Remove the cable from trunk lid lock assembly. A: REMOVAL 1. FRONT HOOD OPENER 1) Remove the release cable from hood lock. 2) Remove the bolt, and then detach the opener le- ver.
Page 500 Remote Openers SECURITY AND LOCKS 6) Rotate the fuel lock inside of the quarter panel to 90% and remove. (Either right or left turn) SL-00265 B: INSTALLATION 1. FRONT HOOD OPENER Install in the reverse order of removal. 2. TRUNK LID OPENER Install in the reverse order of removal.
Page 501: Ignition Key Lock
Ignition Key Lock SECURITY AND LOCKS 17.Ignition Key Lock Switch position Terminal No. Standard LOCK — — A: REPLACEMENT Less than 1 # No. 3 and No. 4 1) Disconnect the ground cable from battery. No. 3 and No. 1 2) Remove the steering column.
Page 502: Key Lock Cylinders
Key Lock Cylinders SECURITY AND LOCKS 18.Key Lock Cylinders A: REPLACEMENT 1. MODEL WITHOUT DOUBLE LOCK 1) Raise the front door glass to the top position. 2) Remove the door trim. <Ref. to EI-48, REMOV- AL, Door Trim.> 3) Remove the sealing cover. 4) Remove the rod clamp.
Page 503: Keyless Entry Control Unit
Keyless Entry Control Unit SECURITY AND LOCKS 19.Keyless Entry Control Unit A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the glove box. <Ref. to EI-51, REMOV- AL, Glove Box.> 3) Remove the screw, then remove the keyless en- try control unit while disconnecting the connector.
Page 504: Body Integrated Unit
• If replacing the body integrated unit, check the current setting and note it. <Ref. to LAN(diag)-17, CONFIRMATION OF CURRENT SETTING, OP- ERATION, Subaru Select Monitor.> 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower panel on driver’s side.
Page 505: Keyless Transmitter
Keyless Transmitter SECURITY AND LOCKS 21.Keyless Transmitter • During the battery voltage measurement, the voltage falls more than 1.8 volts in 3 seconds peri- A: REMOVAL 1. KEYLESS TRANSMITTER BATTERY Remove the screw from keyless transmitter, and remove the keyless transmitter battery (1). NOTE: To prevent static electricity damage to the keyless transmitter printed circuit board, touch the steel...
Page 506 Keyless Transmitter SECURITY AND LOCKS 4) While pressing the button of keyless transmitter • If changing from registration mode to clear mode, to be registered twice with door lock switch pressed you cannot go to clear mode unless completing the to UNLOCK.
Page 507: Immobilizer Control Unit
Immobilizer Control Unit SECURITY AND LOCKS 22.Immobilizer Control Unit A: NOTE The control of immobilizer system is carried out in body integrated unit. B: REMOVAL <Ref. to SL-46, REMOVAL, Body Integrated Unit.> C: INSTALLATION Install in the reverse order of removal. SL-49...
Page 508: Immobilizer Antenna
Immobilizer Antenna SECURITY AND LOCKS 23.Immobilizer Antenna A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the screws, and detach the upper col- umn cover and lower column cover. SL-00258 3) Remove the instrument panel lower cover. <Ref. to EI-50, REMOVAL, Instrument Panel Lower Cov- er.>...
Page 509 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 510 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 511 SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) Page General Description ..................2 Sunroof Control System ................5 Glass Lid .....................6 Sunroof Assembly ..................9 Sunroof Motor ...................12 Sunroof Switch ..................15...
Page 512: General Description
General Description SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 1. General Description A: COMPONENT 1. SEDAN MODEL (11) (10) SR-00074 Glass lid Assist rail bracket (Front) Tightening torque: N m (kgf-m, ft-lb) Weatherstrip Sunroof bracket (Rear) T1: 4.5 (0.46, 3.3) Guide rail cover Motor ASSY T2: 6.0 (0.61, 4.4) Sunshade (10)
Page 513 General Description SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 2. WAGON MODEL SR-00102 Glass lid (Front) Drain tube Tightening torque: N m (kgf-m, ft-lb) Glass lid (Rear) Cover (Front and rear) T1: 7.5 (0.76, 5.3) Sunshade Frame bracket T2: 4.5 (0.46, 3.0) Frame ASSY Motor ASSY SR-3...
Page 514 General Description SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) B: CAUTION • Before disassembling or reassembling parts, al- ways disconnect the battery ground cable. When replacing the audio, control unit, and other parts provided with memory functions, record the memo- ry contents before disconnecting the battery ground cable in order to prevent memory deletion.
Page 515: Sunroof Control System
Sunroof Control System SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 2. Sunroof Control System A: WIRING DIAGRAM 1. SUNROOF <Ref. to WI-316, WIRING DIAGRAM, Sunroof System.> B: INSPECTION Symptom Inspection order Water leakage (1) Check roof panel and glass lid for improper or poor sealing. (2) Check drain tube for clogging.
Page 516: Glass Lid
Glass Lid SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 3. Glass Lid 2) Pull out the cover (A) toward arrow mark, and then remove the nut (B). A: REMOVAL 1. SEDAN MODEL 1) Completely close the glass lid, and then open the sunshade. 2) Remove the cover (A), and then remove the ®...
Page 517 Glass Lid SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) B: INSTALLATION Difference in height between glass lid and roof panel L: Install in the reverse order of removal. 1.0 mm (0.079 0.039 in) C: ADJUSTMENT 1. SEDAN MODEL ® Loosen the glass lid mounting TORX bolts (A), and then adjust the height with moving 9.5 mm (0.374 in) nut (B) on lid side.
Page 518 Glass Lid SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 2. WAGON MODEL 1) Raise the left and right side hook (A) of sun- shade. SR-00085 2) Slide the sunshade forward. 3) Remove the plug in the rear side of roof trim. SR-00100 4) Insert the wrench securely until it touches the motor shaft edge.
Page 519: Sunroof Assembly
Sunroof Assembly SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 4. Sunroof Assembly 3) Disconnect the harness connector of motor as- sembly. A: REMOVAL 1. SEDAN MODEL 1) Disconnect the ground cable from battery. 2) Remove the roof trim. <Ref. to EI-67, SEDAN MODEL, REMOVAL, Roof Trim.> 3) Disconnect the harness connector of sunroof motor.
Page 520 Sunroof Assembly SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 8) Remove the bolts (B) and nuts (C), and then remove the frame assembly. SR-00082 B: INSTALLATION 3) Remove the screw from the slider bracket (A) of roof side. Install in the reverse order of removal. CAUTION: Be careful not to snag the harness.
Page 521 Sunroof Assembly SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 3. WAGON MODEL (REAR) E: INSPECTION 1) Remove the frame assembly. 1. CHECK FOR MOVING LOAD OF SUN- 2) Remove the shade stopper (A) of sunshade. SHADE 1) Attach a spring balance to sunshade edge using a cloth.
Page 522: Sunroof Motor
Sunroof Motor SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 5. Sunroof Motor 7) Disconnect the harness connector (A), and then remove the motor assembly mounting bolt (B) and A: REMOVAL nuts (C). CAUTION: • When removing the clip, use great care not to damage the roof trim. •...
Page 523: Sedan Model
Sunroof Motor SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 1. SEDAN MODEL 1) Align the coulisse assembly and link assembly in the same position. SR-00094 (1) Front (2) Coulisse ASSY (3) Link ASSY (4) 4.7 mm (0.185 in) 2) Install the motor assembly. 3) Connect the harness connector of motor assembly, and then connect the battery ground cable to battery. 4) Perform the initialize operation of motor.
Page 524 Sunroof Motor SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 2. WAGON MODEL Check that the wedge of glass lid (front) bracket part is contacting in the direction of vehicle front. At this time, the lid is at fully open position. SR-00095 (1) Front (2) Wedge (3) Glass lid (Front) (4) Glass lid (Rear) 1) Install the motor assembly.
Page 525: Sunroof Switch
Sunroof Switch SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) 6. Sunroof Switch C: INSPECTION A: REMOVAL 1. SEDAN MODEL 1) Disconnect the ground cable from battery. Measure the sunroof switch resistance. 2) Remove the spot map light lens (A) and sunroof switch mounting screws (B). R128 LI-00313 R187...
Page 526 Sunroof Switch SUNROOF/T-TOP/CONVERTIBLE TOP (SUNROOF) NOTE: If glass lid does not operate or is not supplied with power, move the glass lid using the emergency handle. <Ref. to SR-7, FORCED DRIVE, Glass Lid.> SR-16...
Page 527 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 528 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 529 EXTERIOR/INTERIOR TRIM Page General Description ..................2 Front Grille ....................24 Front Hood Grille..................25 Front Under Cover ..................26 Floor Under Protector................27 Fuel Tank Protector...................28 Mud Guard ....................29 Front Bumper ....................30 Rear Bumper.....................37 Cowl Panel ....................39 Roof Spoiler ....................40 Side Sill Spoiler ..................41 Side Protector ...................42 Side Garnish .....................44 Rear Quarter Protector................45...
Page 530: General Description
General Description EXTERIOR/INTERIOR TRIM 1. General Description A: COMPONENT 1. FRONT GRILLE EI-00627 Front grille Front grille emblem Front grille clip 2. UNDER COVER EI-00681 Tightening torque: N m (kgf-m, ft-lb) T: 14 (1.42, 10.3) EI-2...
Page 531 General Description EXTERIOR/INTERIOR TRIM 3. UNDER PROTECTOR EI-00799 Floor under protector Fuel tank protector LH Plastic nut Fuel tank protector RH EI-3...
Page 532 General Description EXTERIOR/INTERIOR TRIM 4. FRONT HOOD GRILLE EI-00707 Front hood grille Grille duct upper Grille duct lower EI-4...
Page 533 General Description EXTERIOR/INTERIOR TRIM 5. FRONT BUMPER (10) (11) (14) (12) (13) EI-00795 Bumper face Energy absorber foam upper (13) Lower center bracket Towing hook cover Energy absorber foam lower (14) Radiator guide Fog light cover Main beam reinforcement Lower side bracket (10) Main beam bracket Tightening torque: N...
Page 534 General Description EXTERIOR/INTERIOR TRIM 6. REAR BUMPER (SEDAN MODEL) EI-00796 Bumper face Lower bracket Bumper beam bracket Exhaust end cover Bumper side support upper Beam upper rear Bumper side support lower Tightening torque: N m (kgf-m, ft-lb) Bracket corner Beam main reinforcement T: 33 (3.4, 24) EI-6...
Page 535 General Description EXTERIOR/INTERIOR TRIM 7. REAR BUMPER (WAGON MODEL) EI-00797 Bumper face Lower bracket Bumper beam bracket Exhaust end cover Bumper side support upper Beam upper rear Bumper side support lower Tightening torque: N m (kgf-m, ft-lb) Bracket corner Beam main reinforcement T: 33 (3.4, 24) EI-7...
Page 536 General Description EXTERIOR/INTERIOR TRIM 8. MUD GUARD EI-00835 Front mud guard Rear mud guard 9. COWL PANEL EI-00832 Cowl panel Cover cowl panel Cowl side panel Weather strip EI-8...
Page 537 General Description EXTERIOR/INTERIOR TRIM 10.ROOF SPOILER EI-00833 Roof spoiler Washer nozzle Tightening torque: N m (kgf-m, ft-lb) High-mounted stop light T: 4.5 (0.46, 3.32) 11.SIDE SILL SPOILER EI-00733 Side sill spoiler Double-sided tape Air flap side sill end EI-9...
Page 538 General Description EXTERIOR/INTERIOR TRIM 12.ROOF MOLDING EI-00752 Roof molding Clip Tightening torque: N m (kgf-m, ft-lb) Roof carrier attachment Roof carrier attachment bracket T: 4.5 (0.46, 3.32) 13.SIDE PROTECTOR EI-00829 Front door protector Rear door protector EI-10...
Page 539 General Description EXTERIOR/INTERIOR TRIM 14.SIDE GARNISH EI-00800 Front fender garnish Rear door garnish Rear quarter garnish Front door garnish 15.TRUNK LID GARNISH EI-00806 EI-11...
Page 540 General Description EXTERIOR/INTERIOR TRIM 16.REAR GATE GARNISH EI-00807 Rear gate garnish License plate light Back-up light or rear fog light Ornament Rear fog light or back-up light License plate light bracket EI-12...
Page 541 General Description EXTERIOR/INTERIOR TRIM 17.DOOR TRIM (12) (10) (11) EI-00714 Front door trim Door grip Power window switch Gusset cover Door grip bracket upper (10) Step light cover Upper weather strip Door grip frame (11) Speaker cover Inner remote cover Door grip bracket lower (12) Rear door trim...
Page 542 General Description EXTERIOR/INTERIOR TRIM 18.CONSOLE BOX (10) (11) (12) (13) EI-00812 Upper lid Rear lid (11) Console pocket Console cover Rear cup holder (12) Front accessory power supply socket Seat heater switch Ash tray Front cup holder Lid hinge (13) Console box harness Console box outer (10)
Page 543 General Description EXTERIOR/INTERIOR TRIM 19.INSTRUMENT PANEL (10) (11) (13) (12) (14) (15) EI-00813 Steering support beam bracket Console side garnish (13) Console front panel (AT model) Steering support beam Instrument panel lower cover (14) Console front panel (MT model) upper Instrument panel pad &...
Page 544 General Description EXTERIOR/INTERIOR TRIM (10) (12) (11) (14) (13) EI-00814 Air vent side duct Navigation unit bracket (Model (10) Audio bracket (LH) with navigation system) Air vent center duct (11) Audio bracket (RH) Instrument panel pad & frame Glove box panel (12) Center panel Air vent defroster grille...
Page 545 General Description EXTERIOR/INTERIOR TRIM 20.INNER TRIM (SEDAN MODEL) (21) (20) (18) (19) (17) (13) (16) (15) (10) (22) (14) (11) (12) (23) (24) (11) EI-00715 Front pillar upper trim (11) Bolt cover (Model with curtain air- (20) Curtain airbag guide center bag) (Model with curtain airbag) Front pillar lower trim...
Page 546 General Description EXTERIOR/INTERIOR TRIM 21.INNER TRIM (WAGON MODEL) (21) (20) (18) (19) (17) (23) (16) (22) (13) (15) (24) (14) (10) (11) (11) (12) EI-00716 Front pillar upper trim (11) Bolt cover (Model with curtain air- (19) Curtain airbag guide front (Model bag) with curtain airbag) Front pillar lower trim...
Page 547 General Description EXTERIOR/INTERIOR TRIM 22.REAR GATE TRIM EI-00808 Rear gate panel upper trim Rear gate panel pillar trim Rear gate panel lower trim 23.ROOF TRIM (SEDAN MODEL) EI-00755 EI-19...
Page 548 General Description EXTERIOR/INTERIOR TRIM 24.ROOF TRIM (WAGON MODEL) EI-00756 25.TRUNK ROOM TRIM EI-00722 Trunk lid trim Trunk room mat Combination light cover Trunk lid arm cover Trunk side trim Trunk room end cover EI-20...
Page 549 General Description EXTERIOR/INTERIOR TRIM 26.LUGGAGE FLOOR MAT EI-00757 Front floor mat Center floor mat Luggage floor end cover Floor box (RH) Side floor mat (RH) Floor box (LH) Side floor mat (LH) EI-21...
Page 550 General Description EXTERIOR/INTERIOR TRIM 27.ROOM INNER PARTS EI-00789 Room mirror Assist grip Tightening torque: N m (kgf-m, ft-lb) Sun visor Coat hook (Wagon model) T: 7.4 (0.75, 5.46) 28.HEAT SHIELD COVER EI-00798 Front heat shield cover (5AT Center heat shield cover (Turbo Rear heat shield cover RH model) model)
Page 551 General Description EXTERIOR/INTERIOR TRIM B: PREPARATION TOOL TOOL NAME REMARKS Clip remover Used for removal of trim. Clip clamp pliers Used for removal of various clips and clamps. EI-23...
Page 552: Front Grille
Front Grille EXTERIOR/INTERIOR TRIM 2. Front Grille A: REMOVAL 1) Open the hood. 2) Remove the push clips (A) and front grille clips (B) from each side of front grille. EI-00551 3) Remove the clips on the back side of front grille. 4) Pull lower side of the front grille forward, remove hooks (A), and then remove the front grille from ve- hicle body.
Page 553: Front Hood Grille
Front Hood Grille EXTERIOR/INTERIOR TRIM 3. Front Hood Grille 2) Insert the hooks (B) of the front hood duct into holes (A) of the front hood. A: REMOVAL 1) Open the front hood. 2) Remove the front hood insulator. <Ref. to EB- 13, FRONT HOOD INSULATOR, REMOVAL, Front Hood.>...
Page 554: Front Under Cover
Front Under Cover EXTERIOR/INTERIOR TRIM 4. Front Under Cover A: REMOVAL 1) Lift-up the vehicle. 2) Remove the clips (A), (C) and bolts (B) in front fender, and then remove the front under cover. • Large type (Turbo model) EI-00735 •...
Page 555: Floor Under Protector
Floor Under Protector EXTERIOR/INTERIOR TRIM 5. Floor Under Protector A: REMOVAL 1) Lift-up the vehicle. NOTE: Plate type lift can not be used. 2) Remove the push turn clips (A) and bolts (B), and remove the floor under protector. EI-00637 B: INSTALLATION Install in the reverse order of removal.
Page 556: Fuel Tank Protector
Fuel Tank Protector EXTERIOR/INTERIOR TRIM 6. Fuel Tank Protector A: REMOVAL 1) Lift-up the vehicle. 2) Remove the bolts (A) and plastic nuts (B), and then remove the fuel tank protector. EI-00638 B: INSTALLATION Install in the reverse order of removal. Tightening torque: Bolt 17.5 N...
Page 557: Mud Guard
Mud Guard EXTERIOR/INTERIOR TRIM 7. Mud Guard A: REMOVAL 1. FRONT MUD GUARD 1) Jack-up the vehicle. 2) Remove the front wheels. 3) Loosen the screws and clips to remove mud guard. EI-00639 2. REAR MUD GUARD 1) Jack-up the vehicle. 2) Remove the rear wheels.
Page 558: Front Bumper
Front Bumper EXTERIOR/INTERIOR TRIM 8. Front Bumper 2. FRONT BUMPER BEAM ASSEMBLY 1) Disconnect the ground cable from battery. A: REMOVAL 2) Remove the front grille. <Ref. to EI-24, REMOV- 1. FRONT BUMPER FACE AL, Front Grille.> 3) Remove the front bumper face. <Ref. to EI-30, 1) Disconnect the ground cable from battery.
Page 559 Front Bumper EXTERIOR/INTERIOR TRIM 7) Remove the clips, and remove the radiator guide. EI-00801 8) Remove the bolts and clips, and remove the bumper lower center bracket. EI-00578 B: INSTALLATION 1. FRONT BUMPER FACE 1) Install in the reverse order of removal. 2) Fit the slider (A) to the guide plate (B) securely.
Page 560 Front Bumper EXTERIOR/INTERIOR TRIM C: REPAIR 1. COATING METHOD FOR PP BUMPER Process Process name Job contents Place the bumper on a paint worktable as Bumper installation required. Use the paint worktable conforming to inner shape of bumper when possible. EI-00234 (1) Bumper (2) Set bumper section...
Page 561 Front Bumper EXTERIOR/INTERIOR TRIM 2. REPAIR INSTRUCTIONS FOR COLORED PP BUMPER NOTE: All PP bumpers are provided with a grained surface, and if the surface is damaged, it cannot normally be re- stored to its former condition. Damages limited to the shallow scratches that cause only a change in the luster of the base material or coating, can be almost fully restored.
Page 562 Front Bumper EXTERIOR/INTERIOR TRIM 3) Deep damage such as a break or hole that requires filling Much of the peripheral grained surface must be sacrificed for repair. The degree of restoration is not really worth the expense. (The surface, however, will become almost flush with adjacent areas.) Recommended repair kit: PP Part Repair Kit (NRM) Process Process name...
Page 563 Front Bumper EXTERIOR/INTERIOR TRIM Process Process name Job contents Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam- aged area. Welding EI-00237 (1) Welding rod (2) Melt hatched area (3) Section NOTE: •...
Page 564 Front Bumper EXTERIOR/INTERIOR TRIM Process Process name Job contents Drying Allow the coated surface to dry for 20 minutes at 20"C (68"F) [or 30 minutes at 60"C (140"F)]. Sanding (III) Sand the coated surface and its surrounding areas using #400 sand paper and water. Cleaning/ degreas- Same as Process No.
Page 565: Rear Bumper
Rear Bumper EXTERIOR/INTERIOR TRIM 9. Rear Bumper • Sedan model: trunk side trim A: REMOVAL 1. REAR BUMPER FACE 1) Disconnect the ground cable from battery. 2) Remove the rear combination light assembly. <Ref. to LI-25, REMOVAL, Rear Combination Light Assembly.>...
Page 566 Rear Bumper EXTERIOR/INTERIOR TRIM 2. REAR BUMPER BRACKET 3) Remove the nuts, and remove the beam main reinforcement from vehicle body. 1) Remove the rear bumper face from vehicle body. 2) Remove the rear bumper bracket corner from vehicle body. (both sides) EI-00803 4) Remove the nuts, and remove the bumper beam bracket and beam upper rear from vehicle body.
Page 567: Cowl Panel
Cowl Panel EXTERIOR/INTERIOR TRIM 10.Cowl Panel 5) Remove the cowl panel side and clip (A). A: REMOVAL 1) Open the hood. 2) Remove the wiper arm. <Ref. to WW-17, RE- MOVAL, Front Wiper Arm.> 3) Remove the weather strip clip, and remove the weather strip.
Page 568: Roof Spoiler
Roof Spoiler EXTERIOR/INTERIOR TRIM 11.Roof Spoiler A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear gate trim. <Ref. to EI-69, RE- MOVAL, Rear Gate Trim.> 3) Disconnect the connector of the high mounted stop light and the washer hose of rear washer. 4) Remove the cap nut and plastic caps.
Page 569: Side Sill Spoiler
Side Sill Spoiler EXTERIOR/INTERIOR TRIM 12.Side Sill Spoiler A: REMOVAL Remove the clips (two for front fender arch area, six for side sill spoiler lower area), and remove the side spoiler. EI-00733 Side sill spoiler Double-sided tape End cover B: INSTALLATION Install in the reverse order of removal.
Page 570: Side Protector
Side Protector EXTERIOR/INTERIOR TRIM 13.Side Protector A: REMOVAL EI-00829 Front door protector Rear door protector 1) Slide in a thin thread (A) of 0.8 mm (0.031 in) di- • If the double-sided tape remains thick on the sur- ameter or less (fishing line etc.) between body and face due to interfacial peeling, apply the solvent af- protector, cut the double-sided tape, and pull the ter slicing off the double-sided tape using a cutter.
Page 571 Side Protector EXTERIOR/INTERIOR TRIM 4) Cover the area where solvent is applied using Double-sided tape: plastic wrap (A), and then heat the double-sided 3M 5531-5 or equivalent tape for 5 to 10 minutes in 40 — 60"C (104 — 2) Heat the adhering part using a heat lamp. 140"F) using a heat lamp (B).
Page 572: Side Garnish
Side Garnish EXTERIOR/INTERIOR TRIM 14.Side Garnish A: REMOVAL EI-00805 For removal of side garnish, refer to the removal procedure of “Side Protector”. <Ref. to EI-42, REMOVAL, Side Protector.> EI-44...
Page 573: Rear Quarter Protector
Rear Quarter Protector EXTERIOR/INTERIOR TRIM 15.Rear Quarter Protector A: REMOVAL 1) Remove the side sill spoilers. <Ref. to EI-41, RE- MOVAL, Side Sill Spoiler.> 2) Remove the clips (A) with rotating it rearward us- ing the fender arch as a fulcrum, and then remove the rear quarter protector.
Page 574: Roof Molding
Roof Molding EXTERIOR/INTERIOR TRIM 16.Roof Molding 5) Remove the nuts, and remove the roof carrier at- tachment. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the roof carrier attachment cover, and remove the bolts. (2 places for each side) EI-00658 3) Pull the roof molding upward, and remove it from vehicle body.
Page 575: Roof Rail
Roof Rail EXTERIOR/INTERIOR TRIM 17.Roof Rail A: REMOVAL 1) Remove the roof trim. <Ref. to EI-67, REMOVAL, Roof Trim.> 2) Remove the six nuts. EI-00834 B: INSTALLATION Install in the reverse order of removal. CAUTION: When removing or installing the roof rail, be careful not to scratch the body panel with the stud bolt of roof rail.
Page 576: Door Trim
Door Trim EXTERIOR/INTERIOR TRIM 18.Door Trim • Rear door trim A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the cover (A) at inner remote area. EI-00656 B: INSTALLATION Install in the reverse order of removal. NOTE: EI-00649 Be careful not to install the hand grip cover and 3) Pull the hand grip cover toward you, and remove plate clip of hand grip in the wrong direction.
Page 577 Door Trim EXTERIOR/INTERIOR TRIM • Lower side of the hand grip cover for front door has pawl part. • The lowest clip of rear door faces the opposite di- rection EI-00655 EI-49...
Page 578: Instrument Panel Lower Cover
Instrument Panel Lower Cover EXTERIOR/INTERIOR TRIM 19.Instrument Panel Lower Cov- A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the front door inside scuff plate (A) and front pillar lower trim (B). <Ref. to EI-60, REMOV- AL, Lower Inner Trim.> EI-00758 3) Remove the clips, and remove the instrument panel lower cover under.
Page 579: Glove Box
Glove Box EXTERIOR/INTERIOR TRIM 20.Glove Box 6) Remove the clip, and remove the glove box low- er cover. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. <Ref. to EI-53, RE- MOVAL, Console Box.> 3) Remove the console front panel. EI-00764 7) Remove the console side panel.
Page 580 Glove Box EXTERIOR/INTERIOR TRIM B: INSTALLATION Install in the reverse order of removal. EI-52...
Page 581: Console Box
Console Box EXTERIOR/INTERIOR TRIM 21.Console Box A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the parking brake lever cover. EI-00810 3) Remove the bolts and clips. EI-00811 4) Disconnect the connector, and remove the con- sole box. B: INSTALLATION Install in the reverse order of removal.
Page 582: Center Console
Center Console EXTERIOR/INTERIOR TRIM 22.Center Console 6) Remove the clip at the console side panel tip. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console box. <Ref. to EI-53, RE- MOVAL, Console Box.> 3) Remove the console front panel. EI-00769 7) Remove the passenger side front inside scuff plate (A) and front pillar lower trim (B).
Page 583 Center Console EXTERIOR/INTERIOR TRIM 9) Remove the screws, and remove the console side panel. EI-00770 10) Loosen the screws to pull out the audio unit as- sembly, and disconnect the connector to remove audio unit. EI-00794 NOTE: Audio unit assembly can be removed without re- moving the console side panel.
Page 584: Instrument Panel Assembly
Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 23.Instrument Panel Assembly 10) Remove the screw at the side of center con- sole. A: REMOVAL 1. INSTRUMENT PANEL (EXCLUDING STEERING SUPPORT BEAM) CAUTION: Be careful to the harness of airbag system when servicing the instrument panel. Damage may cause the system malfunction.
Page 585 Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 21) Loosen the screws to remove glove box striker. NOTE: • If necessary, make matching marks for easy re- assembly. • When storing the removed instrument panel, be sure to prepare a table or the like to put instrument panel on to prevent damage.
Page 586 Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 5) Remove the steering support beam bracket. 8) Loosen the bolts on the center console side. EI-00617 EI-00620 9) Disconnect each connector, and remove the in- 3. INSTRUMENT PANEL ASSEMBLY (IN- strument assembly. CLUDING STEERING SUPPORT BEAM) NOTE: CAUTION: If necessary, make matching marks for easy reas-...
Page 587 Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 3. INSTRUMENT PANEL ASSEMBLY (IN- CLUDING STEERING SUPPORT BEAM) 1) Insert the matching pins (3 places) on the instru- ment panel tip into the grommet (A) and (B) on the body panel side. EI-00621 2) Check the inserted state of matching pins, and pull the harness around.
Page 588: Lower Inner Trim
Lower Inner Trim EXTERIOR/INTERIOR TRIM 24.Lower Inner Trim 5) Remove the clip (A), and remove the inside scuff plate. A: REMOVAL 1) Remove the hook, and remove the inside scuff plate. : (B) EI-00781 (B) Hook : (A) EI-00778 6) Remove the door molding (A) and door catcher cover (B), and then remove the outside scuff plate.
Page 589 Lower Inner Trim EXTERIOR/INTERIOR TRIM 8) Remove the center pillar lower trim while push- ing the pawl part on the upper and lower side of dropout prevention clip. EI-00784 B: INSTALLATION Install in the reverse order of removal. EI-61...
Page 590: Upper Inner Trim
Upper Inner Trim EXTERIOR/INTERIOR TRIM 25.Upper Inner Trim 5) Remove the center pillar upper trim. A: REMOVAL 1) From the top side of trim, remove the metal clip using flat tip driver. EI-00787 6) Remove the seat belt lower anchor bolt cover. EI-00785 CAUTION: When metal clip is removed from upper inner...
Page 591: Rear Quarter Trim
Rear Quarter Trim EXTERIOR/INTERIOR TRIM 26.Rear Quarter Trim 3) Remove the cap on the upper side of trim, and remove the bolt inside. A: REMOVAL 1. SEDAN MODEL (MODEL WITHOUT CURTAIN AIRBAG) 1) Remove the rear seat. <Ref. to SE-14, SEDAN MODEL, REMOVAL, Rear Seat.>...
Page 592 Rear Quarter Trim EXTERIOR/INTERIOR TRIM 3) Remove the clip, and remove the quarter front 8) Remove the screws (A) and bolts (B), and re- pillar trim. move the quarter lower trim. EI-00840 EI-00567 4) Remove the quarter rear pillar trim. NOTE: •...
Page 593: Sun Visor
Sun Visor EXTERIOR/INTERIOR TRIM 27.Sun Visor A: REMOVAL 1) Remove the cover, loosen the mounting screws, and remove the sun visor. EI-00661 2) Disconnect the connector. (Model with vanity mirror light) 3) Press the (A) on both side using flat tip driver, pull the sun visor hook and remove it.
Page 594: Assist Grip
Assist Grip EXTERIOR/INTERIOR TRIM 28.Assist Grip A: REMOVAL 1) Remove the screw cover, and remove the screw inside. 2) Pull the left side of assist grip toward you, and ro- tate the right side of it counterclockwise to remove. EI-00809 3) Remove the roof trim.
Page 595: Roof Trim
Roof Trim EXTERIOR/INTERIOR TRIM 29.Roof Trim 2. WAGON MODEL 1) Disconnect the ground cable from battery. A: REMOVAL 2) Remove the spot map light. <Ref. to LI-34, RE- 1. SEDAN MODEL MOVAL, Spot Map Light.> 3) Remove the room light. <Ref. to LI-35, REMOV- 1) Disconnect the ground cable from battery.
Page 596 Roof Trim EXTERIOR/INTERIOR TRIM CAUTION: Do not remove the roof end trim with excessive force. Otherwise roof trim may be damaged. EI-00669 B: INSTALLATION 1. SEDAN MODEL Install in the reverse order of removal. 2. WAGON MODEL Install in the reverse order of removal. EI-68...
Page 597: Rear Gate Trim
Rear Gate Trim EXTERIOR/INTERIOR TRIM 30.Rear Gate Trim 5) Remove the clips (A) and (B), remove the rear gate lower trim. A: REMOVAL 1) Remove the clips (A), and remove the rear gate pillar trim. EI-00672 6) Remove the rear gate weather strip. :(A) EI-00670 2) Remove the clips, and detach the rear gate up-...
Page 598: Rear Shelf Trim
Rear Shelf Trim EXTERIOR/INTERIOR TRIM 31.Rear Shelf Trim B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. Securely insert the vehicle body panel into the hook 2) Remove the rear quarter trim. <Ref. to EI-63, of rear shelf trim center, and then install the rear SEDAN MODEL (MODEL WITH CURTAIN AIR- shelf trim.
Page 599: Trunk Room Trim
Trunk Room Trim EXTERIOR/INTERIOR TRIM 32.Trunk Room Trim 2) Remove the trim clips (A), and remove the trunk room end cover. A: REMOVAL 1. TRUNK LID TRIM 1) Remove the trim clips and stopper rubbers, and remove the trunk lid trim. :(B) EI-00624 (B) Clip...
Page 600 Trunk Room Trim EXTERIOR/INTERIOR TRIM 5) Remove the trim clips, and remove the trunk side trim. EI-00626 B: INSTALLATION 1. TRUNK LID TRIM Install in the reverse order of removal. 2. TRUNK ROOM TRIM Install in the reverse order of removal. EI-72...
Page 601: Floor Mat
Floor Mat EXTERIOR/INTERIOR TRIM 33.Floor Mat A: REMOVAL 1) Remove the front seats. <Ref. to SE-7, REMOV- AL, Front Seat.> 2) Remove the rear seat cushion. <Ref. to SE-14, REMOVAL, Rear Seat.> 3) Remove the console box. <Ref. to EI-53, Con- sole Box.>...
Page 602: Luggage Floor Box
Luggage Floor Box EXTERIOR/INTERIOR TRIM 34.Luggage Floor Box A: REMOVAL 1) Remove the luggage floor mat. 2) Remove the clips, and remove the luggage floor box. EI-00678 B: INSTALLATION Install in the reverse order of removal. EI-74...
Page 603: Trunk Lid Garnish
Trunk Lid Garnish EXTERIOR/INTERIOR TRIM 35.Trunk Lid Garnish A: REMOVAL Remove the license plate, loosen the bolts (A), and remove the trunk lid garnish. EI-00568 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 7.5 N m (0.76 kgf-m, 5.5 ft-lb) EI-75...
Page 604: Rear Gate Garnish
Rear Gate Garnish EXTERIOR/INTERIOR TRIM 36.Rear Gate Garnish A: REMOVAL 1) Remove the rear gate trim. <Ref. to EI-69, RE- MOVAL, Rear Gate Trim.> 2) Remove the clip (A), and remove the rear gate panel side cover. EI-00569 3) Remove the hexagon cap nut. EI-00630 4) Remove the nuts, disconnect each connector, and remove the rear gate garnish.
Page 605: Heat Shield Cover
Heat Shield Cover EXTERIOR/INTERIOR TRIM 37.Heat Shield Cover A: REMOVAL 1. FRONT HEAT SHIELD COVER Remove the four bolts to remove front heat shield cover. DI-00211 (A) Transmission mount 2. CENTER HEAT SHIELD COVER Remove the nut and bolt to remove center heat shield cover.
Page 606: Ornament
Ornament EXTERIOR/INTERIOR TRIM 38.Ornament A: INSTALLATION 1. LETTER MARK Adhere the letter mark with following dimension. • Sedan model EI-00815 Apply the apply tape with aligning Apply the apply tape with aligning Align the slit of apply tape to panel the cut out to the end of trunk lid R stop on the top end of trunk lid end.
Page 607 Ornament EXTERIOR/INTERIOR TRIM • Wagon model EI-00816 Apply the apply tape with aligning Apply the apply tape with aligning Align the slit of apply tape to panel the cut out to the end of rear gate outer bottom end of rear gate gar- end.
Page 608 Ornament EXTERIOR/INTERIOR TRIM • Wagon model (RH side) EI-00742 • Wagon model (LH side) EI-00743 Apply the apply tape with aligning Gradation end of ceramic print the cut out to the ceramic print. 1 mm (0.04 in) Molding Front side of vehicle Glass antenna wire EI-80...
Page 609 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 610 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 611 EXTERIOR BODY PANELS Page General Description ..................2 Front Hood ....................13 Front Fender Panel ...................16 Front Door ....................17 Front Sealing Cover ..................20 Rear Door....................21 Rear Sealing Cover...................24 Trunk Lid ....................25 Rear Gate....................27...
Page 612: General Description
General Description EXTERIOR BODY PANELS 1. General Description A: SPECIFICATION 1. SIDE (E),(F) EB-00176 Front hood panel Rear door panel Side sill Front fender panel Rear quarter panel Rear quarter lower protector Front door panel Door panel Section Part Standard value Front hood panel to Front fender panel 3.5!1.0 mm (0.14!0.04 in) Front fender panel to Front door panel...
Page 613 General Description EXTERIOR BODY PANELS 2. FRONT EB-00177 Front bumper Front hood panel Front fender panel Front grille Headlight Section Part Standard value Front bumper to Front grille (Longitudinal direction) 1.0!0.7 mm (0.04!0.03 in) Front hood panel to Front bumper 4.0 —...
Page 614 General Description EXTERIOR BODY PANELS 3. REAR (SEDAN MODEL) EB-00178 Trunk lid panel Rear bumper Fuel filler flap lid Rear combination light Rear fender panel Trunk lid garnish Section Part Standard value Trunk lid garnish to Rear bumper 7.0!1.5 mm (0.28!0.06 in) Trunk lid garnish to Rear combination light 4.0!1.0 mm (0.16!0.04 in) Trunk lid panel to Rear combination light...
Page 615 General Description EXTERIOR BODY PANELS 4. REAR (WAGON MODEL) EB-00179 Rear gate panel Roof panel Rear fender panel Rear bumper Rear gate glass Fuel filler flap lid Rear combination light Door quarter glass Roof spoiler Section Part Standard value Rear gate panel to Rear bumper 8.0!1.5 mm (0.31!0.06 in) Rear gate panel to Rear combination light 5.1!1.0 mm (0.20!0.04 in)
Page 616 General Description EXTERIOR BODY PANELS B: COMPONENT 1. FRONT HOOD EB-00148 " Front hood panel Intake duct weather strip Tightening torque: N m (kgf-m, ft-lb) Front hood insulator Front hood weather strip T1: 33 (3.4, 24.5) Front hood hinge Front hood striker T2: 24.5 (2.5, 18.1) EB-6...
Page 617 General Description EXTERIOR BODY PANELS 2. FRONT FENDER PANEL EB-00145 " Tightening torque: N m (kgf-m, ft-lb) T: 7.4 (0.75, 5.5) EB-7...
Page 618: Front Door Panel
General Description EXTERIOR BODY PANELS 3. FRONT DOOR PANEL EB-00149 " Front door panel Lower hinge Tightening torque: N m (kgf-m, ft-lb) Sealing cover Door trim bracket upper T1: 7.4 (0.75, 5.5) Front door weather strip Door trim bracket lower T2: 24.5 (2.5, 18.1) Checker T3: 29.4 (3.0, 21.7)
Page 619: Rear Door Panel
General Description EXTERIOR BODY PANELS 4. REAR DOOR PANEL EB-00150 " Rear door panel Lower hinge Tightening torque: N m (kgf-m, ft-lb) Sealing cover Door trim bracket upper T1: 7.4 (0.75, 5.5) Rear door weather strip Door trim bracket lower T2: 24.5 (2.5, 18.1) Checker T3: 29.4 (3.0, 21.7)
Page 620: Trunk Lid Panel
General Description EXTERIOR BODY PANELS 5. TRUNK LID PANEL EB-00161 " Trunk lid panel Trunk lid trim Tightening torque: N m (kgf-m, ft-lb) License plate light cover Trunk lid arm cover T1: 17.6 (1.8, 12.9) Trunk lid garnish Trunk lid arm ASSY T2: 14 (1.43, 10.3) Trunk lid lock ASSY Torsion bar...
Page 621 General Description EXTERIOR BODY PANELS 6. REAR GATE PANEL EB-00182 " Rear gate damper stay Rear gate panel Tightening torque: N m (kgf-m, ft-lb) Hinge Rear gate side panel cover T1: 7.5 (0.76, 5.5) T2: 14.0 (1.43, 10.3) T3: 25.0 (2.6, 18.4) C: CAUTION •...
Page 622 General Description EXTERIOR BODY PANELS D: PREPARATION TOOL 1. SPECIAL TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925610000 WRENCH Used for removing and installing door hinge. ST-925610000 927780000 REMOVER Used for removing and installing trunk torsion bar. ST-927780000 2. GENERAL TOOL TOOL NAME REMARKS Support jack...
Page 623: Front Hood
Front Hood EXTERIOR BODY PANELS 2. Front Hood 3. FRONT HOOD HINGE 1) Remove the bolts, and remove the front hood A: REMOVAL panel. <Ref. to EB-14, FRONT HOOD PANEL, RE- 1. FRONT HOOD INSULATOR MOVAL, Front Hood.> 1) Open the hood. 2) Release the clips to remove the front hood insu- lator.
Page 624 Front Hood EXTERIOR BODY PANELS 4. FRONT HOOD STRIKER 7) Remove the bolts, and remove the front hood panel from front hood hinge. 1) Open the hood. 2) Remove the bolt, and remove the front hood striker. EB-00138 B: INSTALLATION EB-00144 1.
Page 625 Front Hood EXTERIOR BODY PANELS 2) Use a hinge mounting bolts to align the front hood longitudinally and laterally. EB-00138 3) Adjust the height at the front end of hood. <Ref. to SL-40, ADJUSTMENT, Front Hood Lock Assem- bly.> 4) Rotate the hood buffer to adjust lateral height. EB-00164 EB-15...
Page 626: Front Fender Panel
Front Fender Panel EXTERIOR BODY PANELS 3. Front Fender Panel A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the side sill spoilers. <Ref. to EI-41, RE- MOVAL, Side Sill Spoiler.> 3) Remove the front grille. <Ref. to EI-24, REMOV- AL, Front Grille.>...
Page 627: Front Door
Front Door EXTERIOR BODY PANELS 4. Front Door 11) Remove the front door weather strip. A: REMOVAL 1. FRONT DOOR PANEL 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Remove the outer mirror assembly.
Page 628 Front Door EXTERIOR BODY PANELS 4) Disconnect the connector of door harness from B: INSTALLATION body harness. 1. FRONT DOOR PANEL Install in the reverse order of removal. Tightening torque: Refer to “COMPONENT” of “General Descrip- tion”. <Ref. to EB-8, FRONT DOOR PANEL, COM- PONENT, General Description.>...
Page 629 Front Door EXTERIOR BODY PANELS 2) Loosen the screws (A), and tap the striker (B) using plastic hammer to adjust the gap between rear end surface of front door panel and front end surface of rear door. CAUTION: Do not use an impact wrench. Welding area on the striker nut plate is easily broken.
Page 630: Front Sealing Cover
Front Sealing Cover EXTERIOR BODY PANELS 5. Front Sealing Cover A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Remove the front speaker. <Ref. to ET-6, RE- MOVAL, Front Speaker.>...
Page 631: Rear Door
Rear Door EXTERIOR BODY PANELS 6. Rear Door 10) Remove the rear door inner weather strip. A: REMOVAL 1. REAR DOOR PANEL 1) Disconnect the ground cable from battery. 2) Remove the rear door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Remove the rear speaker.
Page 632 Rear Door EXTERIOR BODY PANELS 3) Remove the center pillar inner protector lower. 7) Remove the door-side bolts for upper and lower hinges to remove the rear door panel. SB-00144 EB-00015 4) Remove the harness holder (A), and disconnect the door harness connector inside pillar. 8) Remove the door hinge from vehicle.
Page 633 Rear Door EXTERIOR BODY PANELS C: ADJUSTMENT 1) Open the rear door, loosen the door-side bolts of upper and lower hinges to align the position of rear door panel longitudinally and laterally. EB-00015 2) Loosen the screws (A), and tap the striker (B) using plastic hammer to adjust the gap between rear end surface of rear door panel and body sur- face.
Page 634: Rear Sealing Cover
Rear Sealing Cover EXTERIOR BODY PANELS 7. Rear Sealing Cover A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear door trim. <Ref. to EI-48, RE- MOVAL, Door Trim.> 3) Pull back the sealing cover. NOTE: • Carefully remove the butyl tape. Excessive force will easily break the cover.
Page 635: Trunk Lid
Trunk Lid EXTERIOR BODY PANELS 8. Trunk Lid 8) Remove the bolts to remove the trunk lid arm. A: REMOVAL 1. TORSION BAR 1) Open the trunk lid. 2) Using the ST, remove the torsion bar from the hinge link. ST 927780000 REMOVER CAUTION:...
Page 636 Trunk Lid EXTERIOR BODY PANELS 2. TRUNK LID ARM Install in the reverse order of removal. Tightening torque: Refer to “COMPONENT” of “General Descrip- tion”. <Ref. to EB-10, TRUNK LID PANEL, COMPO- NENT, General Description.> 3. TRUNK LID PANEL 1) Install in the reverse order of removal. 2) Install with attention to make uniform clearance around the trunk lid panel.
Page 637: Rear Gate
Rear Gate EXTERIOR BODY PANELS 9. Rear Gate 12) Remove the rubber duct (A) connection, and pull out the harness and washer hose from the rear A: REMOVAL gate. 1. REAR GATE PANEL 1) Disconnect the ground cable from battery. 2) Open the rear gate.
Page 638 Rear Gate EXTERIOR BODY PANELS 15) Remove the rear gate hinge bolts, and remove 4) Remove the clips and then detach the rear com- the rear gate panel. bination light covers. LI-00295 EB-00023 16) Remove the rear gate hinge from vehicle. 5) Remove the mounting bolt (A), and remove the damper stay.
Page 639 Rear Gate EXTERIOR BODY PANELS 2. REAR GATE DAMPER STAY Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter at a point 10 to 200 mm (0.39 to 7.87 in) from door 1) Prevent the rear gate from closing using prop or side, and bleed rear gate damper stay gas com- the like.
Page 640 Rear Gate EXTERIOR BODY PANELS EB-30...
Page 641 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 642 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 643 CRUISE CONTROL SYSTEM Page General Description ..................2 Cruise Control Unit..................4 Cruise Control Command Switch ..............5 Stop Light and Brake Switch ...............6 Clutch Switch ....................7 Inhibitor Switch....................8 Neutral Position Switch ................9...
Page 644: General Description
General Description CRUISE CONTROL SYSTEM 1. General Description A: COMPONENT CC-00263 Engine control module (ECM) Cruise indicator light & cruise set Inhibitor switch (AT model) indicator light Cruise control command switch Neutral position switch (MT model) Stop light & brake switch Transmission control module Clutch switch (MT model) (TCM) (AT model)
Page 645 General Description CRUISE CONTROL SYSTEM B: CAUTION • Before disassembling or reassembling parts, al- ways disconnect the battery ground cable from bat- tery. When repairing the audio, control module, etc. which are provided with memory functions, record the memory contents before disconnecting the ground cable from battery.
Page 646: Cruise Control Unit
Cruise Control Unit CRUISE CONTROL SYSTEM 2. Cruise Control Unit A: NOTE The control of cruise control system is carried out in Engine control module (ECM). B: REMOVAL <Ref. to FU(H4SO 2.0)-34, REMOVAL, Engine Control Module (ECM).> <Ref. to FU(H4SO 2.5)- 36, REMOVAL, Engine Control Module (ECM).>...
Page 647: Cruise Control Command Switch
Cruise Control Command Switch CRUISE CONTROL SYSTEM 3. Cruise Control Command 8) Remove one screw to remove the cruise control command switch from lower cover. Switch A: REMOVAL WARNING: Before servicing, be sure to read the notes in the “AB” section for proper handling of the driver’s airbag module.
Page 648: Stop Light And Brake Switch
Stop Light and Brake Switch CRUISE CONTROL SYSTEM 4. Stop Light and Brake Switch A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector from stop light & brake switch, and then remove the switch. <Ref. to BR- 45, REMOVAL, Stop Light Switch.>...
Page 649: Clutch Switch
Clutch Switch CRUISE CONTROL SYSTEM 5. Clutch Switch A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector from clutch switch, and then remove the switch. <Ref. to CL-27, DIS- ASSEMBLY, Clutch Pedal.> B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Measure the clutch switch resistance.
Page 650: Inhibitor Switch
Inhibitor Switch CRUISE CONTROL SYSTEM 6. Inhibitor Switch A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector from inhibitor switch, and then remove the switch. <Ref. to 4AT-52, RE- MOVAL, Inhibitor Switch.> B: INSTALLATION Install in the reverse order of removal. C: INSPECTION Measure the inhibitor switch resistance.
Page 651: Neutral Position Switch
Neutral Position Switch CRUISE CONTROL SYSTEM 7. Neutral Position Switch A: REMOVAL 1) Disconnect the ground cable from battery. 2) Disconnect the connector from neutral position switch, and then remove the switch. <Ref. to 5MT- 41, BACK-UP LIGHT SWITCH AND NEUTRAL POSITION SWITCH, REMOVAL, Switches and Harness.>...
Page 652 Neutral Position Switch CRUISE CONTROL SYSTEM CC-10...
Page 653 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 654 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 655 Page Basic Diagnostic Procedure ................2 General Description ..................4 Electrical Component Location ..............5 Engine Control Module (ECM) I/O Signal ...........6 Subaru Select Monitor.................8 Diagnostics with Phenomenon..............10 List of Diagnostic Trouble Code (DTC) .............12 Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....15...
Page 656: Basic Diagnostic Procedure
Basic Diagnostic Procedure CRUISE CONTROL SYSTEM (DIAGNOSTICS) 1. Basic Diagnostic Procedure A: PROCEDURE Step Check CHECK MALFUNCTION INDICATOR LIGHT. Does the malfunction indicator Go to step 5. Go to step 2. Ensure the malfunction indicator light illumi- light illuminate? nates. CHECK CRUISE INDICATOR LIGHT.
Page 657 Basic Diagnostic Procedure CRUISE CONTROL SYSTEM (DIAGNOSTICS) Step Check CHECK SET/COAST OPERATION. Does the vehicle speed Go to step 10. Go to phenome- Check the SET/COAST switch operation. decrease after SET/COAST non 6. <Ref. to switch has been pressed? CC(diag)-10, DIAGNOSTIC PROCEDURE WITH PHENOME-...
Page 658: General Description
TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 2.
Page 659: Electrical Component Location
Electrical Component Location CRUISE CONTROL SYSTEM (DIAGNOSTICS) 3. Electrical Component Location A: LOCATION CC-00263 Engine control module (ECM) Transmission control module Neutral position switch (MT (TCM) (AT model) model) Cruise control command switch Stop and brake switch Inhibitor switch (AT model) Clutch switch (MT model) Cruise indicator light and cruise set indicator light...
Page 660 Engine Control Module (ECM) I/O Signal CRUISE CONTROL SYSTEM (DIAGNOSTICS) 4. Engine Control Module (ECM) I/O Signal A: ELECTRICAL SPECIFICATION To A: B134 To B: B135 To C: B136 To D: B137 17 16 12 11 17 16 12 11 12 11 17 16 12 11...
Page 661 Engine Control Module (ECM) I/O Signal CRUISE CONTROL SYSTEM (DIAGNOSTICS) • 2.0 L non-turbo model, 2.5 L KS, KA model Termi- Measurement Condition and I/O Signal Content nal No. (Idling with ignition ON: Except cruise set light) Main power VB (CONTROL 1) •...
Page 662: Subaru Select Monitor
CC-00029 although cruise cancel condition is not entered. 4) Connect the Subaru Select Monitor to data link (2) Cruise control memory in ECM stores the connector. cancel condition (Code No.) which occurred dur- (1) Data link connector is located in the lower ing driving.
Page 663 1) Connect the Subaru Select Monitor. 2) Turn the ignition switch and cruise control main switch to ON. 3) Turn the Subaru Select Monitor switch to ON. 4) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
Page 664: Diagnostics With Phenomenon
Diagnostics with Phenomenon CRUISE CONTROL SYSTEM (DIAGNOSTICS) 6. Diagnostics with Phenomenon A: DIAGNOSTIC PROCEDURE WITH PHENOMENON Phenomenon Checking item Reference Cruise control main switch is (1) Check the cruise indicator <Ref. to CC(diag)-11, CHECK CRUISE INDICATOR not turned to ON. (Cruise light.
Page 665 Diagnostics with Phenomenon CRUISE CONTROL SYSTEM (DIAGNOSTICS) B: CHECK CRUISE INDICATOR LIGHT & CRUISE SET INDICATOR LIGHT. TROUBLE SYMPTOM: Cruise control can be set, but the cruise indicator light & cruise set indicator light do not illuminate. Step Check CHECK CRUISE INDICATOR LIGHT & Does the cruise indicator light Go to step 2.
Page 666: List Of Diagnostic Trouble Code (Dtc)
List of Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) 7. List of Diagnostic Trouble Code (DTC) A: LIST Item Contents of diagnosis Reference Main switch Main switch of cruise control command switch is turned This DTC is indicated to OFF, and then the cruise control is released. without operating the main switch.
Page 667 List of Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) Item Contents of diagnosis Reference Cruise Control Switch Mal- When the ignition switch is turned to ON, each switch of This DTC is indicated function When Ignition cruise control command switch is already turned to ON. without operating the main Switch Is Turned To ON switch.
Page 668 List of Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) Item Contents of diagnosis Reference WAIT is prohibited after Controlled vehicle speed increased above the limit dur- This DTC is displayed operating accelerator ing cruising. when driving at higher pedal. speed than appropriate cruise control speed.
Page 669 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) 8. Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC 11, 15, 21 AND 24 CRUISE CONTROL COMMAND SWITCH TROUBLE SYMPTOM: • Cruise control cannot be set. (Cancelled immediately.) •...
Page 670 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) • 2.0 L non-turbo model, 2.5 L KS, KA model SET/ RESUME/ MAIN CANCEL CRUISE CONTROL COAST ACCEL SWITCH SWITCH COMMAND SWITCH SWITCH SWITCH STEERING ROLL CONNECTOR B122 : LHD MODEL : RHD MODEL : TERMINAL No.
Page 671: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)
Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) Step Check CHECK CRUISE CONTROL COMMAND Is the voltage more than 5 V? Go to step 2. Check the harness SWITCH. for open or short 1) Remove the driver’s airbag module. <Ref. circuit between to AB-14, REMOVAL, Driver’s Airbag Module.>...
Page 672 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) B: DTC 12 and 25 STOP LIGHT SWITCH AND BRAKE SWITCH TROUBLE SYMPTOM: • Cruise control cannot be set. • Cruise control cannot be released. WIRING DIAGRAM: • 2.0 L turbo model, 3.0 L model, 2.5 L EC, K4 and EK model BATTERY SBF-1 SBF-3...
Page 673 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) • 2.0 L non-turbo model, 2.5 L for KS, KA model BATTERY SBF-1 SBF-3 F/B No.8 IGNITION RELAY SBF-9 F/B No.4 STOP LIGHT SWITCH AND BRAKE SWITCH STOP LIGHT SWITCH CLUTCH SWITCH (MT) BRAKE...
Page 674 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) Step Check CHECK STOP LIGHT SWITCH AND BRAKE Is the voltage more than 10 V? Go to step 2. • Check fuse No. SWITCH CIRCUIT. 8 (in fuse & relay 1) Turn the ignition switch to OFF.
Page 675 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) C: DTC 13 CLUTCH SWITCH TROUBLE SYMPTOM: • Cruise control cannot be set. • Cruise control cannot be released. WIRING DIAGRAM: • 2.5 L EC, K4 and EK model BATTERY SBF-1 SBF-3...
Page 676 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) • 2.0 L non-turbo model, 2.5 L KS, KA model BATTERY SBF-1 SBF-3 F/B No.8 IGNITION RELAY SBF-9 F/B No.4 STOP LIGHT SWITCH AND BRAKE SWITCH STOP LIGHT SWITCH CLUTCH SWITCH (MT) BRAKE SWITCH...
Page 677 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) Step Check CHECK CLUTCH SWITCH CIRCUIT. Is the voltage more than 10 V? Go to step 2. • Check fuse No. 1) Turn the ignition switch to OFF. 4 (in fuse & relay 2) Disconnect the clutch switch harness con- box).
Page 678 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) D: DTC 14 NEUTRAL POSITION SWITCH TROUBLE SYMPTOM: Cruise control cannot be set. WIRING DIAGRAM: • 2.0 L turbo model, 3.0 L model B137 B137 1 2 3 4 10 11 12 14 15 16 17 18...
Page 679 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) • 2.5 L EC, K4 and EK model B137 INHIBITOR SWITCH NEUTRAL POSITION SWITCH : MT MODEL : AT MODEL B137 1 2 3 4 1 2 3 4 5 6 11 12 13 14 15 16 17 5 6 7 8...
Page 680 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) • 2.0 L non-turbo model, 2.5 L KS, KA model B135 INHIBITOR SWITCH STARTER MOTOR NEUTRAL POSITION SWITCH B122 : MT MODEL : AT MODEL : LHD MODEL : RHD MODEL : TERMINAL No.
Page 681 CHECK NEUTRAL POSITION SWITCH. Is ON displayed in the Subaru Replace the ECM. Go to step 3. 1) Connect the Subaru Select Monitor to data Select Monitor when the select <Ref. to link connector. lever is in “P” or “N” range?
Page 682 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) Step Check CHECK INHIBITOR SWITCH. Is the inhibitor switch OK? Replace the ECM. Replace the inhibi- Remove and check the inhibitor switch. <Ref. <Ref. to FU(H4SO tor switch. to CC-8, Inhibitor Switch.> 2.0)-34, Engine Control Module (ECM).>...
Page 683 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) E: DTC 16 IGNITION SWITCH TROUBLE SYMPTOM: Cruise control cannot be set. WIRING DIAGRAM: • 2.0 L turbo model, 3.0 L model, 2.5 L EC, K4 and EK model IGNITION BATTERY SWITCH...
Page 684 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) • 2.0 L non-turbo model, 2.5 L KS, KA model IGNITION BATTERY SWITCH F/B No.12 SBF-1 SBF-7 B135 B135 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 29 30 31...
Page 685 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) Step Check CHECK IGNITION SWITCH CIRCUIT. Is the voltage more than 10 V? Check poor con- • Check fuse No. 1) Turn the ignition switch to OFF. tact in ECM con- 12 (in fuse &...
Page 686 Diagnostic Procedure with Diagnostic Trouble Code (DTC) CRUISE CONTROL SYSTEM (DIAGNOSTICS) F: DTC 22 AND 32 VEHICLE SPEED SENSOR DIAGNOSIS: Disconnection or short circuit of vehicle speed sensor system. TROUBLE SYMPTOM: Cruise control cannot be set. (Cancelled immediately.) Step Check CHECK ABS WARNING LIGHT.
Page 687 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 688 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 689 Basic Diagnostic Procedure ................2 General Description ..................4 Electrical Component Location ..............6 Immobilizer Control Module I/O Signal............7 Subaru Select Monitor.................8 Read Diagnostic Trouble Code (DTC) ............9 Clear Memory Mode..................10 Diagnostics Chart for Immobilizer Indicator Light........11 List of Diagnostic Trouble Code (DTC) .............15...
Page 690: Basic Diagnostic Procedure
Repair the related 1) Turn the ignition switch to OFF. screen? parts. 2) Connect the Subaru Select Monitor to data link connector. <Ref. to IM(diag)-8, Subaru Select Monitor.> 3) Turn the ignition switch and Subaru Select Monitor switch to ON.
Page 691 Basic Diagnostic Procedure IMMOBILIZER (DIAGNOSTICS) Step Check PERFORM THE DIAGNOSIS. Is the DTC displayed on Inspect using the Finish the diagno- 1) Inspect using the “Diagnostic Procedure screen? “Diagnostic Proce- sis. with Diagnostic Trouble Code (DTC)”. dure with Diagnos- <Ref. to IM(diag)-17, Diagnostic Procedure tic Trouble Code with Diagnostic Trouble Code (DTC).>...
Page 692: General Description
General Description IMMOBILIZER (DIAGNOSTICS) 2. General Description • When repeatedly turning the ignition switch to ON or OFF while diagnostic items are being A: CAUTION checked, it should be switched in cycles of “ON” for at least 5 seconds ! “OFF” for at least CAUTION: 8 seconds.
Page 693 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 2.
Page 694: Electrical Component Location
Electrical Component Location IMMOBILIZER (DIAGNOSTICS) 3. Electrical Component Location A: LOCATION IM-00083 Antenna Body integrated unit Transponder Immobilizer indicator light (LED bulb) NOTE: Body integrated unit location for RHD model is symmetrically opposite. IM(diag)-6...
Page 695: Immobilizer Control Module I/O Signal
Immobilizer Control Module I/O Signal IMMOBILIZER (DIAGNOSTICS) 4. Immobilizer Control Module I/O Signal A: WIRING DIAGRAM 1. IMMOBILIZER <Ref. to WI-246, WIRING DIAGRAM, Immobilizer System.> IM(diag)-7...
Page 696: Subaru Select Monitor
1. HOW TO USE SUBARU SELECT MONI- 1) Prepare the Subaru Select Monitor kit. CC-00045 (1) Power switch 6) Using the Subaru Select Monitor, call up DTCs and various data, then record them. CC-00028 2. READ DIAGNOSTIC TROUBLE CODE 2) Connect the diagnosis cable to Subaru Select (DTC) FOR ENGINE AND BODY INTEGRAT- Monitor.
Page 697: Read Diagnostic Trouble Code (Dtc)
{History Diagnostic Code(s)}, and then press the [YES] key. NOTE: • For detailed operation procedure, refer to the SUBARU SELECT MONITOR OPERATION MAN- UAL. • For detailed concerning DTC, refer to the List of DTC. <Ref. to IM(diag)-15, LIST, List of Diagnostic Trouble Code (DTC).>...
Page 698: Clear Memory Mode
4) On the «Engine Diagnosis» display screen, se- lect the {Clear Memory} and press the [YES] key. 5) When the ‘Done’ are shown on the display screen, turn the Subaru Select Monitor and ignition switch to OFF. NOTE: • After the memory has been cleared, the idle air control solenoid valve must be initialized.
Page 699 Diagnostics Chart for Immobilizer Indicator Light IMMOBILIZER (DIAGNOSTICS) 8. Diagnostics Chart for Immobilizer Indicator Light A: INSPECTION 1. CHECK IMMOBILIZER INDICATOR CIRCUIT WIRING DIAGRAM: BATTERY SBF-1 SBF-9 F/B No.7 IGNITION SWITCH SBF-4 F/B No.12 R167 i102 M/B No.8 COMBINATION METER IMMOBILIZER INDICATOR LIGHT...
Page 700: Diagnostics Chart For Immobilizer Indicator Light
Diagnostics Chart for Immobilizer Indicator Light IMMOBILIZER (DIAGNOSTICS) Step Check CHECK IMMOBILIZER WARNING LIGHT. Does the immobilizer indicator Go to step 2. Go to step 5. 1) Turn the ignition switch to OFF. light illuminate? 2) Disconnect the harness connector from body integrated unit.
Page 701 Diagnostics Chart for Immobilizer Indicator Light IMMOBILIZER (DIAGNOSTICS) 2. CHECK KEY SWITCH CIRCUIT WIRING DIAGRAM: BATTERY M/B No.14 KEY WARNING SWITCH B350 B281 BODY INTEGRATED UNIT B350 B281 5 6 7 1 2 3 4 11 12 13 14 15 16 17 18 19 20 21 22 23...
Page 702 Diagnostics Chart for Immobilizer Indicator Light IMMOBILIZER (DIAGNOSTICS) Step Check CHECK POWER SUPPLY CIRCUIT. Is the voltage more than 10 V? Go to step 2. Check the harness 1) Disconnect the harness connector from key for open or short warning switch. circuit between 2) Turn the ignition switch to “ACC”...
Page 703: List Of Diagnostic Trouble Code (Dtc)
List of Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTICS) 9. List of Diagnostic Trouble Code (DTC) A: LIST 1. ECM Item Contents of diagnosis Index No. <Ref. to IM(diag)-17, DTC P0513 INCOR- Incorrect immobilizer key (Use of RECT IMMOBILIZER KEY, Diagnostic Pro- P0513 Incorrect Immobilizer Key unregistered key in body integrated...
Page 704 • DTC B0402 is recorded as freeze frame data when the ignition switch is turned to OFF. When trying to start the engine with unregistered immobilizer key, DTC is not displayed on Subaru Select Monitor immediately. Turn the ignition switch to OFF once and turn to ON again before checking DTC. At this time (when turning the ignition switch to ON again), be careful that the DTC is displayed as freeze frame data even with the reg- istered immobilizer key.
Page 705: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)
Diagnostic Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTICS) 10.Diagnostic Procedure with Diagnostic Trouble Code (DTC) A: DTC P0513 INCORRECT IMMOBILIZER KEY DTC DETECTING CONDITION: Incorrect immobilizer key (Use of unregistered key in body integrated unit) Step Check PERFORM TEACHING OPERATION ON IG- Is the teaching operation for all END.
Page 706 Diagnostic Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTICS) B: DTC P1570 ANTENNA DTC DETECTING CONDITION: Faulty antenna WIRING DIAGRAM: B351 B281 BODY INTEGRATED UNIT B351 B281 5 6 7 11 12 13 14 15 16 17 18 19 20 21 22 23 27 28 IM-00079...
Page 707 Diagnostic Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTICS) Step Check CHECK ANTENNA CIRCUIT. Is the resistance less than 10 Go to step 2. Replace the "? 1) Turn the ignition switch to OFF. antenna. <Ref. to 2) Disconnect the harness connector from SL-50, Immobi- antenna.
Page 708 Diagnostic Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTICS) Step Check CHECK IGNITION KEY (TRANSPONDER). Does the engine start? Replace all the Replace the body 1) Remove the key from ignition switch. ignition keys integrated unit 2) Start the engine using other keys that have (including tran- <Ref.
Page 709 Diagnostic Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTICS) C: DTC P1571 REFERENCE CODE INCOMPATIBILITY DTC DETECTING CONDITION: Reference code incompatibility between body integrated unit and ECM Step Check PERFORM TEACHING OPERATION ON IG- Is the teaching operation for all END.
Page 710 Diagnostic Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTICS) D: DTC P1572 IMM CIRCUIT FAILURE (EXCEPT ANTENNA CIRCUIT) DTC DETECTING CONDITION: Communication failure between body integrated unit and ECM WIRING DIAGRAM: IGNITION BATTERY SWITCH SBF-1 SBF-4 F/B No.12 SBF-9 F/B No.7 M/B No.8 : 2.0 L NA MODEL AND 2.5 L KS, KA MODEL...
Page 711 Diagnostic Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTICS) Step Check CHECK BODY INTEGRATED UNIT POWER Is the voltage more than 10 V? Go to step 2. Check the harness SUPPLY CIRCUIT. for open or short 1) Turn the ignition switch to OFF. circuit between 2) Disconnect the harness connector from body integrated...
Page 712 (ECM).> <Ref. to 3) Start the communication line check. <Ref. the all ignition keys FU(H4SO 2.5)-36, to IM(diag)-8, COMMUNICATION LINE (including tran- Engine Control CHECK, OPERATION, Subaru Select Moni- sponder). Execute Module (ECM).> tor.> the registration <Ref. to procedure next.
Page 713 Diagnostic Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTICS) E: DTC P1574 KEY COMMUNICATION FAILURE DTC DETECTING CONDITION: Failure of body integrated unit to verify key (transponder) ID code Step Check Is the voltage #30 to 30 V? CHECK BODY INTEGRATED UNIT FUNC- Go to step 2.
Page 714 Diagnostic Procedure with Diagnostic Trouble Code (DTC) IMMOBILIZER (DIAGNOSTICS) H: DTC P1578 METER FAILURE DTC DETECTING CONDITION: Reference code incompatibility between body integrated unit and combination meter 1. CHECK LAN COMMUNICATION SYSTEM Inspect LAN communication system in the following situation. <Ref. to LAN(diag)-2, Basic Diagnostic Proce- dure.>...
Page 715 AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) 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. LIGHTING SYSTEM This manual includes the procedures...
Page 716 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7...
Page 717 Basic Diagnostic Procedure ................2 Check List for Interview................3 General Description ..................5 Electrical Component Location ..............7 Control Module I/O Signal ................9 Subaru Select Monitor................14 Read Diagnostic Trouble Code (DTC) ............24 Clear Memory Mode..................25 Read Current Data ..................26 Function Setting (Customize)..............27 List of Diagnostic Trouble Code (DTC) .............28 Diagnostic Procedure with Diagnostic Trouble Code (DTC) .....30...
Page 718: Basic Diagnostic Procedure
1. WITH SUBARU SELECT MONITOR CAUTION: • Subaru Select Monitor is required for reading DTC, performing diagnosis and reading current data. • Remove foreign matter (dust, water and oil etc.) from the body integrated unit connector during re- moval and installation.
Page 719: Check List For Interview
Check List for Interview LAN SYSTEM (DIAGNOSTICS) 2. Check List for Interview A: CHECK Inspect the following items about the vehicle’s state. 1. DISPLAY OF FREEZE FRAME DATA Freeze frame data is dis- When and how often are they displayed? J Always played in odo/trip meter.
Page 720 Check List for Interview LAN SYSTEM (DIAGNOSTICS) 4. CONDITIONS UNDER WHICH TROUBLE OCCURS J At standstill (While idling) Driving condition J When the vehicle is running Vehicle speed km/h (MPH) J When accelerating Acceleration km/h (MPH) to km/h (MPH) J Decelerating (With braking) Deceleration km/h (MPH) to km/h (MPH) J Decelerating (Without braking)
Page 721: General Description
(ECM customizing) (A) Bypass wire connection of body integrated unit. <Ref. to LAN(diag)-20, • If the characteristics of the twisted pair line is FREEZE FRAME DATA, OPERATION, Subaru changed, it may cause extremely weakness to the Select Monitor.> noise.
Page 722 TOOL NUMBER DESCRIPTION REMARKS 24082AA230 CARTRIDGE Troubleshooting for electrical system. ST24082AA230 22771AA030 SUBARU SELECT Troubleshooting for electrical system. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030 2.
Page 723: Electrical Component Location
Electrical Component Location LAN SYSTEM (DIAGNOSTICS) 4. Electrical Component Location A: LOCATION (11) (12) (10) LAN00101 Body integrated unit A/C control panel (10) Steering angle sensor Engine control module (ECM) Center display (11) ABSCM&H/U or VDCCM&H/U (In engine compartment) Auto A/C control unit Transmission control module (TCM) Navigation module...
Page 724 Electrical Component Location LAN SYSTEM (DIAGNOSTICS) LAN00104 LAN00105 LAN00007 LAN00106 (11) (10) LAN00107 LAN00008 km/h SPORT CRUISE (12) LAN00111 LAN(diag)-8...
Page 725: Control Module I/O Signal
Control Module I/O Signal LAN SYSTEM (DIAGNOSTICS) 5. Control Module I/O Signal A: ELECTRICAL SPECIFICATION B280 B281 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 11 12 13 14 15 16 17 18 19 20 11 12 13 14 15...
Page 726 Control Module I/O Signal LAN SYSTEM (DIAGNOSTICS) Signal (V or ") Connector Description Terminal No. NOTE Ignition switch ON (engine OFF) Door switch input Less than 1 V (10 — 13 V at OFF) Rear LH door open (ON) Rear LH seat Door switch Less than 1 V (10 —...
Page 727 (sending and receiving) Serial communication Low-speed CAN circuit (Model with auto A/C) B280 2 (Lo) Immobilizer antenna B281 C20 — C21 Serial communication Immobilizer communi- cation B280 (Back-up Serial communication (Main) B28) Subaru Select Monitor B280 Serial communication communication LAN(diag)-11...
Page 728 IMMOBILIZER PILOT LIGHT WIPER DEICER RELAY OUTPUT ALARM CONTROL ECM (EK MODEL) REAR DEFOGGER SWITCH SECURITY HORN OUTPUT (MODEL WITH MANUAL A/C) (EXCEPT FOR EK MODEL) SUBARU SELECT MONITOR REAR DEFOGGER RELAY OUTPUT COMMUNICATION (BLUE) B280 B281 5 6 7...
Page 729 (14) (18) (17) (15) (13) (13) (16) LAN00109 Body integrated unit Audio#A/C control panel (15) Subaru Select Monitor communi- cation line Navigation system (10) Center display (16) Subaru Select Monitor VDC/ABSCM (11) Combination meter (17) Low speed CAN (Body integrated...
Page 730: Subaru Select Monitor
Diagnostic Trouble Code (DTC). <Ref. to LAN(di- ag)-28, List of Diagnostic Trouble Code (DTC).> LAN00015 4) Connect the Subaru Select Monitor to data link connector. Data link connector is located in the lower portion of the instrument panel (on the driver’s side).
Page 731 Subaru Select Monitor LAN SYSTEM (DIAGNOSTICS) 2. READ CURRENT DATA 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Integ. Unit mode} and press the [YES] key.
Page 732 Subaru Select Monitor LAN SYSTEM (DIAGNOSTICS) 4. DISPLAY OF ON/OFF DATA Items to be displayed Unit of measure R fog lamp output ON/OFF Items to be displayed Unit of measure R fog lamp monitor ON/OFF key-lock warning SW ON/OFF Immobilizer lamp output...
Page 733 Subaru Select Monitor LAN SYSTEM (DIAGNOSTICS) NOTE: Items to be displayed Unit of measure For details concerning operation procedure, refer Auto A/C failure OK/NG to “SUBARU SELECT MONITOR OPERATION EBD Warning Light OK/OFF MANUAL”. ABS Warning Light OK/OFF VDC OFF flag ON/OFF...
Page 734 Subaru Select Monitor LAN SYSTEM (DIAGNOSTICS) 6. REGISTRATION BODY INTEGRATED 3) Turn the ignition switch to ON and Subaru Select Monitor to ON. UNIT (EQUIPMENT SETTING) CAUTION: Body integrated unit is core of LAN system, and also can select the function of all vehicle sys- tem control.
Page 735 Subaru Select Monitor LAN SYSTEM (DIAGNOSTICS) 6) Change the setting with UP/DOWN key and press the [YES] key. • List of body integrated unit registration item NOTE: Setting is different depending on grade of vehicle. Data Initial setting Registration Remarks Illumination control does not operate if A/C ECM setting is set to “OFF”...
Page 736 • If freeze frame data is not stored in memory cor- rectly (caused by low power supply of body inte- grated unit), DTC will be displayed with “?” on the head of it in the Subaru Select Monitor display. This shows it may be an unreliable reading. LAN(diag)-20...
Page 737 Subaru Select Monitor LAN SYSTEM (DIAGNOSTICS) 9. FUNCTION SETTING (ECM CUSTOMIZING) 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key. 2) On the «System Selection Menu» display screen, select the {Integ. Unit mode} and press the [YES] key.
Page 738: Vehicle Equipment
• Do not change the settings except for setting above during operation of equipment setting. • Be sure not to change “Factory” initial setting except in installation of new body integrated unit. NOTE: For details concerning operation procedure, refer to “SUBARU SELECT MONITOR OPERATION MANUAL”. LAN(diag)-22...
Page 739 In order to check the body integrated unit function, inspect the body integrated unit and actuator using Subaru Select Monitor without operating switches. 1) On the «Main Menu» display screen, select the {Each System Check} and press the [YES] key.
Page 740: Read Diagnostic Trouble Code (Dtc)
Code (DTC) A: OPERATION 1. WITHOUT SUBARU SELECT MONITOR NOTE: Use the Subaru Select Monitor, because DTCs can not be read out. 2. WITH SUBARU SELECT MONITOR For details concerning DTC reading procedure, re- fer to “Subaru Select Monitor”. <Ref. to LAN(diag)- 14, READ DIAGNOSTIC TROUBLE CODE (DTC), OPERATION, Subaru Select Monitor.>...
Page 741: Clear Memory Mode
8. Clear Memory Mode A: OPERATION 1. WITHOUT SUBARU SELECT MONITOR NOTE: Use the Subaru Select Monitor for Clear Memory Mode. 2. WITH SUBARU SELECT MONITOR For detailed procedures of clearing DTC, refer to “SUBARU SELECT MONITOR”. <Ref. to LAN(di- ag)-20, CLEAR MEMORY MODE, OPERATION, Subaru Select Monitor.>...
Page 742: Read Current Data
5) Using the scroll key, scroll the display screen up or down until the desired data is shown. <Ref. to LAN(diag)-15, DISPLAY OF ANALOG DA- TA, OPERATION, Subaru Select Monitor.> <Ref. to LAN(diag)-16, DISPLAY OF ON/OFF DATA, OPERATION, Subaru Select Monitor.> <Ref. to LAN(diag)-17, CONFIRMATION OF CURRENT SETTING, OPERATION, Subaru Select Monitor.>...
Page 743: Function Setting (Customize)
Room light delay time Anti-lock out Each function Rear defogger Wiper deicer 2. WITH SUBARU SELECT MONITOR For detailed procedures of function setting (ECM customizing), refer to “SUBARU SELECT MONI- TOR”. <Ref. to LAN(diag)-21, FUNCTION SET- TING (ECM CUSTOMIZING), OPERATION, Subaru Select Monitor.>...
Page 744: List Of Diagnostic Trouble Code (Dtc)
11.List of Diagnostic Trouble Code (DTC) A: LIST Item Content of diagnosis NOTE None Communication for initializing Open or short in Subaru <Ref. to LAN(diag)-30, COMMUNICATION impossible Select Monitor communi- FOR INITIALIZING IMPOSSIBLE, Diagnostic cation line. Procedure with Diagnostic Trouble Code (DTC).>...
Page 745 List of Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Item Content of diagnosis NOTE B0223 CAN-HS VDC/ABS no-receive Not received error data <Ref. to LAN(diag)-62, DTC B0223 CAN-HS data from VDC/ABS unit. VDC/ABS NO-RECEIVE DATA, Diagnostic Pro- cedure with Diagnostic Trouble Code (DTC).> B0300 CAN-LS malfunction Open or short in low-...
Page 746: Diagnostic Procedure With Diagnostic Trouble Code (Dtc)
• DTC is displayed in the sequence of the amount of counter numbers. • When more than two DTCs are displayed, perform the diagnosis of top of them. DIAGNOSIS: Subaru Select Monitor communication line is open or shorted. TROUBLE SYMPTOM: Not communicable with Subaru Select Monitor.
Page 747 Go to step 5. LECT MONITOR. displayed? 1) Turn the ignition switch to ON. 2) Using the Subaru Select Monitor, check whether communication to other systems can be executed normally. CHECK COMMUNICATION OF SUBARU SE- Are system and model year Go to step 7.
Page 748 Connector & terminal (B280) No. 19 — Chassis ground: CHECK POOR CONTACT IN CONNECTORS. Is there poor contact at control Replace the body Repair the poor unit ground and Subaru Select integrated unit. contact connector. Monitor? <Ref. to SL-46, Body Integrated Unit.>...
Page 749 • Freeze frame data in odo/trip meter is not cleared. • “No trouble code” is displayed on Subaru Select Monitor. NOTE: If DTC is not displayed on Subaru Select Monitor, LAN communication System should be OK. Step Check CHECK FREEZE FRAME DATA WITH COM-...
Page 750 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) D: DTC B0101 BATT P/SUPPLY MALFUNCTION CONT. DTC DETECTING CONDITION: BATT power supply control circuit is open or shorted. TROUBLE SYMPTOM: No malfunction occurs with back-up power supply function. NOTE: When some B0102 BATT p/supply malfunction backup are output at the same time, all function of body in- tegrated unit may not function.
Page 751 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check CHECK FUSE (No. 7). Is the fuse blown out? Replace the fuse Go to step 2. 1) Turn the ignition switch to OFF. (No. 7). If the 2) Remove the fuse (No. 7). replaced fuse has blown out easily, repair the short cir-...
Page 752 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) E: DTC B0102 BATT P/SUPPLY MALFUNCTION CONT. DTC DETECTING CONDITION: BATT power backup circuit is open or shorted. TROUBLE SYMPTOM: • Engine malfunction indicator light may be illuminates. • Keyless entry, room light, key illumination does not operate. •...
Page 753 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check CHECK FUSE (No. 8). Is the fuse blown out? Replace the fuse Go to step 2. 1) Turn the ignition switch to OFF. (No. 8). If the 2) Remove the fuse (No. 8). replaced fuse has blown out easily, repair the short cir-...
Page 754 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) F: DTC B0103 IGNITION POWER FAILURE DTC DETECTING CONDITION: IGN power supply circuit is open or shorted. TROUBLE SYMPTOM: Symptom that illuminating engine malfunction indicator light, “Er HC” high speed CAN error display may be occurred.
Page 755 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check CHECK FUSE (No. 12). Is the fuse blown out? Replace the fuse Go to step 2. 1) Turn the ignition switch to OFF. (No. 12). If the 2) Remove the fuse (No. 12). replaced fuse has blown out easily, repair the short cir-...
Page 756 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) G: DTC B0104 ACC POWER FAILURE DTC DETECTING CONDITION: ACC power supply circuit is open or shorted. TROUBLE SYMPTOM: Rear wiper may not operate on ACC. WIRING DIAGRAM: IGNITION SWITCH BATTERY MAIN SBF-11 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23...
Page 757 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check CHECK FUSE (No. 31). Is the fuse blown out? Replace the fuse Go to step 2. 1) Turn the ignition switch to OFF. (No. 31). If the 2) Remove the fuse (No. 31). replaced fuse has blown out easily, repair the short cir-...
Page 758 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) H: DTC B0106 SHIFT LOCK CIRCUIT FAILURE DTC DETECTING CONDITION: Shift lock circuit is ground shorted. TROUBLE SYMPTOM: Key interlock does not unlock or lock. WIRING DIAGRAM: REF.TO POWER SUPPLY ROUTING FB-28 FB-37 MB-28...
Page 759 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check Is the resistance 10 — 30 "? CHECK HARNESS. Go to step 5. Go to step 2. 1) Disconnect the body integrated unit con- nector (B280). 2) Measure the resistance between body inte- grated unit connector and chassis ground.
Page 760 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) I: DTC B0107 R FOG LAMP CIRCUIT FAILURE DTC DETECTING CONDITION: Rear fog input/output circuits are ground shorted. TROUBLE SYMPTOM: • Rear fog light does not come on or go off. •...
Page 761 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check CHECK HARNESS. Is the voltage 10 — 13 V? Temporary poor Go to step 2. 1) Disconnect the body integrated unit con- contact. nector (B280). 2) Measure the voltage between body inte- grated unit connector and chassis ground.
Page 762 Is the “Yes” displayed? Go to step 6. Replace the body Read the data of “body integrated unit data integrated unit. received” on ECM data display using Subaru <Ref. to SL-46, Select Monitor. Body Integrated Unit.> CHECK BODY INTEGRATED UNIT.
Page 763 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) K: DTC B0202 CAN-HS BUS OFF DTC DETECTING CONDITION: • Locate the unit or CAN line which trouble occurs, and repair and replace it. • Not received data and error data may be detected at the same time. TROUBLE SYMPTOM: “Er HC”...
Page 764 <Ref. to 4AT-140, 2) Perform the clear memory of body inte- Transmission Con- grated unit. <Ref. to LAN(diag)-20, CLEAR trol Device.> <Ref. MEMORY MODE, OPERATION, Subaru to 5AT-61, Trans- Select Monitor.> mission Control 3) Read DTC of body integrated unit.
Page 765 (B280) No. 30 (+) — Chassis ground ( CHECK DTC. Is DTC other than “CAN com- Perform the diag- Go to step 13. Read the DTC of ECM using Subaru Select munication” displayed? nosis according to Monitor. <Ref. to EN(H4SO 2.0)(diag)-25, DTC.
Page 766 BLE CODE (DTC), OPERATION, Subaru Select Monitor.> CHECK DTC. Is DTC other than “CAN com- Perform the diag- Replace the body Read the DTC of TCM using Subaru Select munication” displayed? nosis according to integrated unit. Monitor. <Ref. to 4AT(diag)-17, READ DIAG- DTC.
Page 767 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) L: DTC B0211 CAN-HS ECM DATA ABNORMAL DTC DETECTING CONDITION: Defective data from ECM. TROUBLE SYMPTOM: “Er HC” or “Er EG” is displayed in odo/trip meter. WIRING DIAGRAM: B280 B136 BODY INTEGRATED B137 UNIT...
Page 768 LAN SYSTEM (DIAGNOSTICS) Step Check CHECK ECM. Is DTC other than “CAN com- Perform the diag- Replace the ECM. Read the DTC of ECM using Subaru Select munication” displayed? nosis according to <Ref. to FU(H4SO Monitor. DTC. 2.0)-34, Engine Control Module (ECM).>...
Page 769 Step Check CHECK TCM. Is DTC other than “CAN com- Perform the diag- Replace the TCM. Read the DTC of TCM using Subaru Select munication” displayed? nosis according to <Ref. to 4AT-65, Monitor. <Ref. to 4AT(diag)-17, READ DIAG- DTC. Transmission Con-...
Page 770 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) N: DTC B0213 CAN-HS VDC/ABS DATA ABNORMAL DTC DETECTING CONDITION: VDC/ABSCM body error, or harness between the main harness splice and TCM is open or short, the con- nector is not connected securely and the terminal has poor caulking. TROUBLE SYMPTOM: •...
Page 771 LAN SYSTEM (DIAGNOSTICS) Step Check CHECK VDC/ABSCM. Is DTC other than “CAN com- Perform the diag- Replace the VDC/ Read the DTC of VDC/ABSCM using Subaru munication” displayed? nosis according to ABSCM. <Ref. to Select Monitor. DTC. ABS-6, ABS Con-...
Page 772 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) O: DTC B0221 CAN-HS ECM NO-RECEIVE DATA DTC DETECTING CONDITION: Defective ECM. (If error is in the main harness, Diagnostic Trouble Code (DTC) P0600 High-speed CAN cir- cuit is input simultaneously.) TROUBLE SYMPTOM: •...
Page 773 Connector & terminal 2.0)(diag)-25, (B280) No. 20 — No. 30: READ DIAGNOS- TIC TROUBLE CODE (DTC) FOR ENGINE (NOR- MAL MODE), OPERATION, Subaru Select Monitor.> <Ref. to EN(H4SO 2.5)(diag)-26, READ DIAGNOS- TIC TROUBLE CODE (DTC) FOR ENGINE (NOR- MAL MODE),...
Page 774 *2: Except for 2.0 L SOHC RHD and 2.5 L MAL MODE), FU(H4DOTC)-35, (KA) RHD model, 2.5 L (EC, K4) LHD OPERATION, Engine Control model, 3.0 L LHD model Subaru Select Module (ECM).> (B137) No. 18 — No. 26: Monitor.> <Ref. to <Ref. to EN(H4SO FU(H6DO)-34, 2.5)(diag)-26,...
Page 775 Connector & terminal CODE (DTC) FOR (B280) No. 20 (+) — Chassis ground ( ENGINE (NOR- (B280) No. 30 (+) — Chassis ground ( MAL MODE), OPERATION, Subaru Select Monitor.> <Ref. to EN(H4SO 2.5)(diag)-26, READ DIAGNOS- TIC TROUBLE CODE (DTC) FOR...
Page 776 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) P: DTC B0222 CAN-HS TCM NO-RECEIVE DATA DTC DETECTING CONDITION: TCM error, or harness between the main harness splice and TCM is open or short, the connector is not con- nected securely and the terminal has poor caulking.
Page 777 (B54) No. 3 — No. 4: CHECK TCM. Is DTC other than “CAN com- Perform the diag- Replace the TCM. Read the DTC of TCM using Subaru Select munication” displayed? nosis according to <Ref. to 4AT-65, Monitor. <Ref. to 4AT(diag)-17, READ DIAG- DTC.
Page 778 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Q: DTC B0223 CAN-HS VDC/ABS NO-RECEIVE DATA DTC DETECTING CONDITION: Defective VDC/ABSCM. (If error is in the main harness, DTC P0600 High-speed CAN circuit is input at the same time.) TROUBLE SYMPTOM: •...
Page 779 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check Is the resistance 55 — 65 "? CHECK HARNESS. Read the DTC of Go to step 2. 1) Disconnect the harness connector of body VDC/ABSCM, and integrated unit. perform the diag- 2) Measure the resistance between harness nosis according to...
Page 780 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check CHECK VDC/ABSCM. Is DTC other than “CAN com- Perform the diag- Temporary poor 1) Connect all the connectors. munication” displayed? nosis according to contact occurs. 2) Read the DTC of VDC/ABSCM using Sub- DTC concerning Check the con- aru Select Monitor.
Page 781 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) R: DTC B0300 CAN-LS MALFUNCTION DTC DETECTING CONDITION: Each side of low-speed CAN communication line is open or shorted, connector is not connected securely, the terminal has poor caulking. TROUBLE SYMPTOM: “Er LC”...
Page 782 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check CHECK HARNESS. Is the resistance less than 10 Go to step 2. Repair or replace "? 1) Disconnect the CAN junction connector the short circuit of (i77) and body integrated unit connector (i84). harness.
Page 783 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check CHECK AUTO A/C. Is the self-diagnosis OK? Go to step 9. Replace the auto Perform the auto A/C self-diagnosis. <Ref. to A/C control unit. AC(diag)-13, A/C CONTROL SYSTEM SELF- <Ref.
Page 784 Does the data display change? Go to step 3. Go to step 5. 1) Display the current data of body integrated unit using Subaru Select Monitor. 2) Display the number of blower fan level in the analog data. 3) Read the data display when the blower fan level is changed on air conditioner control part.
Page 785 Is the “Yes” displayed? Go to step 11. Replace the body Read the data of “body integrated unit data integrated unit. received” on ECM data display using Subaru <Ref. to SL-46, Select Monitor. Body Integrated Unit.> CHECK BODY INTEGRATED UNIT.
Page 786 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) T: DTC B0302 CAN-LS BUS OFF DTC DETECTING CONDITION: Because of occurring a lot of error data, some units are disconnected not to affect other units. Communication error from the unit which error is occurred is input at the same time. TROUBLE SYMPTOM: “Er LC”...
Page 787 Go to step 5. MANUAL A/C, GO TO STEP 3.) 1) Display the current data of body integrated unit using Subaru Select Monitor. 2) Display the number of blower fan level in the analog data. 3) Read the data display when the number of blower fan level is changed on air conditioner control part.
Page 788 Is the “Yes” displayed? Go to step 11. Replace the body Read the data of “body integrated unit data integrated unit. received” on ECM data display using Subaru <Ref. to SL-46, Select Monitor. Body Integrated Unit.> CHECK BODY INTEGRATED UNIT.
Page 789 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) U: DTC B0311 CAN-LS METER UNIT DATA ABNORMAL DTC DETECTING CONDITION: Combination meter error, or harness between the main harness splice and combination meter is open or short, the connector is not connected securely and the terminal has poor caulking. TROUBLE SYMPTOM: “Er Lc”...
Page 790 Is center display fail OK? Go to step 2. Replace the center 1) Display the current data of body integrated display. unit using Subaru Select Monitor. 2) Read the fail display of center display. CHECK NAVIGATION. Is NAVI fail OK? Replace the center...
Page 791 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) W: DTC B0321 CAN-LS METER NO-RECEIVE DATA DTC DETECTING CONDITION: Combination meter unit error, or harness between the main harness splice and combination meter unit is open or short, the connector is not connected securely and the terminal has poor caulking. TROUBLE SYMPTOM: Fail mode occurs because the data is not received from combination meter unit.
Page 792 Go to step 2. Perform the self- 1) Warm up the engine. diagnosis for com- 2) Compare the data of body integrated unit bination meter. and combination meter using Subaru Select <Ref. to IDI-3, Monitor. SELF-DIAGNO- Check item: SIS, INSPEC- •...
Page 793 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) X: DTC B0500 KEYLESS UART COM. MALFUNCTION DTC DETECTING CONDITION: UART between keyless control unit and body integrated unit is open or shorted, connector is not connected securely, the terminal has poor caulking. TROUBLE SYMPTOM: Door lock does not operate with keyless.
Page 794 Diagnostic Procedure with Diagnostic Trouble Code (DTC) LAN SYSTEM (DIAGNOSTICS) Step Check CHECK HARNESS. Is the resistance less than 10 Go to step 2. Repair or replace "? 1) Disconnect the body integrated unit con- the open circuit of nector (i84) and keyless entry control unit con- harness.
Page 795: General Diagnostic Table
General Diagnostic Table LAN SYSTEM (DIAGNOSTICS) 13.General Diagnostic Table A: INSPECTION Read the DTC or inspect and diagnose the following data in the current data display using Subaru Select Monitor. 1. LAN SYSTEM Specifications Item Operation NOTE Perform the diag-...
Page 796 General Diagnostic Table LAN SYSTEM (DIAGNOSTICS) Specifications Item Operation NOTE Body integrated Reconfigure the Does Vehicle equipment corre- unit registration Correspondence values according to — spond to setting values? function setting vehicle equipment. When changing customize setting, Inspect body inte- Customize Registered —...