1. Manuals
  2. Brands
  3. Subaru Manuals
  4. Automobile
  5. 2004 LEGACY
  6. Service manual

Subaru LEGACY 2004 Service Manual

Hide thumbs Also See for LEGACY 2004:
Table of Contents

Advertisement

Quick Links

See also: Service Manual , Owner's Manual
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

Advertisement

Table of Contents
loading

Related Manuals for Subaru LEGACY 2004

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

    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 4: 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 5 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 6 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 7 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 8 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 9 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 10 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 11 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 12: 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 13 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 14 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. Ω? Measure the resistance between the harness switch is OK. connector terminal and chassis ground when the door lock switch is moved to UNLOCK.
  • Page 15 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 16 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 17: 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 18 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 19 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 20 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 21 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 22 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 23 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 24 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 25 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 26 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 27 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 28 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 29 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 30: 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 31: 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 32: 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 33: 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.> 2) Remove the pawl of front door latch security cov- 6 5 4 3 2 1 er, and then remove the cover.

  • Page 34: 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 35: 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 36: 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 37: 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.> 2) Remove the pawl of rear door latch security cov- 6 5 4 3 2 1 er, and then remove the cover.

  • Page 38: 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 39: 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 40 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 41: 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 42: 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 43: 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 44 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 45: Ignition Key Lock

    Ignition Key Lock SECURITY AND LOCKS 17.Ignition Key Lock Switch position Terminal No. Standard LOCK — — A: REPLACEMENT Less than 1 Ω No. 3 and No. 4 1) Disconnect the ground cable from battery. No. 3 and No. 1 2) Remove the steering column.

  • Page 46: 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 47: 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 48: 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 49: 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 50 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 51: 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 52: 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.>...

Table of Contents