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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

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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

    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 4: 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 5 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 6: Front Door Glass

    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 7: Rear Door Glass

    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 8 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 9: Special Tool

    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 10: 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 11: 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 12: 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 13 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 14 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 15 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 16 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 17: 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 18: 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 19: 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 20: 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-00277 GW-00278...
  • Page 21: 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 22: 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 23 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 24: 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 25 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 26: 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 27: 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 28 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 29 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 30: 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 31: 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 32: 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 33: 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 34 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 35: 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 36: 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 37: 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 38: 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 39: 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 40 Wiper Deicer Switch GLASS/WINDOWS/MIRRORS GW-38...

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