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Subaru legacy 2003 Service Manual

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2003 LEGACY SERVICE MANUAL

BODY SECTION

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

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Summary of Contents for Subaru legacy 2003

  • Page 1: Body Section

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

  • Page 3: Table Of Contents

    LIGHTING SYSTEM Page General Description ..................2 Headlight and Tail Light System ..............3 Front Fog Light System................4 Rear Fog Light System ................5 Turn Signal and Hazard Light System ............6 Back-up Light System .................7 Stop Light System ..................8 Interior Light System ...................9 Headlight Beam Leveler System...............10 Combination Switch (Light) ...............11 Combination Base Switch Assembly............13...

  • Page 4: General Description

    GENERAL DESCRIPTION LIGHTING SYSTEM 1. General Description A: SPECIFICATIONS Headlight 12 V — 55 W/55 W (Halogen) Front turn signal light 12 V — 21 W Side turn signal light 12 V — 5 W Parking light 12 V — 5 W Front fog light 12 V —...

  • Page 5: Headlight And Tail Light System

    HEADLIGHT AND TAIL LIGHT SYSTEM LIGHTING SYSTEM 2. Headlight and Tail Light Sys- B: INSPECTION 1. HEADLIGHT RELAY A: SCHEMATIC Measure headlight relay resistance between termi- nals while connecting terminal No. 4 to battery pos- 1. HEADLIGHT LHD MODEL itive terminal No. 3 to battery ground terminal. <Ref.

  • Page 6: Front Fog Light System

    FRONT FOG LIGHT SYSTEM LIGHTING SYSTEM 3. Front Fog Light System 2. FRONT FOG LIGHT RELAY Measure front fog light relay resistance between A: SCHEMATIC terminals while connecting terminal No. 4 to battery 1. FRONT FOG LIGHT 4 CYLINDER EN- positive terminal and terminal No.

  • Page 7: Rear Fog Light System

    REAR FOG LIGHT SYSTEM LIGHTING SYSTEM 4. Rear Fog Light System A: SCHEMATIC 1. REAR FOG LIGHT <Ref. to WI-294, SCHEMATIC, Rear Fog Light System.> B: INSPECTION 1. REAR FOG LIGHT SWITCH 1) Turn ignition switch ON. 2) Turn on the headlight or front fog light. 3) Push the rear fog light switch and check if the rear fog light turns on.

  • Page 8: Turn Signal And Hazard Light System

    TURN SIGNAL AND HAZARD LIGHT SYSTEM LIGHTING SYSTEM 5. Turn Signal and Hazard Light 3. TURN SIGNAL & HAZARD MODULE System Connect battery and turn signal light bulb to the module, as shown in the figure. The module is A: SCHEMATIC properly functioning if it blinks when power is sup- plied to the circuit.

  • Page 9: Back-Up Light System

    BACK-UP LIGHT SYSTEM LIGHTING SYSTEM 6. Back-up Light System A: SCHEMATIC 1. BACK-UP LIGHT <Ref. to WI-247, SCHEMATIC, Back-up Light Sys- tem.> B: INSPECTION 1. BACK-UP LIGHT SWITCH (M/T) Measure back-up light switch resistance. LI-00006 Switch position Terminal No. Standard When shift lever is set Less than 1 Ω...

  • Page 10: Stop Light System

    STOP LIGHT SYSTEM LIGHTING SYSTEM 7. Stop Light System A: SCHEMATIC 1. STOP LIGHT SEDAN MODEL <Ref. to WI-272, SEDAN MODEL, SCHEMATIC, Stop Light System.> 2. STOP LIGHT WAGON MODEL <Ref. to WI-273, WAGON MODEL, SCHEMATIC, Stop Light System.> B: INSPECTION 1.

  • Page 11: Interior Light System

    INTERIOR LIGHT SYSTEM LIGHTING SYSTEM 8. Interior Light System 2. REAR GATE LATCH SWITCH Measure rear gate latch switch. A: SCHEMATIC Switch position Terminal No. Standard 1. INTERIOR LIGHT LHD MODEL When rear gate is Less than 1 Ω <Ref. to WI-266, LHD MODEL, SCHEMATIC, In open 1 and 2 Compartment Light System.>...

  • Page 12: Headlight Beam Leveler System

    HEADLIGHT BEAM LEVELER SYSTEM LIGHTING SYSTEM 9. Headlight Beam Leveler Sys- A: SCHEMATIC 1. HEADLIGHT BEAM LEVELER <Ref. to WI-234, SCHEMATIC, 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 - 1 - 2 - 3 - 4 - 5.

  • Page 13: Combination Switch (Light)

    COMBINATION SWITCH (LIGHT) LIGHTING SYSTEM 10.Combination Switch (Light) C: INSPECTION Measure combination switch resistance. A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove instrument panel lower cover. <Ref. to EI-35, REMOVAL, Instrument Panel Assembly.> 3) Remove screws which secure upper column cover to lower column cover.
  • Page 14 COMBINATION SWITCH (LIGHT) LIGHTING SYSTEM 3. TURN SIGNAL SWITCH LHD model and RHD model with rear fog light: Switch position Terminal No. Standard Less than 1 Ω Left 1 and 2 Neutral — More than 1 MΩ Less than 1 Ω Right 2 and 3 RHD model without rear fog light:...

  • Page 15: Combination Base Switch Assembly

    COMBINATION BASE SWITCH ASSEMBLY LIGHTING SYSTEM 11.Combination Base Switch 5) Loosen 3 screws. Assembly A: REMOVAL 1. WITHOUT VDC MODEL 1) Remove driver’s airbag module. <Ref. to AB-12, REMOVAL, Driver's Airbag Module.> 2) Remove steering wheel. <Ref. to PS-24, RE- MOVAL, Steering Wheel.>...
  • Page 16 COMBINATION BASE SWITCH ASSEMBLY LIGHTING SYSTEM 2. PARKING SWITCH Measure parking switch resistance. LI-00183 Switch position Terminal No. Standard Less than 1 Ω 2 and 4 Less than 1 Ω 1 and 4 LI-14...

  • Page 17: Headlight Assembly

    HEADLIGHT ASSEMBLY LIGHTING SYSTEM 12.Headlight Assembly A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove duct (A) (when right side headlight is re- moved). ( A ) LI-00073 3) Disconnect headlight bulb connector. LI-00129 4) Remove three bolts and disconnect connectors, and then detach headlight assembly.
  • Page 18 HEADLIGHT ASSEMBLY LIGHTING SYSTEM C: ADJUSTMENT Turn the headlights on and then adjust the low beam pattern to the following positions on the 1. HEADLIGHT AIMING screen. CAUTION: NOTE: • Set the headlight leveler switch to “0” position. Turn off the light before adjusting headlight aiming.

  • Page 19: Headlight Bulb

    HEADLIGHT BULB LIGHTING SYSTEM 13.Headlight Bulb C: INSPECTION 1) Visually check the bulb for blow out. A: REMOVAL 2) Check the bulb specification. <Ref. to LI-2, SPECIFICATIONS, General Description.> CAUTION: • Because the tungsten halogen bulb operates 3) If NG, replace the bulb with a new one. at a high temperature, dirt and oil on the bulb surface reduces the bulb's service life.

  • Page 20: Front Turn Signal Light Bulb

    FRONT TURN SIGNAL LIGHT BULB LIGHTING SYSTEM 14.Front Turn Signal Light Bulb A: REMOVAL 1) Remove headlight assembly. <Ref. to LI-15, RE- MOVAL, Headlight Assembly.> 2) Turn the socket and remove the bulb. LI-00136 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Visually check the bulb for blow out.

  • Page 21: Parking Light Bulb

    PARKING LIGHT BULB LIGHTING SYSTEM 15.Parking Light Bulb A: REMOVAL 1) Remove headlight assembly. <Ref. to LI-15, RE- MOVAL, Headlight Assembly.> 2) Turn the socket and remove the bulb. LI-00137 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Visually check the bulb for blow out.

  • Page 22: Front Fog Light Assembly

    FRONT FOG LIGHT ASSEMBLY LIGHTING SYSTEM 16.Front Fog Light Assembly 3) Remove mounting bolts. A: REMOVAL 1. EXCEPT OUTBACK 1) Disconnect ground cable from battery. 2) Remove two clips and lower the mudguard. LI-00087 4) Remove two clips and lower the mudguard. LI-00084 3) Disconnect harness connector.

  • Page 23: Front Fog Light Bulb

    FRONT FOG LIGHT BULB LIGHTING SYSTEM 17.Front Fog Light Bulb A: REMOVAL 1. EXCEPT OUTBACK 1) Disconnect ground cable from battery. 2) Remove the two clips and lower the mudguard. LI-00084 3) Disconnect harness connector. 4) Remove back cover (A). ( A ) LI-00089 5) Remove spring retainer then detach fog light...

  • Page 24: Rear Combination Light Assembly

    REAR COMBINATION LIGHT ASSEMBLY LIGHTING SYSTEM 18.Rear Combination Light As- 2. WAGON sembly 1) Disconnect ground cable from battery. 2) Remove two rear quarter trim covers. A: REMOVAL 3) Remove two nuts and then remove rear combi- nation light while disconnecting connector. 1.

  • Page 25: Rear Finisher Light Assembly

    REAR FINISHER LIGHT ASSEMBLY LIGHTING SYSTEM 19.Rear Finisher Light Assembly A: REMOVAL 1. SEDAN 1) Disconnect ground cable from battery. 2) Open the trunk lid. 3) Remove cover (A). 4) Disconnect connector (B) from rear finisher light. 5) Remove ten nuts and then detach rear finisher light from trunk lid.

  • Page 26: Brake/Tail Light Bulb

    BRAKE/TAIL LIGHT BULB LIGHTING SYSTEM 20.Brake/Tail Light Bulb A: REMOVAL 1. SEDAN 1) Open trunk lid and remove cover. LI-00098 2) Turn the socket and remove the bulb. 2. WAGON 1) Remove rear combination light assembly. <Ref. to LI-22, WAGON, REMOVAL, Rear Combination Light Assembly.>...

  • Page 27: Back-Up Light Bulb

    BACK-UP LIGHT BULB LIGHTING SYSTEM 21.Back-up Light Bulb A: REMOVAL 1. SEDAN 1) Open trunk lid and remove cover. LI-00102 2) Turn the socket and remove the bulb. 2. WAGON 1) Open rear gate lower trim cover. LI-00103 2) Turn the socket and remove the bulb. B: INSTALLATION Install in the reverse order of removal.

  • Page 28: Rear Turn Signal Light Bulb

    REAR TURN SIGNAL LIGHT BULB LIGHTING SYSTEM 22.Rear Turn Signal Light Bulb A: REMOVAL 1. SEDAN 1) Open trunk lid and remove cover. LI-00104 2) Turn the socket and remove the bulb. 2. WAGON 1) Remove rear combination light assembly. <Ref. to LI-22, WAGON, REMOVAL, Rear Combination Light Assembly.>...

  • Page 29: Rear Fog Light Bulb

    REAR FOG LIGHT BULB LIGHTING SYSTEM 23.Rear Fog Light Bulb A: REMOVAL 1. SEDAN 1) Open trunk lid and remove cover. LI-00099 2) Turn the socket and remove the bulb. 2. WAGON 1) Open rear gate lower trim cover. LI-00101 2) Turn the socket and remove the bulb.

  • Page 30: License Plate Light

    LICENSE PLATE LIGHT LIGHTING SYSTEM 24.License Plate Light A: REMOVAL 1) Remove license plate light mounting screw (A) and then remove the lens (B) SEDAN ( B ) ( A ) LI-00106 WAGON ( B ) ( A ) LI-00107 2) Remove the bulb.

  • Page 31: High-Mounted Stop Light

    HIGH-MOUNTED STOP LIGHT LIGHTING SYSTEM 25.High-mounted Stop Light A: REMOVAL 1. SEDAN 1) Disconnect ground cable from battery. 2) Disconnect connector of high-mounted stop light from body harness. 3) Remove bolts, then detach high-mounted stop light assembly. LI-00108 2. WAGON 1) Disconnect ground cable from battery.

  • Page 32: Side Turn Signal Light

    SIDE TURN SIGNAL LIGHT LIGHTING SYSTEM 26.Side Turn Signal Light A: REMOVAL 1) Disconnect ground cable from battery. 2) Pull out the light from body while pushing it in di- rection of vehicle front. 3) Disconnect harness connector and remove the light.

  • Page 33: Spot Light

    SPOT LIGHT LIGHTING SYSTEM 27.Spot Light A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove lens (A) and spot light mounting screw (B). ( A ) ( B ) LI-00109 3) Disconnect harness connectors and remove spot light. B: INSTALLATION Install in the reverse order of removal.

  • Page 34: Room Light

    ROOM LIGHT LIGHTING SYSTEM 28.Room Light A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove lens (A) and room light mounting screws (B). ( B ) ( B ) ( A ) LI-00040 3) Disconnect harness connectors and remove the light.

  • Page 35: Luggage Room Light

    LUGGAGE ROOM LIGHT LIGHTING SYSTEM 29.Luggage Room Light C: INSPECTION A: REMOVAL 1. LUGGAGE ROOM LIGHT BULB 1) Disconnect ground cable from battery. 1) Visually check the bulb for blow out. 2) Remove lens (A) and luggage room light mount- 2) Check the bulb specification.

  • Page 36: Trunk Room Light

    TRUNK ROOM LIGHT LIGHTING SYSTEM 30.Trunk Room Light A: REMOVAL 1) Disconnect ground cable from battery. 2) Disconnect harness connectors and remove trunk room light. LI-00110 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Visually check the bulb for blow out. 2) Check the bulb specification.

  • Page 37: Glove Box Light

    GLOVE BOX LIGHT LIGHTING SYSTEM 31.Glove Box Light A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove glove box. <Ref. to EI-32, REMOVAL, Glove Box.> 3) Disconnect harness connector. 4) Remove glove box light. LI-00111 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Visually check the bulb for blow out.

  • Page 38: Door Step Light

    DOOR STEP LIGHT LIGHTING SYSTEM 32.Door Step Light A: REMOVAL Remove the lens then detach the bulb. LI-00012 B: INSTALLATION Install in the reverse order of removal. C: INSPECTION 1) Visually check the bulb for blow out. 2) Check the bulb specification. <Ref. to LI-2, SPECIFICATIONS, General Description.>...

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