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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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Table of Contents
Related Manuals for Subaru 2003 LEGACY BODY SECTION
Summary of Contents for Subaru 2003 LEGACY BODY SECTION
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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...
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Page 3: Table Of Contents
EXTERIOR/INTERIOR TRIM Page General Description ..................2 Front Grille ....................12 Front Under Cover ..................13 Front Bumper ....................14 Rear Bumper.....................20 Mud Guard ....................22 Protector....................23 Cowl Panel ....................27 Spoiler .......................28 Side Sill Spoiler ..................29 Front Door Trim ..................30 Rear Door Trim ..................31 Glove Box....................32 Roof Rail ....................33 Console Box....................34 Instrument Panel Assembly ..............35... -
Page 4: General Description
GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 1. General Description A: COMPONENT 1. FRONT BUMPER ( 3 ) ( 1 ) ( 4 ) ( 7 ) ( 5 ) ( 3 ) ( 6 ) ( 2 ) ( 4 ) ( 8 ) ( 5 ) EI-00402 (1) Bumper face (Except OUTBACK) - Page 5 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 2. REAR BUMPER (SEDAN) ( 6 ) ( 1 ) ( 2 ) ( 3 ) ( 6 ) ( 5 ) ( 4 ) EI-00403 (1) Bumper beam (4) Side stay Tightening torque: N·m (kgf-m, ft-lb) (2) Side bracket (5) Hook 93 (9.5, 69)
- Page 6 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 3. REAR BUMPER (WAGON) ( 2 ) ( 6 ) ( 1 ) ( 5 ) ( 3 ) ( 4 ) EI-00404 (1) Bumper beam (4) Bumper face (OUTBACK) Tightening torque: N·m (kgf-m, ft-lb) (2) Side bracket (5) Side stay 93 (9.5, 96) (3) Bumper face (Except OUTBACK)
- Page 7 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 4. SIDE PROTECTOR ( A ) ( 2 ) ( 6 ) ( 1 ) ( B ) ( 7 ) ( 5 ) ( 4 ) ( 3 ) EI-00405 (A) Except OUTBACK (3) Side protector (Front fender) (7) Side protector (Side sill) (B) OUTBACK (4) Side protector (Front door)
- Page 8 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 5. DOOR TRIM ( A ) ( B ) ( C ) (11) EI-00287 (A) Front door (3) Weatherstrip upper (8) Weatherstrip lower (B) Rear door (4) Clip (9) Upper trim (C) Rear gate (5) Pad (10) Side trim (1) Gusset cover (6) Trim panel...
- Page 9 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 6. INNER TRIM (SEDAN) ( 3 ) ( 4 ) ( 8 ) ( 2 ) ( 9 ) ( 1 ) (10) (12) (11) ( 7 ) (13) ( 6 ) ( 5 ) EI-00290 (1) Front pillar upper trim (6) Trunk rear trim (11) Side sill rear lower cover...
- Page 10 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 7. INNER TRIM (WAGON) ( 3 ) ( 4 ) ( 5 ) ( 2 ) ( 6 ) ( 1 ) ( 7 ) ( 9 ) (10) ( 8 ) (11) (13) (12) (14) EI-00291 (1) Front pillar upper trim (6) Rear quarter lower trim...
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Page 11: Instrument Panel
GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 8. INSTRUMENT PANEL ( 2 ) ( 1 ) (24) ( 3 ) (25) (23) ( 4 ) (22) (21) (20) ( 5 ) ( 6 ) (18) ( 7 ) (19) ( 9 ) (15) ( 8 ) (14) (16) - Page 12 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM 9. INNER ACCESSORIES ( 1 ) ( 3 ) ( 2 ) EI-00293 Hook Sun visor Assist grip EI-10...
- Page 13 GENERAL DESCRIPTION EXTERIOR/INTERIOR TRIM B: PREPARATION TOOL TOOL NAME REMARKS Clip remover Used for removal of trim. Adhesive remover Used for removal of side protector. Primer Used for installation of side protector. Infrared lamp Used for disassembly/assembly of side protector. Tow-sided tape Used for installation of side protector.
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Page 14: Front Grille
FRONT GRILLE EXTERIOR/INTERIOR TRIM 2. Front Grille A: REMOVAL 1) Open hood. 2) Loosen bolts and nuts to remove front grill. EI-00125 B: INSTALLATION Install in the reverse order of removal. Tightening torque: A (Nut): 4.4±1.5 N·m (0.45±0.15 kgf-m, 3.3±1.1 ft-lb) B (Bolt): 0.9±2.0 N·m (0.7±0.2 kgf-m, 5.1±1.4 ft-lb) EI-12... -
Page 15: Front Under Cover
FRONT UNDER COVER EXTERIOR/INTERIOR TRIM 3. Front Under Cover A: REMOVAL 1) Lift-up the vehicle. 2) Loosen bolts and clips to remove under cover. EI-00126 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 18.4 N·m (1.88 kgf-m, 13.6 ft-lb) EI-13... -
Page 16: Front Bumper
FRONT BUMPER EXTERIOR/INTERIOR TRIM 4. Front Bumper 7) Remove bumper beam. A: REMOVAL 1) Open hood. 2) Disconnect ground cable from battery. 3) Pull off front side of front mud guard, then re- move bolts from inside the mud gruand. EI-00131 B: INSTALLATION Install in the reverse order of removal. - Page 17 FRONT BUMPER EXTERIOR/INTERIOR TRIM C: REPAIR 1. COATING METHOD FOR PP BUMPER Pro- cess Process name Job contents ( A ) Set bumper (A) on paint worktable (B) if Bumper mounting required. Use paint worktable conforming to inner shape of bumper when possible. ( B ) EI-00132 Mask specified part (black base) with masking tape.
- Page 18 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. Damage limited to shallow scratches that cause only a change in the lustre of the base material or coating, can be almost fully restored.
- Page 19 FRONT BUMPER EXTERIOR/INTERIOR TRIM Pro- cess Process name Job contents Surface prepara- Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent tion (NRM No. 900 Precleno, white gasoline, or alcohol). ( 3 ) ( 1 ) If nature of damage are cracks or holes, cut a guide slit of 20 to 30 mm (0.79 to 1.18 in) in...
- Page 20 FRONT BUMPER EXTERIOR/INTERIOR TRIM Pro- cess Process name Job contents Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife, operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rpm will cause the PP substrate to melt from the heat.
- Page 21 FRONT BUMPER EXTERIOR/INTERIOR TRIM Pro- cess Process name Job contents Apply a clear coat three times at an interval of 3 to 5 minutes. • Recommended paint: SC710 Overlay Clear No. 307 Flex Hardener SC Reducer (thinner) Top coat (II) Not required.
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Page 22: Rear Bumper
REAR BUMPER EXTERIOR/INTERIOR TRIM 5. Rear Bumper 5) Remove two nuts from each side to remove rear bumper. A: REMOVAL 1. SEDAN 1) Lift-up the vehicle. 2) Remove bolts and clips. EI-00140 6) Loosen clips to remove upper beam (A) from bumper face. - Page 23 REAR BUMPER EXTERIOR/INTERIOR TRIM 4) Pull off rear end of rear quarter lower trim to re- B: INSTALLATION move cap. 1. SEDAN 1) Install in the reverse order of removal. 2) Fit slider (A) to guide pin (B) securely. ( B ) ( A ) EI-00144 5) Loosen bolts to remove rear bumper.
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Page 24: Mud Guard
MUD GUARD EXTERIOR/INTERIOR TRIM 6. Mud Guard A: REMOVAL 1) Jack-up the vehicle. 2) Remove screws and clips to remove mud guard. ( A ) ( B ) EI-00296 (A) Except OUTBACK (B) OUTBACK B: INSTALLATION Insert hook into body, and tighten it with screw and clip. -
Page 25: Protector
PROTECTOR EXTERIOR/INTERIOR TRIM 7. Protector A: REMOVAL 1) Except OUTBACK: ( a ) ( c ) ( b ) ( A ) ( B ) ( C ) EI-00297 Section A Section B Section C NOTE: Pay attention to the position of clips (a), (c). EI-23... - Page 26 PROTECTOR EXTERIOR/INTERIOR TRIM OUTBACK: Remove clip (a) and bolt (b). ( c ) ( b ) ( d ) ( a ) ( a ) ( A ) ( B ) ( C ) ( D ) ( E ) EI-00298 Section A Section C...
- Page 27 PROTECTOR EXTERIOR/INTERIOR TRIM 2) Attach masking tape to outer perimeter of side 4) Apply an even coat of adhesive remover to the protector. (If original side protector is re-installed, two-sided tape. tape the entire protector.) Recommended adhesive remover: 3) Insert fishing line [0.8 mm (0.031 in) dia.] (A) be- SUMITOMO 3M4000 or equivalent tween side protector (B) and vehicle body.
- Page 28 PROTECTOR EXTERIOR/INTERIOR TRIM B: INSTALLATION 1) Apply primer to original side protector (if used), and attach two-sided tape to side protectors as shown. Two-sided tape: Thickness; 1.2 mm (0.047 in) Width; 5 mm (0.20 in) Recommended primer: SUMITOMO 3MK-500 or equivalent Recommended two-sided tape: SUMITOMO 3M5305 or equivalent ( 1 )
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Page 29: Cowl Panel
COWL PANEL EXTERIOR/INTERIOR TRIM 8. Cowl Panel A: REMOVAL 1) Open hood. 2) Remove wiper arm. <Ref. to WW-12, REMOV- AL, Front Wiper Arm.> 3) Remove front panel seal. EI-00158 4) Remove clips (A) and cowl side panel (C). Loos- en clips (D) on six positions, and remove cowl side panel. -
Page 30: Spoiler
SPOILER EXTERIOR/INTERIOR TRIM 9. Spoiler A: REMOVAL 1) Open trunk lid. 2) Disconnect connector (a) of high-mounted stop light. 3) Remove mounting nut of rear spoiler to remove rear spoiler. ( a ) EI-00160 B: INSTALLATION 1) Install in the reverse order of removal. 2) Clean mounting surfaces of trunk lid and spoiler before installation. -
Page 31: Side Sill Spoiler
SIDE SILL SPOILER EXTERIOR/INTERIOR TRIM 10.Side Sill Spoiler A: REMOVAL Remove clips (1 on front, 6 on lower, 1 on side), re- move side spoiler. EI-00161 B: INSTALLATION Install in the reverse order of removal. EI-29... -
Page 32: Front Door Trim
FRONT DOOR TRIM EXTERIOR/INTERIOR TRIM 11.Front Door Trim 5) Remove gusset cover. Disconnect electrical connectors to remove speaker. A: REMOVAL 1) Pull up inner remote cover toward you to remove upper hook. Pull down it to remove lower claw. Re- move inner remote cover. -
Page 33: Rear Door Trim
REAR DOOR TRIM EXTERIOR/INTERIOR TRIM 12.Rear Door Trim 4) Remove seven clips (A) of trim panel using clip remover to remove trim panel. A: REMOVAL CAUTION: : ( A ) Do not apply excessive force to clip. Otherwise the clip may be broken. 1) Pull up inner remote cover toward you to remove upper hook. -
Page 34: Glove Box
GLOVE BOX EXTERIOR/INTERIOR TRIM 13.Glove Box A: REMOVAL 1) Remove stoppers. EI-00177 2) Loosen screws to remove glove box. EI-00178 B: INSTALLATION Install in the reverse order of removal. EI-32... -
Page 35: Roof Rail
ROOF RAIL EXTERIOR/INTERIOR TRIM 14.Roof Rail A: REMOVAL 1) Remove roof trim. <Ref. to EI-42, REMOVAL, Roof Trim.> 2) Remove five mounting nuts and then detach roof rail carefully. EI-00179 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 7.4 N·m (0.75 kgf-m, 5.46 ft-lb) EI-33... -
Page 36: Console Box
CONSOLE BOX EXTERIOR/INTERIOR TRIM 15.Console Box B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1) Remove shift knob (A) (MT model) and front cov- er (B). : ( 1 ) EI-00180 (1) Hook pawl 2) Remove tray (A) and console cover (B). ( A ) ( B ) EI-00181... -
Page 37: Instrument Panel Assembly
INSTRUMENT PANEL ASSEMBLY EXTERIOR/INTERIOR TRIM 16.Instrument Panel Assembly 5) Remove stopper (A) then remove glove box. A: REMOVAL ( A ) Airbag system wiring harness is routed near the combination meter. CAUTION: • All airbag system wiring harness and con- nectors are colored yellow. - Page 38 INSTRUMENT PANEL ASSEMBLY EXTERIOR/INTERIOR TRIM 10) Remove front pillar lower trim of passenger 11) Set temperature control switch (A) to “FULL side. HOT” and then disconnect temperature control ca- ble from bottom of heater unit. (Manual A/C equipped model) ( 1 ) NOTE: Do not move the switch and link when installing.
- Page 39 INSTRUMENT PANEL ASSEMBLY EXTERIOR/INTERIOR TRIM 13) Disconnect harness connectors and remove in- strument panel carefully. CAUTION: Do not pull the harness when disconnecting the connector. NOTE: • If necessary, make matching marks for easy re- assembly. • When storing the removed instrument panel, place it standing up on the floor.
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Page 40: Upper Inner Trim
UPPER INNER TRIM EXTERIOR/INTERIOR TRIM 17.Upper Inner Trim A: REMOVAL 1) Remove front mole (A). 2) Remove front pillar upper trim (B). 3) Detach front seat belt shoulder anchor, then re- move center pillar upper trim (C). ( A ) ( C ) ( B ) ( 1 ) -
Page 41: Lower Inner Trim
LOWER INNER TRIM EXTERIOR/INTERIOR TRIM 18.Lower Inner Trim A: REMOVAL 1) Remove front pillar lower trim (A). 2) Remove side sill front lower cover (B). 3) For sedan: Remove rear seat cushion <Ref. to SE-17, REMOVAL, Rear Seat.>, then remove side sill rear upper cover (C). -
Page 42: Rear Quarter Trim
REAR QUARTER TRIM EXTERIOR/INTERIOR TRIM 19.Rear Quarter Trim 7) Remove rear rail trim (E). A: REMOVAL ( D ) ( C ) 1. SEDAN 1) Remove rear mole (A). ( E ) 2) Remove rear shelf trim. <Ref. to EI-45, REMOV- AL, Rear Shelf Trim.>... -
Page 43: Sun Visor
SUN VISOR EXTERIOR/INTERIOR TRIM 20.Sun Visor A: REMOVAL Remove mounting screws then detach sun visor (A) and hook (B). ( B ) ( A ) EI-00200 B: INSTALLATION Install in the reverse order of removal. EI-41... -
Page 44: Roof Trim
ROOF TRIM EXTERIOR/INTERIOR TRIM 21.Roof Trim 10) Remove rear quarter upper trim (C) of both sides. A: REMOVAL CAUTION: When removing clip, use great care not to dam- age the roof trim. ( C ) 1. SEDAN 1) Disconnect ground cable from battery. ( A ) 2) Remove sunroof switch. - Page 45 ROOF TRIM EXTERIOR/INTERIOR TRIM 6) Remove assist grips (A). 12) Remove cover (B) while detaching snap lock carefully. Put the rear center seat belt tongue (A) out to the other side of the trim through the hole. ( A ) ( B ) EI-00201 ( A )
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Page 46: Rear Gate Trim
REAR GATE TRIM EXTERIOR/INTERIOR TRIM 22.Rear Gate Trim A: REMOVAL CAUTION: Be careful not to damage clips or their holes. 1) Remove clips and detach rear gate lower trim (A). ( A ) EI-00210 2) Remove caps and screws, and then detach high-mounted stop light cover (A). -
Page 47: Rear Shelf Trim
REAR SHELF TRIM EXTERIOR/INTERIOR TRIM 23.Rear Shelf Trim A: REMOVAL 1) Remove high-mounted stop light. EI-00213 2) Remove rear seat backrest. <Ref. to SE-17, SE- DAN, REMOVAL, Rear Seat.> 3) Remove inner seat belt RH, then disconnect in- ner seat belt RH (A) and outer seat belt center (B). ( B ) ( A ) EI-00214... -
Page 48: Trunk Trim
TRUNK TRIM EXTERIOR/INTERIOR TRIM 24.Trunk Trim A: REMOVAL 1) Remove clips, and then detach trunk rear trim (A). 2) Remove luggage hook (B) and clips, then detach trunk side trim (C). ( B ) ( C ) ( A ) EI-00216 B: INSTALLATION Install in the reverse order of removal. -
Page 49: Trunk Lid Trim
TRUNK LID TRIM EXTERIOR/INTERIOR TRIM 25.Trunk Lid Trim A: REMOVAL Remove clips and detach trunk lid trim (A). EI-00300 B: INSTALLATION Install in the reverse order of removal. EI-47... -
Page 50: Floor Mat
FLOOR MAT EXTERIOR/INTERIOR TRIM 26.Floor Mat A: REMOVAL 1) Remove front seats. <Ref. to SE-7, REMOVAL, Front Seat.> 2) Remove rear seat cushion. <Ref. to SE-17, RE- MOVAL, Rear Seat.> 3) Remove console box. <Ref. to EI-34, Console Box.> 4) Remove front pillar lower trim, side sill rear up- per cover and center pillar lower trim. -
Page 51: Luggage Floor Mat
LUGGAGE FLOOR MAT EXTERIOR/INTERIOR TRIM 27.Luggage Floor Mat A: REMOVAL Remove clips, then detach rear floor mats and box- : ( 1 ) EI-00218 (1) Clips B: INSTALLATION Install in the reverse order of removal. EI-49... -
Page 52: Trunk Room Mat
TRUNK ROOM MAT EXTERIOR/INTERIOR TRIM 28.Trunk Room Mat A: REMOVAL Draw out trunk room mat. EI-00219 B: INSTALLATION Install in the reverse order of removal. EI-50...