Subaru Legacy 2003 Service Manual

Subaru Legacy 2003 Service Manual

Body section
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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: Quick Reference Index

    2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) G2300GE7...
  • Page 3: Body Structure

    BODY STRUCTURE Page General Description ..................2 Datum Points....................3 Datum Dimensions..................10...
  • Page 4: General Description

    GENERAL DESCRIPTION BODY STRUCTURE 1. General Description A: PREPARATION TOOL TOOL NAME REMARKS Tram tracking gauge Used for measuring dimen- sion. Tape measure Used for measuring dimen- sion BS-2...
  • Page 5: Datum Points

    DATUM POINTS BODY STRUCTURE 2. Datum Points A: LOCATION NOTE: • Datum points are specified for body repair. • Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment accuracy. • Both right and left reference points are symmetrical. 1.
  • Page 6: Rear Section

    DATUM POINTS BODY STRUCTURE 2. REAR SECTION (90) (38) (93) (91) (94) (46) (95) (100) (99) (98) (84) (83) (97) (86) BS-00065 (38) Front panel instrument panel (90) Rear rale roof trim attaching hole (97) Trunk trim attaching hole at rear attaching hole 18 ×...
  • Page 7 DATUM POINTS BODY STRUCTURE 3. UNDERBODY SECTION (50) (51) (52) (53) (54) (55) (56) (57) (58) (59) BS-00066 (50) Radiator panel (LWR) frame (54) Front side frame (Rr) gauge hole (58) Reinforcement crossmember B gauge hole 15 mm (0.59 in) dia. 20 mm (0.79 in) dia.
  • Page 8 DATUM POINTS BODY STRUCTURE (51) ( 9 ) (52) (50) BS-00486 BS-00490 (56) (55) (54) (58) (57) (53) BS-00487 BS-00491 (46) (59) BS-00488 BS-00492 (10) ( 9 ) ( 8 ) ( 1 ) BS-00489 BS-00493 BS-6...
  • Page 9 DATUM POINTS BODY STRUCTURE (13) ( 6 ) ( 7 ) (14) BS-00494 BS-00498 (47) (49) (34) (11) (72) BS-00495 BS-00499 ( 3 ) ( 4 ) (48) (60) ( 5 ) BS-00496 BS-00500 (10) (11) (43) BS-00501 BS-00497 BS-7...
  • Page 10 DATUM POINTS BODY STRUCTURE (70) (67) BS-00502 BS-00506 (39) (41) (38) (65) (40) (46) BS-00503 BS-00507 (45) (42) (24) BS-00504 BS-00508 (25) (12) (17) BS-00509 BS-00505 BS-8...
  • Page 11 DATUM POINTS BODY STRUCTURE (41) (18) (19) (16) BS-00510 BS-00513 (20) (70) (64) (22) (26) (15) BS-00511 BS-00514 (44) (36) (21) (23) BS-00515 BS-00512 BS-9...
  • Page 12 DATUM DIMENSIONS BODY STRUCTURE 3. Datum Dimensions A: MEASUREMENT Refer to LOCATION for details on measurement points. <Ref. to BS-3, LOCATION, Datum Points.> NOTE: • Using a tram tracking gauge, measure all the di- mensions. • When using a tape measure, carefully measure dimensions without letting the tape measure sag or twist.
  • Page 13: Front Structure

    DATUM DIMENSIONS BODY STRUCTURE 1. FRONT STRUCTURE (10) ( 3 ) ( 8 ) (11) ( 9 ) (13) ( 1 ) ( 7 ) ( 6 ) ( 3 ) ( 4 ) (14) (60) ( 5 ) BS-00099 Point to point Dimension Point to point...
  • Page 14 DATUM DIMENSIONS BODY STRUCTURE 2. CENTER STRUCTURE RH: 44 (1.73) LH: 39 (1.54) (9.96) (16.34) 159 (6.26) (21.46) (12.48) (19.09) 1180 212.5 1170 (46.06) (46.46) (8.37) (14.96) (1.85) 1813 (71.38) (14.80) (16.81) ( 1 ) BS-00516 (1) Unit: min (in) BS-12...
  • Page 15 DATUM DIMENSIONS BODY STRUCTURE MEMO: BS-13...
  • Page 16 DATUM DIMENSIONS BODY STRUCTURE 3. WINDSHIELD AND DOORS (19) (81) (88) (89) (87) (21) (23) (82) (85) (82) (20) (64) (17) (12) (67) (16) (18) (19) (24) (67) (42) (44) (10) (11) (13) (23) (36) (20) (22) (64) (14) BS-00101 BS-14...
  • Page 17 DATUM DIMENSIONS BODY STRUCTURE Point to point Dimension Point to point Dimension (14) RH to (18) RH 1,425 (56.10) (12) to (10) RH 1,136 (44.72) (14) LH to (18) LH 1,425 (56.10) (12) to (10) LH 1,136 (44.72) (13) RH to (64) RH 1,030 (40.55) (11) to (17) RH 1,130 (44.49)
  • Page 18 DATUM DIMENSIONS BODY STRUCTURE 4. COMPARTMENT (12) (17) (38) (39) (21) (65) (40) (15) (41) (22) (26) (25) BS-00102 Point to point Dimension Point to point Dimension (21) RH to (21) LH 1,351 (53.19) (41) to (22) LH 738 (29.06) (15) RH to (15) LH 1,455 (57.28) (41) to (26) RH...
  • Page 19 DATUM DIMENSIONS BODY STRUCTURE MEMO: BS-17...
  • Page 20 DATUM DIMENSIONS BODY STRUCTURE 5. TRUNK LID AND REAR GATE (43) (45) (47) (49) (46) (41) (70) (48) (72) (34) (92) (81) (93) (91) (21) (90) (38) (46) (91) (94) (94) (81) (82) (99) (46) (99) (97) (84) (97) (84) (95) (100) (22)
  • Page 21 DATUM DIMENSIONS BODY STRUCTURE Point to point Dimension Point to point Dimension (45) to (48) 974 (38.35) (84) RH to (84) LH 1,410 (55.51) (45) to (47) RH 797 (31.38) (100) RH to (84) LH 1,226 (48.27) (45) to (47) LH 797 (31.38) (86) to (21) RH 2,073 (81.61)
  • Page 22 DATUM DIMENSIONS BODY STRUCTURE MEMO: BS-20...

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