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Subaru LEGACY 2003 Service Manual

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See also: Service Manual , Owner's Manual
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

    EXTERIOR BODY PANELS Page General Description ..................2 Front Hood ....................9 Fender Panel.....................10 Front Door Panel..................11 Front Sealing Cover ..................13 Rear Door Panel ..................14 Rear Sealing Cover...................16 Trunk Lid Panel ..................17 Rear Gate Panel ..................18...

  • Page 4: General Description

    GENERAL DESCRIPTION EXTERIOR BODY PANELS 1. General Description A: SPECIFICATIONS ( 1 ) ( 2 ) ( 3 ) A - A B - B ( 3 ) ( 4 ) ( 5 ) ( 6 ) C - C D - D EB-00088 Section...
  • Page 5 GENERAL DESCRIPTION EXTERIOR BODY PANELS B: COMPONENT 1. FRONT HOOD ( 7 ) ( 2 ) ( 1 ) ( 6 ) ( 7 ) ( 5 ) ( 4 ) ( 3 ) ( 6 ) ( 8 ) ( 4 ) ( 5 ) EB-00039...

  • Page 6: Front Door Panel

    GENERAL DESCRIPTION EXTERIOR BODY PANELS 2. FRONT DOOR PANEL ( 2 ) ( 5 ) ( 1 ) ( 6 ) ( 4 ) ( 3 ) (11) ( 7 ) (10) ( 8 ) ( 9 ) EB-00040 (1) Gusset (7) Sealing cover Tightening torque: N·m (kgf-m, ft-lb) (2) Weatherstrip (Outer)
  • Page 7 GENERAL DESCRIPTION EXTERIOR BODY PANELS 3. REAR DOOR PANEL ( 1 ) ( 2 ) ( 5 ) ( 3 ) ( 4 ) (10) ( 6 ) ( 7 ) ( 8 ) ( 9 ) EB-00041 (1) Weatherstrip (Outer) (6) Bracket Tightening torque: N·m (kgf-m, ft-lb) (2) Clip (Weatherstrip, outer)
  • Page 8 GENERAL DESCRIPTION EXTERIOR BODY PANELS 4. TRUNK LID PANEL ( 1 ) ( 2 ) ( 3 ) ( 5 ) ( 4 ) EB-00042 (1) Torsion bar (4) Hinge ASSY Tightening torque: N·m (kgf-m, ft-lb) (2) Trunk lid (5) Cover T1: 18 (1.8, 13) (3) Weatherstrip T2: 14 (1.4, 10)
  • Page 9 GENERAL DESCRIPTION EXTERIOR BODY PANELS 5. REAR GATE PANEL ( 3 ) ( 2 ) ( 1 ) ( 5 ) ( 6 ) ( 4 ) EB-00043 (1) Gas stay (4) Buffer (Rear gate) Tightening torque: N·m (kgf-m, ft-lb) (2) Hinge (5) Buffer cover T1: 7.5 (0.76, 5.5)
  • Page 10 GENERAL DESCRIPTION EXTERIOR BODY PANELS C: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925610000 WRENCH Used for removing and installing door hinge. ST-925610000 927780000 REMOVER Used for removing and installing trunk torsion bar. ST-927780000 2. GENERAL TOOL TOOL NAME REMARKS Support Jack...

  • Page 11: Front Hood

    FRONT HOOD EXTERIOR BODY PANELS 2. Front Hood 3) Rotate front hood buffer to adjust lateral height. A: REMOVAL 1) Open front hood to remove washer nozzles. 2) Remove clips to remove hood insulator. EB-00049 EB-00046 3) Remove bolts to disconnect hood from hinges. EB-00047 B: INSTALLATION 1) Install in the reverse order of removal.

  • Page 12: Fender Panel

    FENDER PANEL EXTERIOR BODY PANELS 3. Fender Panel A: REMOVAL 1) Disconnect ground cable from battery. 2) Remove side sill spoilers. <Ref. to EI-29, RE- MOVAL, Side Sill Spoiler.>(If fitted) 3) Remove side protectors and fender protectors. (OUTBACK) 4) Remove front bumper face. <Ref. to EI-14, RE- MOVAL, Front Bumper.>...

  • Page 13: Front Door Panel

    FRONT DOOR PANEL EXTERIOR BODY PANELS 4. Front Door Panel 11) Using special tool, remove body-side bolts for upper and lower hinges, and remove door hinges. A: REMOVAL ST 925610000 DOOR HINGE WRENCH 1) Disconnect ground cable from battery. 2) Remove front door trim. <Ref. to EI-30, RE- MOVAL, Front Door Trim.>...
  • Page 14 FRONT DOOR PANEL EXTERIOR BODY PANELS 3) Loosen screw (A) and tap striker (B) using plas- tic hammer to adjust striker. ( A ) ( B ) EB-00057 CAUTION: Do not use impact wrench. Welding area on striker nut plate is easily broken. EB-12...

  • Page 15: Front Sealing Cover

    FRONT SEALING COVER EXTERIOR BODY PANELS 5. Front Sealing Cover A: REMOVAL 1) Remove front door trim. <Ref. to EI-30, REMOV- AL, Front Door Trim.> 2) Remove front speaker. <Ref. to ET-6, REMOV- AL, Front Speaker.> NOTE: • Carefully remove butyl tape. Excessive force will easily break the cover.

  • Page 16: Rear Door Panel

    REAR DOOR PANEL EXTERIOR BODY PANELS 6. Rear Door Panel 10) Using special tool, remove body-side bolts for upper and lower hinges, and remove door hinges. A: REMOVAL B: INSTALLATION 1) Disconnect ground cable from battery. 1) Install in the reverse order of removal. 2) Remove rear door trim.
  • Page 17 REAR DOOR PANEL EXTERIOR BODY PANELS 3) Loosen screw (A) and tap striker (B) using plas- tic hammer to adjust striker. ( A ) ( B ) EB-00057 CAUTION: Do not use an impact wrench. The welding area on the striker nut plate is easily broken. EB-15...

  • Page 18: Rear Sealing Cover

    REAR SEALING COVER EXTERIOR BODY PANELS 7. Rear Sealing Cover A: REMOVAL 1) Remove rear door trim. <Ref. to EI-31, REMOV- AL, Rear Door Trim.> 2) Remove rear speaker. <Ref. to ET-8, REMOV- AL, Rear Speaker.> NOTE: • Carefully remove butyl tape. Excessive force will easily break the cover.

  • Page 19: Trunk Lid Panel

    TRUNK LID PANEL EXTERIOR BODY PANELS 8. Trunk Lid Panel A: REMOVAL 1. TRUNK LID 1) Open trunk lid. 2) Disconnect trunk lid connector. 3) Loosen trunk lid mounting bolts to remove trunk lid from hinges. EB-00066 2. TORSION BAR 1) Open trunk lid.

  • Page 20: Rear Gate Panel

    REAR GATE PANEL EXTERIOR BODY PANELS 9. Rear Gate Panel 2. GAS STAY 1) Open rear gate. Using a jack to support the rear A: REMOVAL gate. 1. REAR GATE PANEL 1) Open rear gate. 2) Remove rear gate outer handle. <Ref. to SL-27, REMOVAL, Rear Gate Outer Handle.>...
  • Page 21 REAR GATE PANEL EXTERIOR BODY PANELS C: DISPOSAL 1. GAS STAY 1) Before opening a hole with a drill (A), put gas stay (B) into a vinyl sack (C). ( A ) ( B ) ( C ) EB-00071 CAUTION: Prevent the vinyl case from being caught by drill cutting edge 2) Lift body side slightly with piston rods fully ex-...
  • Page 22 REAR GATE PANEL EXTERIOR BODY PANELS MEMO: EB-20...

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