Subaru 2003 LEGACY 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 2003 LEGACY
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Page 1: Body Section
2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION HVAC SYSTEM (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
GLASS/WINDOWS/MIRRORS Page General Description ..................2 Power Window System ................8 Rear Window Defogger System..............9 Windshield Wiper Deicer System ..............10 Remote Control Mirror System..............11 Front Door Glass..................12 Front Regulator and Motor Assembly ............16 Rear Door Glass ..................17 Rear Regulator and Motor Assembly ............18 Windshield Glass ..................19 Rear Gate Glass ..................22 Rear Quarter Glass ...................24... -
Page 4: General Description
GENERAL DESCRIPTION GLASS/WINDOWS/MIRRORS 1. General Description A: COMPONENT 1. FIXED GLASS (SEDAN) ( 2 ) ( 4 ) ( 3 ) ( 5 ) ( 1 ) ( 2 ) ( 6 ) ( 5 ) ( 2 ) ( 7 ) ( 3 ) ( 2 ) ( 2 ) - Page 5 GENERAL DESCRIPTION GLASS/WINDOWS/MIRRORS 2. FIXED GLASS (WAGON) ( 2 ) ( 4 ) ( 1 ) ( 3 ) ( 8 ) ( 5 ) ( 9 ) ( 8 ) ( 6 ) ( 7 ) ( 6 ) ( 2 ) GW-00081 Windshield glass...
- Page 6 GENERAL DESCRIPTION GLASS/WINDOWS/MIRRORS 3. FRONT DOOR GLASS ( 1 ) ( 4 ) ( 3 ) ( 5 ) ( 2 ) GW-00082 Glass Regulator ASSY Tightening torque: N·m (kgf-m, ft-lb) Door sash (Front) Motor ASSY T1: 7.35 (0.75, 5.4) Door sash (Rear) T2: 14 (1.4, 10.1) GW-4...
- Page 7 GENERAL DESCRIPTION GLASS/WINDOWS/MIRRORS 4. REAR DOOR GLASS ( 1 ) ( 4 ) ( 3 ) ( 2 ) ( 5 ) GW-00083 Glass Regulator ASSY Tightening torque: N·m (kgf-m, ft-lb) Door sash (Front) Motor ASSY T1: 7.35 (0.75, 5.4) Door sash (Rear) T2: 14 (1.4, 10.1) GW-5...
- Page 8 GENERAL DESCRIPTION GLASS/WINDOWS/MIRRORS 5. MIRRORS ( 5 ) ( 3 ) ( 2 ) ( 1 ) ( 4 ) GW-00084 Outer mirror Mount Mirror Rearview mirror Spring GW-6...
- Page 9 GENERAL DESCRIPTION GLASS/WINDOWS/MIRRORS B: CAUTION • When electrical connectors are disconnected, always conduct an operational check after connecting them again. • Avoid impact and damage to the glass. C: PREPARATION TOOL TOOL NAME REMARKS Circuit Tester Used for checking voltage and continuity. Piano Wire Used for window glass removal.
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Page 10: Power Window System
POWER WINDOW SYSTEM GLASS/WINDOWS/MIRRORS 2. Power Window System A: SCHEMATIC 1. POWER WINDOW LHD MODEL <Ref. to WI-282, LHD MODEL, SCHEMATIC, Power Window System.> 2. POWER WINDOW RHD MODEL <Ref. to WI-286, RHD MODEL, SCHEMATIC, Power Window System.> B: INSPECTION Symptom Repair order (1) Fuse (SBF-6) (F/B No. -
Page 11: Rear Window Defogger System
REAR WINDOW DEFOGGER SYSTEM GLASS/WINDOWS/MIRRORS 3. Rear Window Defogger System A: SCHEMATIC <Ref. to WI-296, SCHEMATIC, Rear Window Defogger System.> B: INSPECTION Symptom Repair order (1) Fuse (M/B No. 1) (2) Rear defogger relay (3) Defogger switch Rear window defogger does not operate. (4) Rear defogger condenser (5) Deffogger wire (6) Wire harness... -
Page 12: Windshield Wiper Deicer System
WINDSHIELD WIPER DEICER SYSTEM GLASS/WINDOWS/MIRRORS 4. Windshield Wiper Deicer System A: SCHEMATIC <Ref. to WI-328, SCHEMATIC, Wiper Deicer System.> B: INSPECTION Symptom Repair order (1) Fuse (F/B No. 18, 19) (2) Wiper deicer relay Wiper deicer does not operate. (3) Wiper deicer switch (4) Wire harness GW-10... -
Page 13: Remote Control Mirror System
REMOTE CONTROL MIRROR SYSTEM GLASS/WINDOWS/MIRRORS 5. Remote Control Mirror System A: SCHEMATIC 1. REMOTE CONTROL MIRROR LHD MODEL <Ref. to WI-298, LHD MODEL, SCHEMATIC, Remote Controlled Rearview Mirror System.> 2. REMOTE CONTROL MIRROR RHD MODEL <Ref. to WI-299, RHD MODEL, SCHEMATIC, Remote Controlled Rearview Mirror System.> B: INSPECTION Symptom Repair order... -
Page 14: Front Door Glass
FRONT DOOR GLASS GLASS/WINDOWS/MIRRORS 6. Front Door Glass 8) Operate the power window switch to move glass to the position shown in the figure, and then re- A: REMOVAL move the two nuts from service holes. 1) Remove door trim. <Ref. to EI-30, REMOVAL, Front Door Trim.>... - Page 15 FRONT DOOR GLASS GLASS/WINDOWS/MIRRORS C: ADJUSTMENT 4) For adjustment of clearance between front and rear glasses, loosen nuts (A) and (B), and move NOTE: glass sash back and forth until clearance becomes Before adjustment, ensure that all adjusting bolts of the value shown.
- Page 16 FRONT DOOR GLASS GLASS/WINDOWS/MIRRORS 6) Adjust so that upper and lower ends of center pil- 8) After stabilizer adjustment, carry out glass crimp lar are the same size. adjustment. First, visually ensure positional rela- tionship between retainer & molding and glass of the roof side, and then begin with rear sash adjust- ( 2 ) ment.
- Page 17 FRONT DOOR GLASS GLASS/WINDOWS/MIRRORS 10) Make adjustment of front sash in the same manner as that of rear sash. CAUTION: Although front and rear sashes must, as a rule, be adjusted in the same manner, in some door installation, the adjustment in a different man- ner may be required.
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Page 18: Front Regulator And Motor Assembly
FRONT REGULATOR AND MOTOR ASSEMBLY GLASS/WINDOWS/MIRRORS 7. Front Regulator and Motor Assembly A: REMOVAL 1) Remove door trim. <Ref. to EI-30, REMOVAL, Front Door Trim.> 2) Remove sealing cover. <Ref. to EB-13, RE- MOVAL, Front Sealing Cover.> 3) Remove inner remote. <Ref. to SL-19, REMOV- AL, Front Inner Remote.>... -
Page 19: Rear Door Glass
REAR DOOR GLASS GLASS/WINDOWS/MIRRORS 8. Rear Door Glass C: ADJUSTMENT NOTE: A: REMOVAL Rear door glass, as a rule, should be adjusted in 1) Remove door trim. <Ref. to EI-31, REMOVAL, the same manner as front glass, although they are Rear Door Trim.>... -
Page 20: Rear Regulator And Motor Assembly
REAR REGULATOR AND MOTOR ASSEMBLY GLASS/WINDOWS/MIRRORS 9. Rear Regulator and Motor As- C: INSPECTION 1) Make sure that power window motor rotates sembly properly when battery voltage is applied to termi- A: REMOVAL nals of motor connector. 2) Change polarity of battery connections to termi- 1) Remove door trim. -
Page 21: Windshield Glass
WINDSHIELD GLASS GLASS/WINDOWS/MIRRORS 10.Windshield Glass NOTE: Because matching pins are bonded to the corners A: REMOVAL of glass, use piano wire to cut the pin. 1. USING WINDSHIELD KNIFE 1) Remove cowl panel. <Ref. to EI-27, REMOVAL, ( 2 ) Cowl Panel.>... - Page 22 WINDSHIELD GLASS GLASS/WINDOWS/MIRRORS B: INSTALLATION 8) Fit molding mark (B) to notch (A) of ceramic print. 1) Clean external circumference of windshield glass with alcohol or white gasoline. 2) Remove adhesive layer on the body using cutter knife to obtain smooth face 2 mm (0.08 in) thick. ( A ) ( 1 ) ( 2 )
- Page 23 WINDSHIELD GLASS GLASS/WINDOWS/MIRRORS 11) Cut off cartridge nozzle tip and set it in sealant gun as shown. 12 – 15 (0.47 – 0.59) (0.39) (0.59) ( 1 ) GW-00115 (1) Unit: mm (in) 12) Apply adhesive to glass end surface as shown. 13) Fit matching pins using suction rubber cup to install windshield glass.
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Page 24: Rear Gate Glass
REAR GATE GLASS GLASS/WINDOWS/MIRRORS 11.Rear Gate Glass A: REMOVAL 1) Remove real wiper motor. <Ref. to WW-16, REMOVAL, Rear Wiper Motor.> 2) Remove connector from rear defogger terminal. 3) Remove glass in the same procedure as for windshield glass. <Ref. to GW-19, REMOVAL, Windshield Glass.>... - Page 25 REAR GATE GLASS GLASS/WINDOWS/MIRRORS 4) After completion of all work, allow vehicle to stand for about 24 hours. NOTE: For minimum drying time and time the vehicle must be left standing before driving after bonding, follow in- structions or instruction manual from the adhesive manufacturer. •...
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Page 26: Rear Quarter Glass
REAR QUARTER GLASS GLASS/WINDOWS/MIRRORS 12.Rear Quarter Glass A: REMOVAL 1. SEDAN Remove glass in the same procedure as for windshield glass. <Ref. to GW-19, REMOVAL, Windshield Glass.> ( 3 ) ( 2 ) ( 1 ) ( 1 ) ( 4 ) ( 1 ) A - A GW-00118... - Page 27 REAR QUARTER GLASS GLASS/WINDOWS/MIRRORS B: INSTALLATION 1) Cut off nozzle tip as shown in the figure. ( 1 ) ( 2 ) ( 3 ) 15 (0.59) ( 4 ) 12 – 15 (0.47 – 0.59) GW-00119 (1) Dam rubber (2) Locating pin (3) Adhesive (4) Molding...
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Page 28: Rear Window Glass
REAR WINDOW GLASS GLASS/WINDOWS/MIRRORS 13.Rear Window Glass 5) After curing of adhesive, pour water on external surface of vehicle to check that there are no water A: REMOVAL leaks. 1) Disconnect connectors from rear defogger ter- NOTE: minals. When a vehicle is returned to the user, tell him or 2) Remove glass in the same procedure as for her that the vehicle should not be subjected to windshield glass. -
Page 29: Roof Window Glass
ROOF WINDOW GLASS GLASS/WINDOWS/MIRRORS 14.Roof Window Glass A: REMOVAL <Ref. to SR-6, REMOVAL, Sunroof Lid.> B: INSTALLATION <Ref. to SR-6, INSTALLATION, Sunroof Lid.> C: ADJUSTMENT <Ref. to SR-6, ADJUSTMENT, Sunroof Lid.> GW-27... -
Page 30: Inner Rearview Mirror
INNER REARVIEW MIRROR GLASS/WINDOWS/MIRRORS 15.Inner Rearview Mirror A: REMOVAL 1) Turn mirror base 90 degrees clockwise or coun- terclockwise to remove it. GW-00121 2) Remove spring from mirror base. GW-00122 CAUTION: Be careful not to damage the mirror surface. B: INSTALLATION Install in the reverse order of removal. -
Page 31: Power Window Control Switch
POWER WINDOW CONTROL SWITCH GLASS/WINDOWS/MIRRORS 16.Power Window Control Switch A: REMOVAL 1. MAIN SWITCH 1) Remove two hooks (A) of switch panel to re- move power window main switch. : ( A ) GW-00123 2) Disconnect connectors from power window main switch and mirror switch. -
Page 32: Main Switch
POWER WINDOW CONTROL SWITCH GLASS/WINDOWS/MIRRORS C: INSPECTION 1. MAIN SWITCH Measure switch resistance. Driver's switch: Switch position Terminal No. Standard AUTO UP 3 and 9, 7 and 1 Continuity Less than 1 Ω 3 and 9, 7 and 1 Less than 1 Ω 3 and 7 and 1 Less than 1 Ω... -
Page 33: Rear Window Defogger Switch
REAR WINDOW DEFOGGER SWITCH GLASS/WINDOWS/MIRRORS 17.Rear Window Defogger Switch A: REMOVAL <Ref. to AC-34, REMOVAL, Control Unit.> B: INSTALLATION <Ref. to AC-34, INSTALLATION, Control Unit.> C: INSPECTION Check continuity between connectors at the back of heater control unit. 1. AUTO A/C LHD: Switch position Terminal No. -
Page 34: Rear Window Defogger
REAR WINDOW DEFOGGER GLASS/WINDOWS/MIRRORS 18.Rear Window Defogger B: REPAIR 1) Clean broken portion with alcohol or white gaso- A: INSPECTION line. 1) Turn ignition switch to ON. 2) Mask both side of wire with thin film. 2) Turn defogger switch to ON. 3) Apply conductive silver composition (DUPONT 3) Wrap tips of tester pins with aluminum foil to No. -
Page 35: Outer Mirror Assembly
OUTER MIRROR ASSEMBLY GLASS/WINDOWS/MIRRORS 19.Outer Mirror Assembly A: REMOVAL 1) Remove door trim. <Ref. to EI-30, REMOVAL, Front Door Trim.> 2) Remove sealing cover to disconnect mirror con- nector. GW-00129 3) Loosen screws to remove mirror assembly. GW-00130 B: INSTALLATION Install in the reverse order of removal. - Page 36 OUTER MIRROR ASSEMBLY GLASS/WINDOWS/MIRRORS C: INSPECTION Check to ensure that outer mirror moves properly when battery voltage is applied to terminals. Mirror heater not-equipped model: Switch position Terminal No. — 1 (+) and 3 (−) DOWN 3 (+) and 1 (−) LEFT 2 (+) and 3 (−) RIGHT...
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Page 37: Outer Mirror
OUTER MIRROR GLASS/WINDOWS/MIRRORS 20.Outer Mirror A: REPLACEMENT 1) Remove the door mirror assembly. <Ref. to GW- 33, REMOVAL, Outer Mirror Assembly.> 2) Warm the area around the mirror holder (A) with a hair drier until the edges of the mirror holder be- come soft (about 2 or 3 minutes with a 1,000 W dri- er.) 3) Use a flat-bladed screwdriver without sharp edg-... -
Page 38: Remote Control Mirror Switch
REMOTE CONTROL MIRROR SWITCH GLASS/WINDOWS/MIRRORS 21.Remote Control Mirror Switch A: REMOVAL 1) Remove power window main switch panel. : ( A ) GW-00123 2) Remove four hook to remove remote control mir- ror switch. GW-00133 B: INSTALLATION Install in the reverse order of removal. GW-36... -
Page 39: Remote Control Mirror Switch
REMOTE CONTROL MIRROR SWITCH GLASS/WINDOWS/MIRRORS C: INSPECTION Move rearview mirror switch to each position and check continuity between terminals. 4 3 2 9 8 7 GW-00134 Change over switch left position: Switch position Terminal No. Standard — More than 1 MΩ Less than 1 Ω... -
Page 40: Wiper Deicer
WIPER DEICER GLASS/WINDOWS/MIRRORS 22.Wiper Deicer A: INSPECTION Refer to INSPECTION under Rear Window Defog- ger. <Ref. to GW-32, INSPECTION, Rear Window Defogger.> B: REPAIR Refer to REPAIR under Rear Window Defogger. <Ref. to GW-32, REPAIR, Rear Window Defog- ger.> GW-38... -
Page 41: Wiper Deicer Switch
WIPER DEICER SWITCH GLASS/WINDOWS/MIRRORS 23.Wiper Deicer Switch A: REMOVAL 1. RHD MODEL Remove driver side switch panel, and then remove wiper deicer switch. GW-00135 2. LHD MODEL Remove radio bracket, and then remove wiper de- icer switch. <Ref. to ET-5, REMOVAL, Radio Body.>... - Page 42 WIPER DEICER SWITCH GLASS/WINDOWS/MIRRORS MEMO GW-40...
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