Subaru 2003 LEGACY BODY SECTION User manual

FUJI HEAVY INDUSTRIES LTD. G2300GE7
2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
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.
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C) AC
HVAC SYSTEM (DIAGNOSTICS) AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTICS) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEMS WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOWS/MIRRORS GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEATS SE
SECURITY AND LOCKS SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF) SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANELS EB
EXTERIOR/INTERIOR TRIM EI

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G2300GE7
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTICS) CC
IMMOBILIZER (DIAGNOSTICS) IM

EXTERIOR/INTERIOR TRIM EI
Page
1. General Description ....................................................................................2
2. Front Grille ................................................................................................12
3. Front Under Cover ....................................................................................13
4. Front Bumper............................................................................................14
5. Rear Bumper.............................................................................................20
6. Mud Guard................................................................................................22
7. Protector....................................................................................................23
8. Cowl Panel................................................................................................27
9. Spoiler.......................................................................................................28
10. Side Sill Spoiler.........................................................................................29
11. Front Door Trim.........................................................................................30
12. Rear Door Trim .........................................................................................31
13. Glove Box..................................................................................................32
14. Roof Rail ...................................................................................................33
15. Console Box..............................................................................................34
16. Instrument Panel Assembly ......................................................................35
17. Upper Inner Trim.......................................................................................38
18. Lower Inner Trim.......................................................................................39
19. Rear Quarter Trim.....................................................................................40
20. Sun Visor...................................................................................................41
21. Roof Trim ..................................................................................................42
22. Rear Gate Trim .........................................................................................44
23. Rear Shelf Trim.........................................................................................45
24. Trunk Trim.................................................................................................46
25. Trunk Lid Trim...........................................................................................47
26. Floor Mat...................................................................................................48
27. Luggage Floor Mat....................................................................................49
28. Trunk Room Mat .......................................................................................50

EI-2
EXTERIOR/INTERIOR TRIM GENERAL DESCRIPTION
1. General Description
A: COMPONENT
1. FRONT BUMPER
(1) Bumper face (Except OUTBACK) (6) Cover Tightening torque: N·m (kgf-m, ft-lb)
(2) Bumper face (OUTBACK) (7) Toeing hook cover (Except OUT-
BACK) T1: 30 (3.1, 22)
(3) Bumper beam T2: 17.7 (1.8, 13.0)
(4) Side stay (8) Toeing hook cover (OUTBACK) T3: 7.4 (0.75, 5.4)
(5) Side bracket
EI-00402
( 1 )
( 3 )
( 4 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 5 )
T2
T3
T3
T2
T1
T1
T1
T1

EI-3
EXTERIOR/INTERIOR TRIM
GENERAL DESCRIPTION
2. REAR BUMPER (SEDAN)
(1) Bumper beam (4) Side stay Tightening torque: N·m (kgf-m, ft-lb)
(2) Side bracket (5) Hook T1: 93 (9.5, 69)
(3) Bumper face (6) Bracket T2: 7.4 (0.75, 5.4)
T3: 2 (0.2, 1.4)
EI-00403
( 1 ) ( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 6 )
T1
T2
T2
T2
T3

EI-4
EXTERIOR/INTERIOR TRIM GENERAL DESCRIPTION
3. REAR BUMPER (WAGON)
(1) Bumper beam (4) Bumper face (OUTBACK) Tightening torque: N·m (kgf-m, ft-lb)
(2) Side bracket (5) Side stay T1: 93 (9.5, 96)
(3) Bumper face (Except OUTBACK) (6) Hook T2: 7.4 (0.75, 5.4)
T3: 2 (0.2, 1.4)
EI-00404
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
T1
T2
T2 T2
T3
T3

EI-5
EXTERIOR/INTERIOR TRIM
GENERAL DESCRIPTION
4. SIDE PROTECTOR
(A) Except OUTBACK (3) Side protector (Front fender) (7) Side protector (Side sill)
(B) OUTBACK (4) Side protector (Front door)
(1) Front side protector (5) Side protector (Rear door) Tightening torque: N·m (kgf-m, ft-lb)
(2) Rear side protector (6) Side protector (Rear quarter) T: 4.3 (0.44, 3.2)
EI-00405
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( A )
( B )
T
T

EI-6
EXTERIOR/INTERIOR TRIM GENERAL DESCRIPTION
5. DOOR TRIM
(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 (11) Lower trim
(2) Bracket (7) Power window switch cover
EI-00287
( 1 )
( 2 )
( 2 )
( 3 )
( 3 )
( 4 )
( 4 )
( 4 )
( 5 )
( 5 ) ( 5 )
( 6 )
( 6 )
( 7 )
( 7 )
( 8 )
( 8 )
( 9 )
(10)
(11)
( A )
( B )
( C )
(10)

EI-7
EXTERIOR/INTERIOR TRIM
GENERAL DESCRIPTION
6. INNER TRIM (SEDAN)
(1) Front pillar upper trim (6) Trunk rear trim (11) Side sill rear lower cover
(2) Center pillar upper trim (7) Trunk side trim (12) Front pillar lower trim
(3) Rear pillar upper trim (8) Rear pillar lower trim (13) Side sill front lower cover
(4) Rear shelf trim (9) Side sill rear upper cover
(5) Rear bulk trim (10) Center pillar lower trim
EI-00290
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
(11)
(12)
(13)

EI-8
EXTERIOR/INTERIOR TRIM GENERAL DESCRIPTION
7. INNER TRIM (WAGON)
(1) Front pillar upper trim (6) Rear quarter lower trim (11) Center pillar lower trim
(2) Center pillar upper trim (7) Lid (12) Side sill rear lower cover
(3) Rear pillar upper trim (8) Rear skirt trim (13) Front pillar lower trim
(4) Rear rail trim (9) Hook (14) Side sill front lower cover
(5) Pocket (10) Side sill rear upper cover
EI-00291
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
(11)
(12)
(13)
(14)

EI-9
EXTERIOR/INTERIOR TRIM
GENERAL DESCRIPTION
8. INSTRUMENT PANEL
NOTE:
This illustration is for LHD model.
The location for RHD model is symmetrically opposite.
(1) Pad & frame (11) Front cover (MT) (21) Front cup holder
(2) Grille side (D) (12) Rear cup holder (22) Switch panel
(3) Hook (13) Console box (23) Meter visor
(4) Grille side (P) (14) Rear ash tray (24) Grille vent (D)
(5) Grille vent (P) (15) Console lid (25) Grille center
(6) Glove box panel (16) Console cover
(7) Glove box lid (17) Tray Tightening torque: N·m (kgf-m, ft-lb)
(8) Center panel side (D) (18) Ash tray T: 7
±
±±
±
1 (0.7
±
±±
±
0.1, 5.1
±
±±
±
0.7)
(9) Center panel side (P) (19) Lower cover
(10) Front cover (AT) (20) Center panel
EI-00292
( 1 ) ( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(25)
(24)
(23)
(22)
T
T
T
T
T

EI-10
EXTERIOR/INTERIOR TRIM GENERAL DESCRIPTION
9. INNER ACCESSORIES
(1) Hook (2) Sun visor (3) Assist grip
EI-00293
( 1 )
( 2 )
( 3 )

EI-11
EXTERIOR/INTERIOR TRIM
GENERAL DESCRIPTION
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.
TORX®T30 Used for disassembly/assembly of crossbar.

EI-12
EXTERIOR/INTERIOR TRIM FRONT GRILLE
2. Front Grille
A: REMOVAL
1) Open hood.
2) Loosen bolts and nuts to remove front grill.
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-00125
A
B

EI-13
EXTERIOR/INTERIOR TRIM
FRONT UNDER COVER
3. Front Under Cover
A: REMOVAL
1) Lift-up the vehicle.
2) Loosen bolts and clips to remove under cover.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
18.4 N·m (1.88 kgf-m, 13.6 ft-lb)
EI-00126

EI-14
EXTERIOR/INTERIOR TRIM FRONT BUMPER
4. Front Bumper
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.
4) Remove clip at bottom of bumper.
5) Remove clip (A), and pull out bumper slightly.
6) Disconnect electrical connector of fog light to re-
move bumper.
7) Remove bumper beam.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. <Ref. to EI-2, FRONT BUMPER, COM-
PONENT, General Description.>
EI-00127
EI-00128
EI-00129
( A )
( A )
EI-00131

EI-15
EXTERIOR/INTERIOR TRIM
FRONT BUMPER
C: REPAIR
1. COATING METHOD FOR PP BUMPER
Pro-
cess
No. Process name Job contents
1 Bumper mounting Set bumper (A) on paint worktable (B) if required. Use paint worktable conforming to
inner shape of bumper when possible.
2Masking Mask specified part (black base) with masking tape. Use masking tapefor PP (example, Nichiban
No. 533, etc.).
3Degreasing, clean-
ing Clean all parts to be painted with white gasoline, normal alcohol, etc. to remove dirt, oil, fat, etc.
4 Primer paint Apply primer one to all parts to be painted, using air gun. Use primer (clear).
5Drying Dry at normal temperature [10 to 15 min. at 20°C (68°F)]. In half-dried condition, PP primer paint is dissolved by solvent, e.g. thinner, etc.
Therefore, if dust or dirt must be removed, use ordinary alcohol, etc.
6 Top coat paint (I)
Solid color Metallic color
Use section (block) paint for top coat.
•Paint in use (for each color):
Solid paint
Hardener PB
Thinner T-301
•Mixing ratio:
Main agent vs. hardener = 4:1
•Viscosity: 10 —13 sec/20°C (68°F)
•Film thickness: 35 —45µ
•Spraying pressure: 245 —343 kPa
(2.5 —3.5 kg/cm2, 36 —50 psi)
Use section (block) paint for top coat.
•Paint in use (for each color):
Metallic paint
Hardener PB
Thinner T-306
•Mixing ratio:
Main agent vs. hardener = 10 : 1
•Viscosity: 10 —13 sec/20°C (68°F)
•Film thickness: 15 —20µ
•Spraying pressure: 245 —343 kPa
(2.5 —3.5 kg/cm2, 36 —50 psi)
7 Drying Not required. Dry at normal temperature [10 min. or more at 20°C (68°F)].
In half-dried condition, avoid dust, dirt.
8 Top coat paint (II) Not required.
Apply a clear coat to parts with top coat paint
(I), three times, at 5 —7 minutes intervals.
•Paint in use:
Metallic paint
Hardener PB
Thinner T-301
•Mixing ratio: Clear vs. hardener = 6 : 1
•Viscosity: 14 —16 sec/20°C (68°F)
•Film thickness: 25 —30µ
•Spraying pressure: 245 —343 kPa
(2.5 —3.5 kg/cm2, 36 —50 psi)
9Drying 60°C (140°F), 60 min. or 80°C (176°F), 30 min.
If higher than 80°C (176°F), PP may be deformed. Keep maximum temperature of 80°C (176°F).
10 Inspection Paint check.
11 Masking removal Remove masking in process No. 2.
EI-00132
( A )
( B )

EI-16
EXTERIOR/INTERIOR TRIM FRONT BUMPER
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 bealmost fully restored. Before repairing a damaged area, explain this point
to the customer and get an understanding about the matter. Repair methods are outlined below, based on a
classification of the extent of damage.
•Minor damage causing only a change in the lustre of the bumper due to a light touch
Almost restorable.
•Deep damage caused by scratching fences, etc.
A dent cannot be repaired but a whitened or swelled part can be removed.
•Deep damage such as a break or hole that requires filling
Muchof the peripheralgrainedsurfacemust besacrificedforrepair,andthedegreeof restorationisnot really
worth the expense. (The surface, however, will become almost flush with adjacent areas.)
Recommended repair kit: PP Part Repair Kit (NRM)
Pro-
cess
No. Process name Job contents
1 Cleaning Clean the area to be repaired using water.
2 Sanding Grind the repairing area with #500 sand paper in a “feathering”motion.
3Finish
Resin section Coated section
Repeatedly apply wax to the affected area
using a soft cloth (such as flannel). Recom-
mended wax: NITTO KASEI Soft 99 TIRE WAX
BLACK, or equivalent.
Perform either the same operation as for the
resin section or process No. 18 and subse-
quent operations in the “(3)”section, depending
on the degree and nature of damage.
Polish the waxed area with a clean cloth after 5
to 10 minutes.
Pro-
cess
No. Process name Job contents
1 Cleaning Clean damaged area with water.
2Removal of dam-
aged area Cut off protruding area, if any, due to collision, using a putty knife.
3 Sanding Grind the affected area with #100 to #500 sand paper.
4Finish Resin section Coated section
Same as Process No. 3 in the “(1)”section. Perform Process No. 12 and subsequent oper-
ations in the “(3)”section.
Pro-
cess
No. Process name Job contents
1 Bumper removal Remove bumper as required.
2 Part removal Remove parts built into bumper as required.
3 Bumper placement
Place bumper (A) on a paint worktable (B) as
required.
It is recommended that contour of worktable
accommodate internal shape of bumper.
EI-00132
( A )
( B )

EI-17
EXTERIOR/INTERIOR TRIM
FRONT BUMPER
4Surface prepara-
tion Remove dust, oil, etc. from areas to be repaired and surrounding areas, using a suitable solvent (NRM No. 900 Precleno, white gasoline, or alcohol).
5 Cutting
If nature of damage are cracks or holes, cut a
guide slit of 20 to 30 mm (0.79 to 1.18 in) in
length along the crack or hole up to the
bumper's base surface. Then, bevel or “vee-
out”the affected area using a knife or grinder. (1) Paint surface
(2) PP base surfave
(3) 20 —30 mm (0.79 —1.18 in)
(4) 3 mm (0.12 in)
6 Sanding (I) Grind beveled surface with sand paper (#40 to #60) to smooth finish.
7 Cleaning Clean the sanded surface with the same solvent as used in Process No. 4.
8 Temporary welding
Grind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a sol-
vent.
Temporarily spot-weld the side, using a PP welding rod and heater gun.
(1) Welded spot (Use heater gun and PP welding rod)
(2) PP base surface
(3) Beveled section
N
O
TE:
•Do not melt welding rod until it flows out. This results in reduced strength.
•Leave the welded spot unattended until it cools completely.
9 Welding
Using a heater gun and PP welding rod, weld the beveled spot while melting the rod and dam-
aged area.
(1) Melt hatched area
(2) Welding rod
(3) Section
N
O
TE:
•Melt the sections indicated by hatched area.
•Do not melt welding rod until it flows out, in order to provide strength.
•Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
•Leave the welded spot unattended until it cools completely.
Pro-
cess
No. Process name Job contents
EI-00294
( 1 )
( 2 )
( 3 )
( 4 )
EI-00135
( 1 )
( 2 )
( 3 )
EI-00136
( 1 )
( 2 )
( 2 )
( 3 )

EI-18
EXTERIOR/INTERIOR TRIM FRONT BUMPER
10 Sanding (II)
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.
Sand the welded spot smooth with #240 sand paper.
11 Masking Mask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
12 Cleaning/
degreasing Completely clean the entire coated area, using solvent similar to that used in Process No. 4.
13 Primer coating
Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if nec-
essary.
Recommended primer: Mp/ 364 PP Primer
N
O
TE:
Be sure to apply one coat of primer at a spraying pressure of 245 to 343 kPa
(2.5 to 3.5 kg/cm2, 36 to 50 psi) with a spray gun.
14 Leave unattended.
Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer is half-dry.
NOTE:
If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampended with alcohol.
(Do not use thinner since the coated area tends to melt.)
15 Primer surfacer
coating
Apply a coat of primer surfacer to the repaired area two or three times at an interval of 3 to 5 min-
utes.
Recommended surfacer:
•UPS 300 Flex Primer
•No. 303 UPS 300 Exclusive hardener
•NPS 725 Exclusive Reducer (thinner)
•Mixing ratio: 2 : 1 (UPS 300: No. 303)
•Viscosity: 12 —14 sec/20°C (68°F)
•Coated film thickness: 40 —50µ
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at 60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sand paper and water.
18 Cleaning/
degreasing Same as Process No. 12.
19 Top coat (I)
Solid color Metallic color
Use a “block”coating method.
•Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
•Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener
•Viscosity: 11 —13 sec/20°C (68°F)
•Coated film thickness: 40 —50µ
•Spraying thickness: 245 —343 kPa
(2.5 —3.5 kg/cm2, 36 —50 psi)
Use a “block”coating method.
•Recommended paint:
Suncryl (SC)
No. 307 Flex Hardener
SC Reducer (thinner)
•Mixing ratio: 3 : 1
Suncryl (SC) vs. No. 307 Flex Hardener
•Viscosity: 11 —13 sec/20°C (68°F)
•Coated film thickness: 20 —30µ
•Spraying thickness: 245 —343 kPa
(2.5 —3.5 kg/cm2, 36 —50 psi)
20 Leave unattended. Not required.
Leave unattended at 20°C (68°F) for at least 10
minutes until the topcoated area is half-dry.
N
O
TE:
Be careful to keep dust or dirt from coming in
contact with the affected area.
Pro-
cess
No. Process name Job contents
EI-00042