Subaru 2003 Legacy 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

AIRBAG SYSTEM (DIAGNOSTICS) AB
Page
1. Basic Diagnostic Procedure........................................................................2
2. Check List for Interview...............................................................................3
3. General Description ....................................................................................4
4. Electrical Components Location................................................................15
5. Airbag Connector......................................................................................17
6. Airbag Warning Light Illumination Pattern.................................................19
7. Read Diagnostic Trouble Code (DTC)......................................................20
8. Inspection Mode........................................................................................21
9. Clear Memory Mode..................................................................................22
10. Airbag Warning Light Failure.....................................................................24
11. List of Diagnostic Trouble Code (DTC).....................................................28
12. Diagnostic Chart with Diagnostic Trouble Code (DTC).............................30

AB-2
AIRBAG SYSTEM (DIAGNOSTICS)
BASIC DIAGNOSTIC PROCEDURE
1. Basic Diagnostic Procedure
A: PROCEDURE
Step Value Yes No
1 Read DTC.
<Ref. to AB-20, Read Diagnostic TroubleCode
(DTC).>
Is the normal code being
detected? Finish the diagno- sis. Go to step 2.
2 Read DTC.
<Ref. to AB-20, Read Diagnostic TroubleCode
(DTC).>
Is the DTC being detected? Go to step 3. Go to “Airbag
Warning Light Fail-
ure”.<Ref. to AB-
24, Airbag Warn-
ing Light Failure.>
3 Perform the diagnosis.
1) Judge the possible cause from “List of
Diagnostic Trouble Code (DTC)”<Ref. to
AB-28, List of Diagnostic Trouble Code
(DTC).> .
2) Inspect using “Diagnostic Chart with Diag-
nostic Trouble Code (DTC)”.
3) Repair the cause of the trouble.
4) Perform the clear memory mode. <Ref. to
AB-22, Clear Memory Mode.>
5) Perform the inspection mode. <Ref. to AB-
21, Inspection Mode.>
6) Read DTC.
Is the DTC being detected? Perform the proce-
dure 1) to 5) in
step 3.
Finish the diagno-
sis.

AB-3
AIRBAG SYSTEM (DIAGNOSTICS)
CHECK LIST FOR INTERVIEW
2. Check List for Interview
A: CHECK
Customer's Name Inspector's Name
Date Vehicle Brought In / / Registration No.
Odometer Reading km
Miles Vin No.
Date Problem Occurred / / Registration Year / /
Weather ❏Fine ❏Cloudy ❏Rainy ❏Snowy ❏Other:
Temperature °C (°F)
Road Condition ❏Level road ❏Uphil ❏Downhill ❏Rough road ❏Others:
Vehicle Operation ❏Starting ❏Idling ❏Driving (❏Constant Speed ❏Acceleration ❏Deceleration
❏Steering wheel turn ❏Other: )
Details of Problem
Check Airbag Warning Light ❏Remains ON ❏Remains OFF
Check DTC ❏Normal Code ❏Trouble Code: (Code: )

AB-4
AIRBAG SYSTEM (DIAGNOSTICS) GENERAL DESCRIPTION
3. General Description
A: CAUTION
•When servicing a vehicle, be sure to turn the ig-
nition switch OFF, disconnect the ground cable
from the battery, and wait formore than20 seconds
before starting work.
•The airbag system is fitted with a backup power
source. If the airbag system is serviced within 20
seconds after the ground cable is disconnected, it
may inflate.
•If the airbag warning light illuminates, repair the
vehicleimmediately.Airbagor pretensionermay in-
flate incorrectly, or not inflate in collision.
•If sensors, airbag module, airbag control module
pretensioner, and harness are deformed or dam-
aged, replace them with new genuine parts.
•Do not use the airbag system and pretensioners
on other vehicles. When replacing parts, be sure to
replace them with new parts.
•When checking the system, be sure to use a dig-
ital circuit tester.
Use of an analog circuit tester may cause the air-
bag to activate erroneously.
•When checking, use a test harness. Do not di-
rectlyapplythe testerprobeto anyconnectortermi-
nal of the airbag.
AB-00002
AB-00120 (1) Test harness
AB-00121
AB-00122
( 1 )

AB-5
AIRBAG SYSTEM (DIAGNOSTICS)
GENERAL DESCRIPTION
•Do not drop the airbag modulator parts, subject
them to high temperature over 93°C (199°F), or let
water, oil, or grease get on them; otherwise, the in-
ternal parts may be damaged and reliability greatly
lowered.
•If any damage, opening or rust is found on the
airbag system wire harness, do not attempt to re-
pair using soldering equipment. Be sure to replace
the faulty harness with a new genuine part.
•Install the wire harness securely with the speci-
fied clips to avoid interference or tangled up with
other parts.
•Do not allow water or oil to come in contact with
the connector terminals. Do not touch the connec-
tor terminals.
•The airbag module (driver, passenger, and side,
pretensioner) must not be disassembled.
•The airbag module cannot be used again once
inflated.
AB-00123
AB-00124
AB-00125
AB-00126
AB-00127

AB-6
AIRBAG SYSTEM (DIAGNOSTICS) GENERAL DESCRIPTION
•After removal, keep the airbag module with the
pad facing upward on a dry, clean, and flat surface
away from heat and light sources, and moisture
and dust.
•Do not check continuity of the airbag module
(driver, passenger, and side, pretensioner).
•The removed front seat with the airbag module
must be keptat least 200 mm(8 in)away fromwalls
and other objects.
•When painting or performing sheet metal work
on the front part of the vehicle, including the front
wheel apron, front fender, and front side frame, re-
move the front sub sensors and wire harness of the
airbag system.
•When painting or performing sheet metal work
on the side of the vehicle, including the side sill,
center pillar, and front and rear doors, remove the
side airbag sensors and wire harness of the airbag
system.
•Do not discard undeployed airbag modules.
They could easily cause a serious accident if acci-
dentally deployed.
•Do not damage the airbag module or drop it.
(1) More than 200 mm (8 in)
AB-00056
AB-00006
AB-00128
( 1 )
AB-00129

AB-7
AIRBAG SYSTEM (DIAGNOSTICS)
GENERAL DESCRIPTION
•When storing a removed airbag module, do not place any objects on it or pile airbag modules on top of
each other. If the airbag inflates for some reason when itis placed with its pad side facing downward or under
any object, a serious accident may result.
(1) Driver side (2) Passenger side
AB-00130
( 1 )
( 2 )

AB-8
AIRBAG SYSTEM (DIAGNOSTICS) GENERAL DESCRIPTION
B: INSPECTION
Before diagnosing, check the following items that
might be related to the engine problem:
1. BATTERY
Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.260

AB-9
AIRBAG SYSTEM (DIAGNOSTICS)
GENERAL DESCRIPTION
C: PREPARATION TOOL
CAUTION:
Be sure to use specified test harness F, G, H, K and I or I2 when measuring voltage, resistance, etc.
of AIRBAG system component parts.
1. TEST HARNESS F
AB-00058
3F
5
6
12
3456
PN 98299FC010
2
1
2F
1F
2F
3F
2
1
2
1
1F
4
3
1
2

AB-10
AIRBAG SYSTEM (DIAGNOSTICS) GENERAL DESCRIPTION
2. TEST HARNESS G
AB-00059
3G
3G
1
2
3
6
5
4
7
8
4
32
1
432
1
4321
43
21
123
45678
1G
1G
2G
PN 98299FC020
2G

AB-11
AIRBAG SYSTEM (DIAGNOSTICS)
GENERAL DESCRIPTION
3. TEST HARNESS H
AB-00060
PN 98299FA030
1H
2H
3H
1H
2H
3H
1
3
3
12
12
12
12
4
5
6
456
2

AB-12
AIRBAG SYSTEM (DIAGNOSTICS) GENERAL DESCRIPTION
4. TEST HARNESS N
AB-00064
2Q
2Q
1Q
1Q
1B
2B
1A
2A
1B 2B 1A 2A
PN 98299SA000

AB-13
AIRBAG SYSTEM (DIAGNOSTICS)
GENERAL DESCRIPTION
5. TEST HARNESS I2
AB-00282
123456
789
10 11 12 41 42 43 44 4546 47 48 49 50 5152
13 14 15 16 17 18
19 20 21 22 23 2425 26
33 34 3536 3727 28 29 30 31 32 38 39 40
5l
4l
3l 6l 2l 1l1l
3l
1l
6l
2l
5l4l
1
112 34
56 9
10 78
2
3
4
2345
1
123456789
101112
23456789 10111213141516171819
32
27
21
38
41
45
42
46
10
12
47
49
50
52
19
29
20
28
40
39
31
30
17
16
14
25
23
13
26
22
1
5
2
6
9
7
20
6789
10 11 12 13 14 15 16 17 18 19 20
12
12
12
12
12
3456
78
11 12 13 14 9 10
100
PN 98299FC041

AB-14
AIRBAG SYSTEM (DIAGNOSTICS) GENERAL DESCRIPTION
6. AIRBAG RESISTOR
The airbag resistor is used during diagnostics. The airbag resistor has the same resistance as the airbag
module and thus provides safety when used instead of the airbag module. It also makes it possible to finish,
diagnostics in less time.
AB-00067
PN 98299PA040
3Y
R
4
12 3654
Y
R2
1
3
1
2

AB-15
AIRBAG SYSTEM (DIAGNOSTICS)
ELECTRICAL COMPONENTS LOCATION
4. Electrical Components Location
A: LOCATION
1. LHD MODEL
(1) Front sub sensor (LH) (7) Roll connector (13) Side airbag sensor (RH)
(2) Front sub sensor (RH) (8) Airbag main harness (14) Side airbag inflator (LH)
(3) Front sub sensor harness (LH) (9) Inflator (Driver) (15) Side airbag inflator (RH)
(4) Front sub sensor harness (RH) (10) Side airbag harness (LH) (a) To body harness
(5) Airbag control module with safety
sensor and electric sensor (11) Side airbag harness (RH) (b) To seal belt pretensioner (LH)
(12) Side airbag sensor (LH) (c) To seal belt pretensioner (RH)
(6) Inflator (Passenger)
Connec-
tor No. (AB1) (AB2) (AB3) (AB6) (AB7) (AB8) (AB9) (AB10) (AB11) (AB12) (AB13) (AB14)
Pole12222822222222
Color Yellow Yellow Yellow Yellow Black Yellow Yellow Yellow Blue Blue Yellow Blue
Male/
Female Male Male Male Female Female Female Female Male Male Female Female Male
Connec-
tor No. (AB15) (AB16) (AB17) (AB18) (AB19) (AB20) (AB21) (AB23) (AB24) (AB25) (AB26) (AB28)
Pole22121222242224
Color Blue Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow
Male/
Female Female Female Female Female Female Male Female Female Female Male Female Female
AB16
AB8
AB3
AB18
AB6
( 1 ) ( 2 )
( 4 )
( 6 )
(14)
( a )
AB15
AB14
AB13
( 3 )
AB12
AB11
B31
AB1
( 8 )
( 7 )
AB17
( 9 )
(15) (13)
(11)
AB26
( c )
AB28
AB25 AB24
AB20
AB19
AB9
AB10
( 5 )
(12)
(10)
AB21
( b )
AB23
AB7
AB-00347

AB-16
AIRBAG SYSTEM (DIAGNOSTICS)
ELECTRICAL COMPONENTS LOCATION
2. RHD MODEL
(1) Front sub sensor (LH) (7) Roll connector (13) Side airbag sensor (RH)
(2) Front sub sensor (RH) (8) Airbag main harness (14) Side airbag inflator (LH)
(3) Front sub sensor harness (LH) (9) Inflator (Driver) (15) Side airbag inflator (RH)
(4) Front sub sensor harness (RH) (10) Side airbag harness (LH) (a) To body harness
(5) Airbag control module with safety
sensor and electric sensor (11) Side airbag harness (RH) (b) To seal belt pretensioner (LH)
(12) Side airbag sensor (LH) (c) To seal belt pretensioner (RH)
(6) Inflator (Passenger)
Connec-
tor No. (AB1) (AB2) (AB3) (AB6) (AB7) (AB8) (AB9) (AB10) (AB11) (AB12) (AB13) (AB14)
Pole12222822222222
Color Yellow Yellow Yellow Yellow Black Yellow Yellow Yellow Blue Blue Yellow Blue
Male/
Female Male Male Male Female Female Female Female Male Male Female Female Male
Connec-
tor No. (AB15) (AB16) (AB17) (AB18) (AB19) (AB20) (AB21) (AB23) (AB24) (AB25) (AB26) (AB28)
Pole22121222242224
Color Blue Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow Yellow
Male/
Female Female Female Female Female Female Male Female Female Female Male Female Female
AB-00348
AB25
AB24
AB20
AB19
AB9
AB10
AB18
B31
AB16
AB13
AB15
AB14
AB8
AB3
AB26
AB28
AB7
AB17
AB6
AB23
AB21
AB12
AB11
AB1
( 2 )
( 3 ) ( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
(11)
(12) (13)
(14) (15)
( a )
( b )
( c )
( 1 )

AB-17
AIRBAG SYSTEM (DIAGNOSTICS)
AIRBAG CONNECTOR
5. Airbag Connector
A: OPERATION
1. POWER SUPPLY
1) How to disconnect:
(1) Move the slide lock (A) in the direction of the
arrow.
(2) Pull the female connector in the direction of
the arrow with slide lock (A) moved.
CAUTION:
When pulling,be sureto hold onto the conector
and not the wire.
2) How to connect:
Holding the connector (A), and push it in carefully
until a connecting sound is head.
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.
2. DRIVER'S AIRBAG, PASSENGER’S AIR-
BAG, SIDE AIRBAG, FRONT SUB SENSOR
HARNESS TO AIRBAG MAIN HARNESS
AND PRETENSIONER
1) How to disconnect:
(1) Push lock arm (A).
(2) With lock arm (A) pushed in, move slide lock
(B) in the direction of the arrow.
(3) With slide lock (B) pulled, remove lock arm
(A) to its original position, and then pull in the di-
rection of the arrow and separate the connector.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.
AB-00015
( A )
AB-00016
( A )
AB-00017
( A )
( B )
AB-00018
AB-00019

AB-18
AIRBAG SYSTEM (DIAGNOSTICS) AIRBAG CONNECTOR
3. DRIVER'S AIRBAG (ROLL CONNECTOR
AND AIRBAG MODULE
1) How to disconnect:
(1) Using a flat tip screwdriver, pry the push
lock upward to unlock.
(2) Pull the connector to disconnect from driv-
er’s side airbag module assembly.
2) How to connect:
Connect the connector in reverse order of discon-
necting. At this time, be sure to insert the connector
in until connecting sound is heard.
CAUTION:
Be sure to insert the connector in until it locks.
Then pull on it gently to make sure that it is
locked.
4. FRONT SUB-SENSOR, SIDE AIRBAG
SENSOR
1) How to disconnect:
(1) Holding outer part (A), pull it in the direction
of the arrow.
CAUTION:
When pulling, be sure to hold onto the connec-
tor and not the wire.
2) How to connect:
Holding the connector, and push it in carefully until
a connecting sound is heard.
CAUTION:
•Outer (A) moves back, and so do not put your
hand on the outer part.
•Be sure to insert the connector in until it
locks. Then pull on it gently to make sure that it
is locked.
AB-00020
AB-00285
( A )
AB-00286
( A )