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