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

LIGHTING SYSTEM LI
Page
1. General Description ....................................................................................2
2. Headlight and Tail Light System .................................................................3
3. Front Fog Light System...............................................................................4
4. Rear Fog Light System ...............................................................................5
5. Turn Signal and Hazard Light System ........................................................6
6. Back-up Light System .................................................................................7
7. Stop Light System.......................................................................................8
8. Interior Light System...................................................................................9
9. Headlight Beam Leveler System...............................................................10
10. Combination Switch (Light) .......................................................................11
11. Combination Base Switch Assembly.........................................................13
12. Headlight Assembly ..................................................................................15
13. Headlight Bulb...........................................................................................17
14. Front Turn Signal Light Bulb .....................................................................18
15. Parking Light Bulb.....................................................................................19
16. Front Fog Light Assembly.........................................................................20
17. Front Fog Light Bulb..................................................................................21
18. Rear Combination Light Assembly............................................................22
19. Rear Finisher Light Assembly ...................................................................23
20. Brake/Tail Light Bulb.................................................................................24
21. Back-up Light Bulb....................................................................................25
22. Rear Turn Signal Light Bulb......................................................................26
23. Rear Fog Light Bulb..................................................................................27
24. License Plate Light....................................................................................28
25. High-mounted Stop Light ..........................................................................29
26. Side Turn Signal Light...............................................................................30
27. Spot Light..................................................................................................31
28. Room Light................................................................................................32
29. Luggage Room Light.................................................................................33
30. Trunk Room Light......................................................................................34
31. Glove Box Light.........................................................................................35
32. Door Step Light .........................................................................................36

LI-2
LIGHTING SYSTEM GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
B: PRECAUTIONS
•Before disassembling or reassembling parts, always disconnect battery ground cable. When replacing ra-
dio, controlmodule, and other parts provided with memory functions, record memory contentsbefore discon-
necting the battery ground cable. Otherwise, the memory will be erased.
•Reassemble in reverse order of disassembly, unless otherwise indicated.
•Adjust parts to the given specifications.
•Connect connectors and hoses securely during reassembly.
•After reassembly, make sure functional parts operate smoothly.
WARNING:
•Airbag system wiring harness is routed near electrical parts and switches. All airbag system wiring
harnesses and connectors are yellow. Do not use electric test equipment on these circuits.
•Be careful not to damage the airbag system wiring harness when servicing electrical parts and
switches.
C: PREPARATION TOOL
1. GENERAL TOOLS
Headlight 12 V —55 W/55 W (Halogen)
Front turn signal light 12 V —21 W
Side turn signal light 12 V —5 W
Parking light 12 V —5 W
Front fog light 12 V —55 W
Rear fog light 12 V —21 W
Rear combination light Tail/Stop light 12 V —5/21 W Turn signal light 12 V —21 W
Back-up light 12 V —21 W
License plate light 12 V —5 W
High-mounted stop light Sedan 12 V —21 W
Wagon 12 V —10 W
Room light 12 V —8 W
Spot light 12 V —8 W
Door step light 12 V —3.4 W
Luggage room light 12 V —13 W
Trunk room light 12 V —5 W
Glove box light 12 V —1.4 W
TOOL NAME REMARKS
Circuit Tester Used for measuring resistance and voltage.

LI-3
LIGHTING SYSTEM
HEADLIGHT AND TAIL LIGHT SYSTEM
2. Headlight and Tail Light Sys-
tem
A: SCHEMATIC
1. HEADLIGHT LHD MODEL
<Ref. to WI-264, LHD MODEL, SCHEMATIC,
Headlight System.>
2. HEADLIGHT RHD MODEL
<Ref. to WI-265, RHD MODEL, SCHEMATIC,
Headlight System.>
3. CLEARANCE LIGHT AND ILLUMINA-
TION LIGHT LHD MODEL
<Ref. to WI-248, LHD 4-CYLINDER ENGINE
MODEL, SCHEMATIC, Clearance Light and Illumi-
nation Light System.>
<Ref. to WI-251, LHD 6-CYLINDER ENGINE
MODEL, SCHEMATIC, Clearance Light and Illumi-
nation Light System.>
4. CLEARANCE LIGHT AND ILLUMINA-
TION LIGHT RHD MODEL
<Ref. to WI-254, RHD 4-CYLINDER NON-TURBO
ENGINE MODEL, SCHEMATIC, Clearance Light
and Illumination Light System.>
<Ref. to WI-257, RHD 6-CYLINDER ENGINE AND
TURBO ENGINE MODEL, SCHEMATIC, Clear-
ance Light and Illumination Light System.>
B: INSPECTION
1. HEADLIGHT RELAY
Measure headlight relay resistance between termi-
nals while connecting terminalNo. 4 to battery pos-
itive terminal No. 3 to battery ground terminal.
2. TAIL AND ILLUMINATION RELAY
Measure tail and illumination relay resistance be-
tween terminals while connecting terminal No. 4 to
batterypositiveterminal No.3 tobattery ground ter-
minal.
Current Terminal No. Standard
Flow 1 and 2 Less than 1 Ω
No flow More than 1 MΩ
Current Terminal No. Standard
Flow 1 and 2 Less than 1 Ω
No flow More than 1 MΩ
LI-00001
(1)
(2)
(1)
(4)
(2)
(3)
(3) (4)
LI-00001
(1)
(2)
(1)
(4)
(2)
(3)
(3) (4)

LI-4
LIGHTING SYSTEM FRONT FOG LIGHT SYSTEM
3. Front Fog Light System
A: SCHEMATIC
1. FRONT FOG LIGHT 4 CYLINDER EN-
GINE MODEL
<Ref. to WI-260, 4-CYLINDER ENGINE MODEL,
SCHEMATIC, Front Fog Light System.>
2. FRONT FOG LIGHT LHD 6 CYLINDER
ENGINE MODEL
<Ref. to WI-261, LHD 6-CYLINDER ENGINE
MODEL, SCHEMATIC, Front Fog Light System.>
3. FRONT FOG LIGHT RHD 6 CYLINDER
ENGINE MODEL
<Ref. to WI-262, RHD 6-CYLINDER ENGINE
MODEL, SCHEMATIC, Front Fog Light System.>
B: INSPECTION
1. FRONT FOG LIGHT SWITCH
Measure front fog light switch resistance.
2. FRONT FOG LIGHT RELAY
Measure front fog light relay resistance between
terminals while connecting terminal No. 4 to battery
positive terminal and terminal No. 3 to battery
ground terminal.
Switch position Terminal No. Standard
OFF —More than 1 MΩ
ON 3 and 5 Less than 1 Ω
LI-00051
12 3654
Current Terminal No. Standard
Flow 1 and 2 Less than 1 Ω
No flow More than 1 MΩ
LI-00001
(1)
(2)
(1)
(4)
(2)
(3)
(3) (4)

LI-5
LIGHTING SYSTEM
REAR FOG LIGHT SYSTEM
4. Rear Fog Light System
A: SCHEMATIC
1. REAR FOG LIGHT
<Ref. to WI-294, SCHEMATIC, Rear Fog Light
System.>
B: INSPECTION
1. REAR FOG LIGHT SWITCH
1) Turn ignition switch ON.
2) Turn on the headlight or front fog light.
3) Push the rear fog light switch and check if the
rear fog light turns on.
2. REAR FOG LIGHT RELAY
Measure rear fog light relay resistance between
terminals while connecting terminal No. 4 to battery
positive terminal and No. 3 to battery ground termi-
nal.
Current Terminal No. Standard
Flow 1 and 2 Less than 1 Ω
No flow More than 1 MΩ
LI-00001
(1)
(2)
(1)
(4)
(2)
(3)
(3) (4)

LI-6
LIGHTING SYSTEM TURN SIGNAL AND HAZARD LIGHT SYSTEM
5. Turn Signal and Hazard Light
System
A: SCHEMATIC
1. TURN SIGNAL LIGHT AND HAZARD
LIGHT LHD MODEL
<Ref. to WI-274, LHD MODEL, SCHEMATIC, Turn
Signal Light and Hazard Light System.>
2. TURN SIGNAL LIGHT AND HAZARD
LIGHT RHD MODEL
<Ref. to WI-276, RHD MODEL, Turn Signal Light
and Hazard Light System.>
B: INSPECTION
1. TURN SIGNAL SWITCH
<Ref. to LI-11, INSPECTION, Combination Switch
(Light).>
2. HAZARD SWITCH
Measure hazard switch resistance.
3. TURN SIGNAL & HAZARD MODULE
Connect battery and turn signal light bulb to the
module, as shown in the figure. The module is
properly functioning if it blinks when power is sup-
plied to the circuit.
Switch position Terminal No. Standard
OFF 6 and 7 Less than 1 Ω
ON 1, 3 and 4 Less than 1 Ω
7 and 8 Less than 1 Ω
LI-00002
87 56
43 12
LI-00003

LI-7
LIGHTING SYSTEM
BACK-UP LIGHT SYSTEM
6. Back-up Light System
A: SCHEMATIC
1. BACK-UP LIGHT
<Ref. to WI-247, SCHEMATIC, Back-up Light Sys-
tem.>
B: INSPECTION
1. BACK-UP LIGHT SWITCH (M/T)
Measure back-up light switch resistance.
2. INHIBITOR SWITCH (A/T)
Measure inhibitor switch resistance.
Switch position Terminal No. Standard
Whenshiftleverisset
in reverse position 1 and 2 Less than 1 Ω
Other positions More than 1 MΩ
Switch position Terminal No. Standard
When select lever is
set in “R”position 1 and 2 Less than 1 Ω
Other positions More than 1 MΩ
LI-00006
12
10 9
LI-00005
123457
12 11 8 7

LI-8
LIGHTING SYSTEM STOP LIGHT SYSTEM
7. Stop Light System
A: SCHEMATIC
1. STOP LIGHT SEDAN MODEL
<Ref. to WI-272, SEDAN MODEL, SCHEMATIC,
Stop Light System.>
2. STOP LIGHT WAGON MODEL
<Ref. to WI-273, WAGON MODEL, SCHEMATIC,
Stop Light System.>
B: INSPECTION
1. STOP LIGHT SWITCH
Measure stop light switch resistance.
(A) Without cruise control
(B) With cruise control
Switch position Terminal No. Standard
Whenbrakepedal
is depressed 1 and 2: Without
cruise control
2 and 3: With
cruise control
Less than 1 Ω
Whenbrakepedal
is released More than 1 MΩ
34
12
12
LI-00064
(A)
(B)

LI-9
LIGHTING SYSTEM
INTERIOR LIGHT SYSTEM
8. Interior Light System
A: SCHEMATIC
1. INTERIOR LIGHT LHD MODEL
<Ref. to WI-266, LHD MODEL, SCHEMATIC, In
Compartment Light System.>
2. INTERIOR LIGHT RHD MODEL
<Ref. to WI-269, RHD MODEL, SCHEMATIC, In
Compartment Light System.>
B: INSPECTION
1. DOOR SWITCH
Measure door switch resistance.
2. REAR GATE LATCH SWITCH
Measure rear gate latch switch.
3. TRUNK ROOM LIGHT SWITCH
Measure trunk room light switch.
(A) Front door switch
(B) Rear door switch
Switch position Terminal No. Standard
When door is open 1 and 3 Less than 1 Ω
When door is closed More than 1 MΩ
LI-00072
( A )
( B )
Switch position Terminal No. Standard
When rear gate is
open 1 and 2 Less than 1 Ω
When rear gate is
closed More than 1 MΩ
Switch position Terminal No. Standard
When trunk lid is open 1 and 2 Less than 1 Ω
When trunk lid is
closed More than 1 MΩ

LI-10
LIGHTING SYSTEM HEADLIGHT BEAM LEVELER SYSTEM
9. Headlight Beam Leveler Sys-
tem
A: SCHEMATIC
1. HEADLIGHT BEAM LEVELER
<Ref. to WI-234, SCHEMATIC, Headlight Beam
Leveler System.>
B: INSPECTION
1. HEADLIGHT BEAM LEVELER ACTUA-
TOR
1) Turn on the headlights.
2) Confirm the headlight beam level is lowered by
changing the switch position to 0 - 1 - 2 - 3 - 4 - 5.
2. HEADLIGHT BEAM LEVELER SWITCH
Connect battery, headlight beam leveler switch
connector, circuit tester and resistor (500 to 800 Ω)
as shown in the figure.Measure the current at each
switch position.
Switch position Current (mA)
08.0
17.2
26.39
35.59
44.78
53.98
LI-00127
RH
500 –800
LH
654321

LI-11
LIGHTING SYSTEM
COMBINATION SWITCH (LIGHT)
10.Combination Switch (Light)
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove instrument panel lower cover. <Ref. to
EI-35, REMOVAL, Instrument Panel Assembly.>
3) Remove screws which secure upper column
cover to lower column cover.
4) Disconnect connector from combination switch.
5) Remove screws which secure switch and re-
move switch.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Measure combination switch resistance.
1. LIGHTING SWITCH
LHD model and RHD model with rear fog light:
RHD model without rear fog light:
2. DIMMER AND PASSING SWITCH
LHD model and RHD model with rear fog light:
RHD model without rear fog light:
LI-00009
LI-00010
(A) LHD model and RHD model with rear fog light
(B) RHD model without rear fog light
Switch position Terminal No. Standard
OFF —More than 1 MΩ
Tail 14 and 16 Less than 1 Ω
Head 13, 14 and 16 Less than 1 Ω
Switch position Terminal No. Standard
OFF —More than 1 MΩ
Tail 9 and 15 Less than 1 Ω
Head 9, 14 and 15 Less than 1 Ω
Switch position Terminal No. Standard
Passing 7, 8 and 16 Less than 1 Ω
Low beam 16 and 17 Less than 1 Ω
High beam 7 and 16 Less than 1 Ω
Switch position Terminal No. Standard
Passing 1, 2 and 9 Less than 1 Ω
Low beam 9 and 10 Less than 1 Ω
High beam 2 and 9 Less than 1 Ω
LI-00184
1514131211 10 917 16 6 5 4 3 2 18 7
1514131211 10 917 16 6 5 4 3 2 18 7
(A)
(B)

LI-12
LIGHTING SYSTEM COMBINATION SWITCH (LIGHT)
3. TURN SIGNAL SWITCH
LHD model and RHD model with rear fog light:
RHD model without rear fog light:
Switch position Terminal No. Standard
Left 1 and 2 Less than 1 Ω
Neutral —More than 1 MΩ
Right 2 and 3 Less than 1 Ω
Switch position Terminal No. Standard
Left 6 and 7 Less than 1 Ω
Neutral —More than 1 MΩ
Right 7 and 8 Less than 1 Ω

LI-13
LIGHTING SYSTEM
COMBINATION BASE SWITCH ASSEMBLY
11.Combination Base Switch
Assembly
A: REMOVAL
1. WITHOUT VDC MODEL
1) Remove driver’s airbag module. <Ref. to AB-12,
REMOVAL, Driver's Airbag Module.>
2) Remove steering wheel. <Ref. to PS-24, RE-
MOVAL, Steering Wheel.>
3) Remove steering column cover.
4) Remove combination switch. <Ref. to LI-11, RE-
MOVAL, Combination Switch (Light).> <Ref. to
WW-8, REMOVAL, Combination Switch (Wiper).>
5) Loosen 4 screws and remove roll connector.
6) Loosen 3 screws.
7) Disconnect connector and remove combination
base switch assembly.
2. WITH VDC MODEL
1) Remove driver’s airbag module. <Ref. to AB-12,
REMOVAL, Driver's Airbag Module.>
2) Remove steering wheel. <Ref. to PS-24, RE-
MOVAL, Steering Wheel.>
3) Remove steering column cover.
4) Remove combination switch. <Ref. to LI-11, RE-
MOVAL, Combination Switch (Light).> <Ref. to
WW-8, REMOVAL, Combination Switch (Wiper).>
5) Loosen 3 screws.
6) Disconnect connector and remove combination
base switch assembly.
CAUTION:
In case of model with VDC, do not separate roll
connector from combination base switch.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Align the attaching direction of roll connector
with steering wheel, before installation of steering
wheel.<Ref. to AB-19, ADJUSTMENT, Roll Con-
nector.>
C: INSPECTION
1. COMBINATION BASE SWITCH ASSEM-
BLY
Perform inspection for the following items and re-
place with a new one, if any damage is found.
•Crack or deformation of combination base switch
assembly or roll connector
CAUTION:
In case of model with VDC, do not separate roll
connector from combination base switch.
LI-00181
LI-00182

LI-14
LIGHTING SYSTEM COMBINATION BASE SWITCH ASSEMBLY
2. PARKING SWITCH
Measure parking switch resistance.
Switch position Terminal No. Standard
OFF 2 and 4 Less than 1 Ω
ON 1 and 4 Less than 1 Ω
12 34
LI-00183

LI-15
LIGHTING SYSTEM
HEADLIGHT ASSEMBLY
12.Headlight Assembly
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove duct(A) (whenright side headlight is re-
moved).
3) Disconnect headlight bulb connector.
4) Remove three bolts and disconnect connectors,
and then detach headlight assembly.
B: INSTALLATION
Install in the reverse order of removal.
LI-00073
( A )
LI-00129
LI-00130

LI-16
LIGHTING SYSTEM HEADLIGHT ASSEMBLY
C: ADJUSTMENT
1. HEADLIGHT AIMING
CAUTION:
Turn off the light before adjusting headlight
aiming. If the light is necessary to check aim-
ing, do not turn on for more than two minutes.
NOTE:
Before checking the headlight aiming, be sure of
the following:
•The area around the headlight has not sustained
any accident, damage or other type of deformation.
•Vehicle is parked on level ground.
•The inflation pressure of tires is correct.
•Vehicle's gas tank is fully charged.
•Bounce the vehicle several times to normalize
the suspension.
•Make certain that someone is seated in the driv-
er's seat.
Turn the headlights on and then adjust the low
beam pattern to the following positions on the
screen.
NOTE:
•Set the headlight leveler switch to “0”position.
•Adjust vertical aim (A) first, then horizontal aim
(B).
This illustration is for LHD model.
The pattern for RHD model is symmetrically opposite.
LI-00131
( A )
( B )
(A) Vehicle center
(B) Bulb center
W mm (in)
H mm (in)
h mm (in) at 3 m (10 ft)
Sedan Wagon Outback
Conventional sus-
pension Air suspension
1,130 (44.69) 665 (26.18) 660 (25.98) 650 (25.59) 725 (28.54) 30 (1.18)
LI-00132
W1
W1
W
W
H
H
3 m (10 ft)
H
W2
W2
h
h
( A )
( A )
( B )

LI-17
LIGHTING SYSTEM
HEADLIGHT BULB
13.Headlight Bulb
A: REMOVAL
CAUTION:
•Because the tungsten halogen bulb operates
at a high temperature, dirt and oil on the bulb
surface reduces the bulb's service life. Hold the
flange portion when replacing the bulb. Never
touch the glass portion.
•Do not leave the headlight without a bulb for
a long time. Dust, moisture, etc. entering the
headlight may affect its the performance.
1) Disconnect ground cable from battery.
2) Remove duct(A) (whenright side headlight is re-
moved).
3) Remove back cover (A).
4) Disconnect harness connector.
5) Push to remove spring retainer and then detach
headlight bulb.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.
LI-00073
( A )
LI-00134
( A )
LI-00135

LI-18
LIGHTING SYSTEM FRONT TURN SIGNAL LIGHT BULB
14.Front Turn Signal Light Bulb
A: REMOVAL
1) Remove headlight assembly. <Ref. to LI-15, RE-
MOVAL, Headlight Assembly.>
2) Turn the socket and remove the bulb.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Visually check the bulb for blow out.
2) Check the bulb specification. <Ref. to LI-2,
SPECIFICATIONS, General Description.>
3) If NG, replace the bulb with a new one.
LI-00136