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

EXTERIOR BODY PANELS EB
Page
1. General Description ....................................................................................2
2. Front Hood..................................................................................................9
3. Fender Panel.............................................................................................10
4. Front Door Panel.......................................................................................11
5. Front Sealing Cover ..................................................................................13
6. Rear Door Panel .......................................................................................14
7. Rear Sealing Cover...................................................................................16
8. Trunk Lid Panel.........................................................................................17
9. Rear Gate Panel .......................................................................................18

EB-2
EXTERIOR BODY PANELS GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
Section Part Specification
A - A (1) Front fender and (2) front door 4.6 ± 1.0 mm (0.181 ± 0.039 in)
B - B (2) Front door and (3) rear door 5.1 ± 1.0 mm (0.201 ± 0.039 in)
C - C (3) Rear door and (4) rear quarter 4.6 ± 1.0 mm (0.181 ± 0.039 in)
D - D (5) Door panel and (6) side sill 4.8 ± 1.0 mm (0.189 ± 0.039 in)
EB-00088
AB
DD
C
( 1 ) ( 2 ) ( 3 )
A - A B - B
( 3 ) ( 4 )
( 5 )
( 6 )
C - C D - D

EB-3
EXTERIOR BODY PANELS
GENERAL DESCRIPTION
B: COMPONENT
1. FRONT HOOD
(1) Front hood (5) Buffer A Tightening torque: N·m (kgf-m, ft-lb)
(2) Seal (Front hood) (6) Buffer B T1: 24.5 (2.5, 18.1)
(3) Hinge (7) Plug
(4) Buffer C (8) Seal ASSY
EB-00039
( 1 ) ( 2 )
( 3 )
T1
T1
( 4 )
( 4 )
( 5 )
( 5 )
( 6 )
( 6 )
( 7 )
( 7 )
( 8 )

EB-4
EXTERIOR BODY PANELS GENERAL DESCRIPTION
2. FRONT DOOR PANEL
(1) Gusset (7) Sealing cover Tightening torque: N·m (kgf-m, ft-lb)
(2) Weatherstrip (Outer) (8) Door checker T1: 7.35 (0.75, 5.4)
(3) Clip (Weatherstrip, outer) (9) Lower hinge T2: 18 (1.8, 13)
(4) Stabilizer (Lifter) (10) Upper hinge T3: 30 (3.1, 22)
(5) Stabilizer (Outer) (11) Door panel
(6) Stabilizer (Inner)
EB-00040
( 1 )
( 2 )
( 3 ) ( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
(11)
T1
T1
T3
T1
T3
T2
T1

EB-5
EXTERIOR BODY PANELS
GENERAL DESCRIPTION
3. REAR DOOR PANEL
(1) Weatherstrip (Outer) (6) Bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) Clip (Weatherstrip, outer) (7) Sealing cover T1: 7.35 (0.75, 5.4)
(3) Stabilizer (Outer) (8) Door checker T2: 18 (1.8, 13)
(4) Stabilizer (Inner) (9) Lower hinge T3: 30 (3.1, 22)
(5) Door panel (10) Upper hinge
EB-00041
( 1 )
( 2 )
( 3 ) ( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
T1
T2
T1
T3
T3
T3

EB-6
EXTERIOR BODY PANELS GENERAL DESCRIPTION
4. TRUNK LID PANEL
(1) Torsion bar (4) Hinge ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Trunk lid (5) Cover T1: 18 (1.8, 13)
(3) Weatherstrip T2: 14 (1.4, 10)
EB-00042
( 1 ) ( 2 )
( 3 )
( 4 )
( 5 )
T1
T1

EB-7
EXTERIOR BODY PANELS
GENERAL DESCRIPTION
5. REAR GATE PANEL
(1) Gas stay (4) Buffer (Rear gate) Tightening torque: N·m (kgf-m, ft-lb)
(2) Hinge (5) Buffer cover T1: 7.5 (0.76, 5.5)
(3) Rear gate (6) Buffer (Back door) T2: 14 (1.4, 10.1)
T3: 25 (2.5, 18.1)
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
T1
T1
T1
T3
T2
EB-00043

EB-8
EXTERIOR BODY PANELS GENERAL DESCRIPTION
C: PREPARATION TOOL
1. SPECIAL TOOLS
2. GENERAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
925610000 WRENCH Used for removing and installing door hinge.
927780000 REMOVER Used for removing and installing trunk torsion bar.
TOOL NAME REMARKS
Support Jack Used for supporting door panel.
ST-925610000
ST-927780000

EB-9
EXTERIOR BODY PANELS
FRONT HOOD
2. Front Hood
A: REMOVAL
1) Open front hood to remove washer nozzles.
2) Remove clips to remove hood insulator.
3) Remove bolts to disconnect hood from hinges.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust clearance between hood and fender.
Clearance must be equal at both sides.
Tightening torque:
24.5 N·m (2.5 kgf-m, 18 ft-lb)
C: ADJUSTMENT
1) Use hinge mounting holes to align front hood
longitudinally and laterally.
2) Adjust height at front end of hood. <Ref. to SL-
31, REMOVAL, Front Hood Lock Assembly.>
3) Rotate front hood buffer to adjust lateral height.
EB-00046
EB-00047
EB-00047
EB-00049

EB-10
EXTERIOR BODY PANELS FENDER PANEL
3. Fender Panel
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove side sill spoilers. <Ref. to EI-29, RE-
MOVAL, Side Sill Spoiler.>(If fitted)
3) Remove side protectors and fender protectors.
(OUTBACK)
4) Remove front bumper face. <Ref. to EI-14, RE-
MOVAL, Front Bumper.>
5) Remove headlights. <Ref. to LI-15, REMOVAL,
Headlight Assembly.>
6) Remove mud guard. <Ref. to EI-22, REMOVAL,
Mud Guard.>
7) Remove bolts and clips to remove front fender.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When fender panel is installed, clearance be-
tween fender panel and hood or front fender must
be equal.
Tightening torque:
7.35 N·m (0.75 kgf-m, 5.4 ft-lb)
EB-00050

EB-11
EXTERIOR BODY PANELS
FRONT DOOR PANEL
4. Front Door Panel
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove front door trim. <Ref. to EI-30, RE-
MOVAL, Front Door Trim.>
3) Remove outer mirror assembly. <Ref. to GW-
33, REMOVAL, Outer Mirror Assembly.>
4) Remove front door regulatorand motor. <Ref.to
GW-16, REMOVAL, Front Regulator and Motor As-
sembly.>
5) Remove front door latch assembly. <Ref. to SL-
21, REMOVAL, Front Door Latch Assembly.>
6) Remove front outer handle. <Ref. to SL-20, RE-
MOVAL, Front Outer Handle.>
7) Remove front pillar lower trim to disconnect con-
nector from body harness.
8) Put wooden block on jack and place jack under
door. Support door with a jack to protect it from
damage.
9) Remove checker bolts.
10) Remove door-side bolts for upper and lower
hinges to remove door.
11) Using special tool, remove body-side bolts for
upper and lower hinges, and remove door hinges.
ST 925610000 DOOR HINGE WRENCH
B: INSTALLATION
1) Install in the reverse order of removal.
2) Apply grease to sliding area of door hinges.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. <Ref. to EB-4, FRONT DOOR PANEL,
COMPONENT, General Description.>
C: ADJUSTMENT
1) Using special tool, loosen body-side bolts of up-
per and lower hinges to align the position of front
door panel longitudinally and vertically.
ST 925610000 DOOR HINGE WRENCH
2) Loosen door-side bolts of upper and lower hing-
es to align the position of front door panel vertically
and laterally at the front end.
EB-00051
EB-00052
EB-00053
EB-00054
ST
EB-00054
ST
EB-00053

EB-12
EXTERIOR BODY PANELS FRONT DOOR PANEL
3) Loosen screw (A) and tap striker (B) using plas-
tic hammer to adjust striker.
CAUTION:
Do not use impact wrench. Welding area on
striker nut plate is easily broken.
EB-00057
( A ) ( B )

EB-13
EXTERIOR BODY PANELS
FRONT SEALING COVER
5. Front Sealing Cover
A: REMOVAL
1) Remove front door trim. <Ref. to EI-30, REMOV-
AL, Front Door Trim.>
2) Remove front speaker. <Ref. to ET-6, REMOV-
AL, Front Speaker.>
NOTE:
•Carefully remove butyl tape. Excessive force will
easily break the cover.
•If cover gets broken, replace it with a new one.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When replacing sealing cover, use butyl tape.
3) Press sealer-applied area firmly to prevent any
floating on surface.
Butyl tape:
3M8626 or equivalent
NOTE:
•Apply a uniform bead of butyl tape.
•Attach sealing cover, keeping it from becoming
wrinkled.
•Breaks in the bead will allow water leakage and
contamination.
C: INSPECTION
If sealing cover is damaged, replace it with a new
one.
EB-00058

EB-14
EXTERIOR BODY PANELS REAR DOOR PANEL
6. Rear Door Panel
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove rear door trim. <Ref. to EI-31, REMOV-
AL, Rear Door Trim.>
3) Remove rear door regulator and motor assem-
bly. <Ref. to GW-18, REMOVAL, Rear Regulator
and Motor Assembly.>
4) Remove rear outer handle. <Ref. to SL-24, RE-
MOVAL, Rear Outer Handle.>
5) Remove center pillar lower trim. <Ref. to EI-39,
REMOVAL, Lower Inner Trim.>
6) Remove seatbelt bracket and blind plug.
Disconnect connector of door harness and remove
door hinge nut.
7) Put a wooden block on the jack and place the
jack under the door. Support the door with the jack
to protect it.
8) Remove checker bolts.
9) Remove door-side bolts for upper and lower
hinges to remove door.
10) Using special tool, remove body-side bolts for
upper and lower hinges, and remove door hinges.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Apply grease to sliding area of door hinges.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. <Ref. to EB-5, REAR DOOR PANEL,
COMPONENT, General Description.>
C: ADJUSTMENT
1) Using special tool, loosen body-side bolts of up-
per and lower hinges to align the position of rear
door panel longitudinally and vertically.
2) Loosen door-side bolts of upper and lower hing-
es to align the position of rear door panel vertically
and laterally at front-end.
EB-00059
EB-00052
EB-00053
EB-00054
ST
EB-00053

EB-15
EXTERIOR BODY PANELS
REAR DOOR PANEL
3) Loosen screw (A) and tap striker (B) using plas-
tic hammer to adjust striker.
CAUTION:
Do not use an impact wrench. The welding area
on the striker nut plate is easily broken.
EB-00057
( A ) ( B )

EB-16
EXTERIOR BODY PANELS REAR SEALING COVER
7. Rear Sealing Cover
A: REMOVAL
1) Remove rear door trim. <Ref. to EI-31, REMOV-
AL, Rear Door Trim.>
2) Remove rear speaker. <Ref. to ET-8, REMOV-
AL, Rear Speaker.>
NOTE:
•Carefully remove butyl tape. Excessive force will
easily break the cover.
•If cover gets broken, replace it with a new one.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When replacing sealing cover, use butyl tape.
3) Press sealer-applied area firmly to prevent any
floating on surface.
Butyl tape:
3M8626 or equivalent
NOTE:
•Apply a uniform bead of butyl tape.
•Attach sealing cover, keeping it from becoming
wrinkled.
•Breaks in the bead will allow water leakage and
contamination.
C: INSPECTION
If sealing cover gets damaged, replace it with a
new one.
EB-00058

EB-17
EXTERIOR BODY PANELS
TRUNK LID PANEL
8. Trunk Lid Panel
A: REMOVAL
1. TRUNK LID
1) Open trunk lid.
2) Disconnect trunk lid connector.
3) Loosen trunk lid mounting bolts to remove trunk
lid from hinges.
2. TORSION BAR
1) Open trunk lid.
2) Using special tool, remove torsion bar from
hinge link.
ST 927780000 REMOVER
CAUTION:
During removal and installation, carefully han-
dle torsion bar. It will generate reactive force.
3) Remove right/left torsion bars.
B: INSTALLATION
1. TRUNK LID
1) Install in the reverse order of removal.
2) Install trunk lid with uniform clearance.
2. TORSION BAR
1) Install in the reverse order of removal.
2) Apply grease to rotating area of hinges and mat-
ing surface of torsion bar.
Tightening torque:
14 N·m (1.4 kgf-m, 10 ft-lb)
EB-00066
EB-00067
ST

EB-18
EXTERIOR BODY PANELS REAR GATE PANEL
9. Rear Gate Panel
A: REMOVAL
1. REAR GATE PANEL
1) Open rear gate.
2) Remove rear gate outer handle. <Ref. to SL-27,
REMOVAL, Rear Gate Outer Handle.>
3) Remove rear gate latch assembly. <Ref. to SL-
28, REMOVAL, Rear Gate Latch Assembly.>
4) Remove rear gate trim. <Ref. to EI-44, REMOV-
AL, Rear Gate Trim.>
5) Remove rear gate key lock cylinders. <Ref. to
SL-35, REAR GATE, REPLACEMENT, Key Lock
Cylinders.>
6) Removerearfinisherlightassembly. <Ref.toLI-
23, REMOVAL, Rear Finisher Light Assembly.>
7) Remove rear wiper. <Ref. to WW-16, REMOV-
AL, Rear Wiper Motor.>
8) Disconnect connectors of rear wiper, rear defog-
ger, and other lighting devices.
9) Disconnect washer hose.
10) Remove rubber duct (A) connection, and pull
out harness and washer hose from rear gate.
11) Using a support, support the rear gate while re-
moving gas stay mounting bolts.
NOTE:
When the rear gate is released, it may hit and dam-
age the body. To prevent this, place a shop cloth
between body and gate.
12) Loosen rear gate bolts to remove rear gate.
2. GAS STAY
1) Open rear gate. Using a jack to support the rear
gate.
CAUTION:
•After gas stay is removed, rear gate cannot
stay open. Supporting the rear gate with a jack,
remove the bolts.
•Do not damage piston rods and oil seals.
•Never disassemble cylinders: They contain
gas.
2) Loosen bolts to remove gas stay from rear gate.
B: INSTALLATION
1. REAR GATE PANEL
1) Install in the reverse order of removal.
2) Install rear gate panel with uniform clearance to
body.
2. GAS STAY
Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. <Ref. to EB-7, REAR GATE PANEL,
COMPONENT, General Description.>
EB-00068
( A )
EB-00069
EB-00069