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