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

BODY STRUCTURE BS
Page
1. General Description ....................................................................................2
2. Datum Points...............................................................................................3
3. Datum Dimensions....................................................................................10

BS-2
BODY STRUCTURE GENERAL DESCRIPTION
1. General Description
A: PREPARATION TOOL
TOOL NAME REMARKS
Tram tracking gauge Used for measuring dimen-
sion.
Tape measure Used for measuring dimen-
sion

BS-3
BODY STRUCTURE
DATUM POINTS
2. Datum Points
A: LOCATION
NOTE:
•Datum points are specified for body repair.
•Guide holes, locators, and indents are provided to facilitate panel replacement and to increase alignment
accuracy.
•Both right and left reference points are symmetrical.
1. ROOM SECTION
(13) Front fener attaching hole at front
pillar center portion M6 (23) Rear quarter outer door switch attaching hole 20 mm (0.79 in)
dia.
(87) Six light glass attaching hole 6.2
mm (0.244 in) dia.
(14) Front fender attaching hole at
front pillar lower portion M6 (88) Retainer attaching square hole at side rail outer 8 ×8 mm (0.31 ×
0.31 in)
(64) Center pillar (LWR) gauge hole 16
mm (0.63 in) dia.
(19) Retainer attaching hole at side rail
outer 3.2 mm (0.126 in) dia. (81) Panel rear center (UPR) gauge
hole 8 mm (0.31 in) dia. (89) Retainer attaching square hole at rear quarter outer 8 ×8 mm (0.31
×0.31 in)
(20) Center pillar outer hole 14 mm
(0.55 in) dia. (82) Bulk head rear trim clip hole 7 mm
(0.28 in) dia.
(21) Front seat belt adjust plate attach-
ing hole M10 (92) Rear panel center hole (UPR) 6 mm (0.24 in) dia.(85) Rear quarter outer gauge hole 20
mm (0.79 in) dia.
(22) Side sill outer hole 20 mm (0.79
in) dia.
BS-00064
(20)
(22)
(14)
(19)
(13)
(81) (89)
(23)
(64)
(85)
(82)
(87)
(88)
(92)
(21)

BS-4
BODY STRUCTURE DATUM POINTS
2. REAR SECTION
(38) Front panel instrument panel
attaching hole 18 ×36 mm (0.71 ×
1.42 in) dia. oblong hole
(90) Rear rale roof trim attaching hole
8 mm (0.31 in) dia. (97) Trunk trim attaching hole at rear skirt 7 mm (0.28 in) dia.
(91) Rear glass attaching hole
RH: 6.5 mm (0.256 in) dia.
LH: (6.5 ×10 mm (0.256 ×0.394
in) oval
(98) Rear bumper slider attaching hole
6.2 mm (0.244 in) dia.(46) Rear/front shock absorber floor
side attaching hole 13 mm (0.51
in) dia. (99) Rear combination light mounting
hole 8 mm (0.31 in) dia.
(83) Rear skirt outer burring hole 20
mm (0.79 in) dia. (93) Rear panel inner trim attaching hole (UPR) 8 mm (0.31 in) dia. (100) Rear bumper beam attaching hole 8.2 mm (0.323 in) dia.
RH: 8.2 mm (0.323 in)
LH: 8.2 ×12 mm (0.323 ×0.472
in) oval
(84) Rear extension attaching hole 6.2
mm (0.244 in) dia. (94) Rear panel inner trim attaching hole (LWR) 8 mm (0.31 in) dia.
(86) Reinforce striker trim attaching
hole 7 mm (0.28 in) dia. (95) Rear bumper attaching hole 12.5 ×17 mm (0.492 ×0.669 in) dia.
oblong hole
BS-00065
(86)
(100)
(91)
(46)
(93)
(94)
(95)
(83)(84)
(98) (97)
(38)
(99)
(90)

BS-5
BODY STRUCTURE
DATUM POINTS
3. UNDERBODY SECTION
(50) Radiator panel (LWR) frame
gauge hole 15 mm (0.59 in) dia. (54) Front side frame (Rr) gauge hole 20 mm (0.79 in) dia. (58) Reinforcement crossmember B hole RH: 15 mm (0.59 in) dia., LH:
12 mm (0.47 in) dia.
(51) Front side frame (Ft) gauge hole
20 mm (0.79 in) dia. (55) Crossmember front floor gauge hole M10 (59) Frame rear floor side gauge hole
30 mm (1.18 in) dia.
(52) Front side frame (Ft) gauge hole
20 mm (0.79 in) dia. (56) Front side frame (Rr) gauge hole 18 mm (0.71 in) dia.
(53) Front suspension bracket COMPL
securing nut (M14) (57) Frame rear floor side gauge hole 25 mm (0.98 in) dia.
BS-00066
(51)
(52)
(53)(54)
(55) (56)
(57) (58) (59)
(50)

BS-6
BODY STRUCTURE DATUM POINTS
BS-00486
(51)
(52)
(50)
BS-00490
( 9 )
BS-00487
(53)
(56)
(55)
(54)
BS-00491
(57)
(58)
BS-00488
(46) (59) BS-00492
BS-00489
( 1 )
BS-00493
( 8 )
( 9 ) (10)

BS-7
BODY STRUCTURE
DATUM POINTS
BS-00494
( 6 ) ( 7 )
BS-00498
(13)
(14)
BS-00495
(11) BS-00499
(47)
(49)
(72)
(34)
BS-00496
( 3 )
( 4 )
( 5 ) (60)
BS-00500
(48)
BS-00497
(43)
BS-00501
(11)
(10)

BS-8
BODY STRUCTURE DATUM POINTS
BS-00502
(70)
BS-00506
(67)
BS-00503
(65)
(41)
(46) BS-00507
(40)
(38) (39)
BS-00504
(45)
BS-00508
(42)
(24)
BS-00505
(12)
(17)
BS-00509
(25)

BS-9
BODY STRUCTURE
DATUM POINTS
BS-00510
(18)
(19)
(16)
BS-00513
(41)
BS-00511
(64)
(20)
(15)
(22)
BS-00514
(70)
(26)
BS-00512
(44)
(36)
(23)
BS-00515
(21)

BS-10
BODY STRUCTURE DATUM DIMENSIONS
3. Datum Dimensions
A: MEASUREMENT
Refer to LOCATION for details on measurement
points. <Ref. to BS-3, LOCATION, Datum Points.>
NOTE:
•Using a tram tracking gauge, measure all the di-
mensions.
•When using a tape measure, carefully measure
dimensions without letting the tape measure sag or
twist.
•Measure the linear dimensions between cores of
holes.
•Suffixes “RH”and “LH”indicate right-hand and
left-hand.
•Measure at the center of the circle around the
outside of the body panel.
(1) Tram tracking gauge
(1) Outside
(2) Inside
(3) Datum point
(4) Body panel
BS-00097
( 1 )
BS-00098
( 1 )
( 2 )
( 3 )
( 4 )

BS-11
BODY STRUCTURE
DATUM DIMENSIONS
1. FRONT STRUCTURE
Point to point Dimension Point to point Dimension
(11) to (1) 888 (34.96) (4) RH to (4) LH 1,320 (51.97)
(11) to (9) RH 519 (20.43) (5) RH to (4) LH 1,073 (42.24)
(11) to (9) LH 519 (20.43) (5) LH to (4) RH 1,073 (42.24)
(11) to (6) RH 950 (37.40) (60) RH to (13) RH 1,179 (46.42)
(11) to (6) LH 950 (37.40) (60) LH to (13) LH 1,179 (46.42)
(11) to (3) RH 1,008 (39.68) (60) RH to (14) RH 1,135 (44.68)
(11) to (3) LH 1,008 (39.68) (60) LH to (14) LH 1,135 (44.68)
(10) RH to (3) RH 897 (35.31) (10) RH to (3) LH 1,679 (66.10)
(10) RH to (8) RH 504 (19.84) (10) LH to (3) RH 1,679 (66.10)
(10) LH to (8) LH 504 (19.84) (8) RH to (8) LH 1,398 (55.04)
(9) RH to (9) LH 1,020 (40.16) (8) RH to (10) LH 1,519 (59.80)
(6) RH to (6) LH 740 (29.13) (8) LH to (10) RH 1,519 (59.80)
(6) RH to (10) LH 1,522 (59.92) (3) RH to (8) LH 1,439 (56.65)
(6) LH to (10) RH 1,522 (59.92) (3) LH to (8) RH 1,439 (56.65)
(8) RH to (3) RH 395 (15.55) (7) RH to (7) LH 870 (34.25)
(8) LH to (3) LH 395 (15.55) (7) RH to (6) LH 943 (37.13)
(10) RH to (10) LH 1,470 (57.87) (7) LH to (6) RH 943 (37.13)
(3) RH to (3) LH 1,370 (53.94) (7) RH to (10) LH 1,322 (52.05)
(5) RH to (5) LH 720 (28.35) (7) LH to (10) RH 1,322 (52.05)
Unit: mm (in)
BS-00099
( 1 )
( 3 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
(11)
(13)
(14)
(60)

BS-12
BODY STRUCTURE DATUM DIMENSIONS
2. CENTER STRUCTURE
(1) Unit: min (in)
BS-00516
220 (8.66)
700 (27.56)
910 (35.83)
850 (33.46)
1020 (40.16)
1209 (47.60)
220 (8.66)
23 (0.91)
23 (0.91)
LH: 39 (1.54)
RH: 44 (1.73)
317
(12.48) 485 (19.09) 212.5
(8.37) 380 (14.96)
415
(16.34)
376
(14.80) 427 (16.81)
219 (8.62)
355 (13.98)
239 (9.41)
1170 (46.06)
47
(1.85)
545
(21.46)
1180
(46.46)
1813 (71.38)
159 (6.26)
253
(9.96)
68 (2.68)
623 (24.53)
51
52
9
54
53 55
23 (0.91)
150 (5.91)
56 57
50
50
51
51
52
52 53 54 56
57
58
59
59
58
57
56
54
53
51 52
9
53
53
9
52
51
46
59
243 (9.57)
856 (33.70)
800 (31.50) 376 (14.80) 776 (30.55)
1222 (48.11)
26 (1.02) 26
(1.02)
1170 (46.06) 930 (36.61)
1052 (41.42)
706 (27.80)
1110 (43.70) 970 (38.19)
54 55
56
56
54 55
57
46
46
57
58 59
59
940 (37.01)
967 (38.07)
854 (33.62)
1532 (60.31)
875 (34.45)
1099 (43.27)
1103 (43.43)
( 1 )

BS-13
BODY STRUCTURE
DATUM DIMENSIONS
MEMO:

BS-14
BODY STRUCTURE DATUM DIMENSIONS
3. WINDSHIELD AND DOORS
BS-00101
(21)
(81) (19) (88) (89)
(87)
(23)
(85)
(82)
(20)
(64)
(12)
(17)
(67)
(10)
(11)
(67) (16) (18) (19) (24) (42)
(44)
(36)
(23)
(22)
(20)
(64)
(14)
(13)
(82)

BS-15
BODY STRUCTURE
DATUM DIMENSIONS
Point to point Dimension Point to point Dimension
(14) RH to (18) RH 1,425 (56.10) (12) to (10) RH 1,136 (44.72)
(14) LH to (18) LH 1,425 (56.10) (12) to (10) LH 1,136 (44.72)
(13) RH to (64) RH 1,030 (40.55) (11) to (17) RH 1,130 (44.49)
(13) LH to (64) LH 1,030 (40.55) (11) to (17) LH 1,130 (44.49)
(16) RH to (64) RH 966 (38.03) (81) to (82) RH 611 (24.06)
(16) LH to (64) LH 966 (38.03) (81) to (82) LH 611 (24.06)
(20) RH to (23) RH 864 (34.02) (81) to (21) RH 1,309 (51.54)
(20) LH to (23) LH 864 (34.02) (81) to (21) LH 1,309 (51.54)
(20) RH to (24) RH 860 (33.86) (81) to (23) RH 812 (31.97)
(20) LH to (24) LH 860 (33.86) (81) to (23) LH 812 (31.97)
(19) RH to (23) RH 899 (35.39) (82) LH to (21) LH 1,019 (40.12)
(19) LH to (23) LH 899 (35.39) (82) RH to (21) LH 1,606 (63.23)
(20) RH to (36) RH 1,548 (60.94) (82) RH to (82) LH 1,140 (44.88)
(20) LH to (36) LH 1,548 (60.94) (85) LH to (20) LH 1,548 (60.94)
(42) RH to (44) RH 1,037 (40.83) (85) LH to (64) LH 1,650 (64.96)
(42) LH to (44) LH 1,037 (40.83) (19) LH to (64) LH 1,029 (40.51)
(11) to (12) 989 (38.94) (20) LH to (87) LH 911 (35.87)
(67) RH to (67) LH 1,100 (43.31) (20) LH to (88) LH 842 (33.15)
(11) to (67) RH 1,119 (44.06) (20) LH to (64) LH 399 (15.71)
(11) to (67) LH 1,119 (44.06) (23) LH to (89) LH 552 (21.73)
(12) to (67) RH 551 (21.69) (88) LH to (64) LH 1,192 (46.93)
(12) to (67) LH 551 (21.69) (89) LH to (64) LH 1,204 (47.40)
Unit: mm (in)

BS-16
BODY STRUCTURE DATUM DIMENSIONS
4. COMPARTMENT
Point to point Dimension Point to point Dimension
(21) RH to (21) LH 1,351 (53.19) (41) to (22) LH 738 (29.06)
(15) RH to (15) LH 1,455 (57.28) (41) to (26) RH 1,459 (57.44)
(22) RH to (22) LH 1,455 (57.28) (41) to (26) LH 1,459 (57.44)
(39) RH to (39) LH 1,385 (54.53) (41) to (25) 1,290 (50.79)
(40) RH to (40) LH 1,392 (54.80) (41) to (12) 1,228 (48.35)
(41) to (38) 1,639 (64.53) (41) to (21) RH 940 (37.01)
(41) to (39) RH 1,642 (64.65) (41) to (21) LH 940 (37.01)
(41) to (39) LH 1,642 (64.65) (41) to (17) RH 1,261 (49.65)
(41) to (40) RH 1,531 (60.28) (41) to (17) LH 1,261 (49.65)
(41) to (40) LH 1,531 (60.28) (65) RH to (65) LH 1,307 (51.46)
(41) to (15) RH 1,342 (52.83) (41) to (65) RH 969 (38.15)
(41) to (15) LH 1,342 (52.83) (41) to (65) LH 969 (38.15)
(41) to (22) RH 738 (29.06) Unit: mm (in)
BS-00102
(12) (17)
(38)
(39)
(40)
(22)
(41)
(25)
(26)
(65)
(21)
(15)

BS-17
BODY STRUCTURE
DATUM DIMENSIONS
MEMO:

BS-18
BODY STRUCTURE DATUM DIMENSIONS
5. TRUNK LID AND REAR GATE
BS-00103
(72) (34)
(48) (70)
(47)
(46)
(41)
(49)
(43) (45)
(46)
(99)
(97)
(84)
(94)
(81)
(90)
(91)
(94)
(99)
(84)
(22)
(83)
(93)
(86)
(91)
(92) (81)
(38)
(82)
(46)
(97)
(95)
(21)
(100)
(100)