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

GLASS/WINDOWS/MIRRORS GW
Page
1. General Description ....................................................................................2
2. Power Window System...............................................................................8
3. Rear Window Defogger System..................................................................9
4. Windshield Wiper Deicer System..............................................................10
5. Remote Control Mirror System..................................................................11
6. Front Door Glass.......................................................................................12
7. Front Regulator and Motor Assembly .......................................................16
8. Rear Door Glass .......................................................................................17
9. Rear Regulator and Motor Assembly........................................................18
10. Windshield Glass ......................................................................................19
11. Rear Gate Glass .......................................................................................22
12. Rear Quarter Glass...................................................................................24
13. Rear Window Glass ..................................................................................26
14. Roof Window Glass...................................................................................27
15. Inner Rearview Mirror................................................................................28
16. Power Window Control Switch..................................................................29
17. Rear Window Defogger Switch.................................................................31
18. Rear Window Defogger.............................................................................32
19. Outer Mirror Assembly ..............................................................................33
20. Outer Mirror...............................................................................................35
21. Remote Control Mirror Switch...................................................................36
22. Wiper Deicer .............................................................................................38
23. Wiper Deicer Switch..................................................................................39

GW-2
GLASS/WINDOWS/MIRRORS GENERAL DESCRIPTION
1. General Description
A: COMPONENT
1. FIXED GLASS (SEDAN)
(1) Windshield glass (4) Rearview mirror mount (7) 6 light glass
(2) Dam rubber (5) Locate pin
(3) Molding (6) Rear window glass
GW-00080
( 2 )
( 6 )
( 2 )
( 2 )
( 2 )
( 7 )
( 2 )
( 3 )
( 5 )
( 1 )
( 2 ) ( 3 ) ( 4 )
( 5 )

GW-3
GLASS/WINDOWS/MIRRORS
GENERAL DESCRIPTION
2. FIXED GLASS (WAGON)
(1) Windshield glass (4) Rearview mirror mount (7) Rear quarter glass
(2) Dam rubber (5) Locate pin (8) Locate pin
(3) Molding (6) Fastener (9) Rear gate glass
GW-00081
( 1 )
( 2 )
( 2 )
( 3 ) ( 4 )
( 5 )
( 6 )
( 6 )
( 7 )
( 8 )
( 8 ) ( 9 )

GW-4
GLASS/WINDOWS/MIRRORS GENERAL DESCRIPTION
3. FRONT DOOR GLASS
(1) Glass (4) Regulator ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Door sash (Front) (5) Motor ASSY T1: 7.35 (0.75, 5.4)
(3) Door sash (Rear) T2: 14 (1.4, 10.1)
GW-00082
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
T1
T1
T2
T2

GW-5
GLASS/WINDOWS/MIRRORS
GENERAL DESCRIPTION
4. REAR DOOR GLASS
(1) Glass (4) Regulator ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Door sash (Front) (5) Motor ASSY T1: 7.35 (0.75, 5.4)
(3) Door sash (Rear) T2: 14 (1.4, 10.1)
GW-00083
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
T1
T1
T2
T2

GW-6
GLASS/WINDOWS/MIRRORS GENERAL DESCRIPTION
5. MIRRORS
(1) Outer mirror (3) Mount (5) Mirror
(2) Rearview mirror (4) Spring
GW-00084
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )

GW-7
GLASS/WINDOWS/MIRRORS
GENERAL DESCRIPTION
B: CAUTION
•When electrical connectors are disconnected, always conduct an operational check after connecting them
again.
•Avoid impact and damage to the glass.
C: PREPARATION TOOL
TOOL NAME REMARKS
Circuit Tester Used for checking voltage and continuity.
Piano Wire Used for window glass removal.
Windshield Knife Used for window glass removal.

GW-8
GLASS/WINDOWS/MIRRORS POWER WINDOW SYSTEM
2. Power Window System
A: SCHEMATIC
1. POWER WINDOW LHD MODEL
<Ref. to WI-282, LHD MODEL, SCHEMATIC, Power Window System.>
2. POWER WINDOW RHD MODEL
<Ref. to WI-286, RHD MODEL, SCHEMATIC, Power Window System.>
B: INSPECTION
Symptom Repair order
All power windows does not operate.
(1) Fuse (SBF-6) (F/B No. 18)
(2) Power window circuit breaker
(3) Power window relay
(4) Wire harness
One window does not operate.
(1) Power window main switch
(2) Power window sub switch
(3) Power window motor
(4) Wire harness
“Window Lock”does not operate. (1) Power window main switch

GW-9
GLASS/WINDOWS/MIRRORS
REAR WINDOW DEFOGGER SYSTEM
3. Rear Window Defogger System
A: SCHEMATIC
<Ref. to WI-296, SCHEMATIC, Rear Window Defogger System.>
B: INSPECTION
Symptom Repair order
Rear window defogger does not operate.
(1) Fuse (M/B No. 1)
(2) Rear defogger relay
(3) Defogger switch
(4) Rear defogger condenser
(5) Deffogger wire
(6) Wire harness

GW-10
GLASS/WINDOWS/MIRRORS
WINDSHIELD WIPER DEICER SYSTEM
4. Windshield Wiper Deicer System
A: SCHEMATIC
<Ref. to WI-328, SCHEMATIC, Wiper Deicer System.>
B: INSPECTION
Symptom Repair order
Wiper deicer does not operate.
(1) Fuse (F/B No. 18, 19)
(2) Wiper deicer relay
(3) Wiper deicer switch
(4) Wire harness

GW-11
GLASS/WINDOWS/MIRRORS
REMOTE CONTROL MIRROR SYSTEM
5. Remote Control Mirror System
A: SCHEMATIC
1. REMOTE CONTROL MIRROR LHD MODEL
<Ref. to WI-298, LHD MODEL, SCHEMATIC, Remote Controlled Rearview Mirror System.>
2. REMOTE CONTROL MIRROR RHD MODEL
<Ref. to WI-299, RHD MODEL, SCHEMATIC, Remote Controlled Rearview Mirror System.>
B: INSPECTION
Symptom Repair order
All function does not operate. (1) Fuse (F/B No. 4) (2) Mirror switch
(3) Wire harness
One side of the mirror motor does not operate. (1) Mirror switch (2) Mirror motor
(3) Wire harness
Mirror heater does not operate. (1) Mirror switch (2) Mirror heater
(3) Wire harness

GW-12
GLASS/WINDOWS/MIRRORS FRONT DOOR GLASS
6. Front Door Glass
A: REMOVAL
1) Remove door trim. <Ref. to EI-30, REMOVAL,
Front Door Trim.>
2) Remove sealing cover. <Ref. to EB-13, RE-
MOVAL, Front Sealing Cover.>
3) Remove inner remote. <Ref. to SL-19, REMOV-
AL, Front Inner Remote.>
4) Remove outer weatherstrip.
5) Remove inner stabilizer.
6) Remove outer mirror. <Ref. to GW-33, REMOV-
AL, Outer Mirror Assembly.>
7) Remove gusset.
8) Operate the power window switch to move glass
to the position shown in the figure, and then re-
move the two nuts from service holes.
9) Take out door glass upward.
NOTE:
Do not turn regulator in the closing direction after
removalof the glass. Otherwise gearmay be disen-
gaged.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Make sure that glass stay is placed securely in
sash.
2) Adjust front door glass. <Ref. to GW-13, AD-
JUSTMENT, Front Door Glass.>
GW-00085
GW-00086
GW-00087
GW-00088

GW-13
GLASS/WINDOWS/MIRRORS
FRONT DOOR GLASS
C: ADJUSTMENT
NOTE:
Before adjustment, ensure thatall adjusting boltsof
stabilizer, upper stopper, and sash are loose and
door glass is raised so that it is in contact with
weatherstrip.
1) Temporarily tighten one adjusting bolt on one
side of rear sash at the midpoint of slotted hole in
the inner panel.
2) Temporarily tighten regulator B-channel in a po-
sition slightly lower than midpoint of slotted hole.
3) Lower door glass 10 to 15 mm (0.39 to 0.59 in)
from fully closed position. While applying outward
pressure of 45±5 N (4.59±0.51 kgf, 10.1±1.1 lb) (F)
to upper edge of glass above midpoint of two outer
stabilizers, press inner stabilizer at 10±5 N
(1.02±0.51 kgf, 2.2±1.1 lb) until it just touches the
glass, then secure it.
4) For adjustment of clearance between front and
rear glasses, loosen nuts (A) and (B), and move
glass sash back and forth until clearance becomes
the value shown.
5) For adjustment of upper and lower ends of cen-
ter pillar, loosen adjusting nut (A) of B-channel (B).
(1) Full close
(2) Stabilizer
(3) 10 –15 mm (0.39 –0.59 in)
GW-00144
F
A
A = A
A
( 1 )
( 2 ) ( 2 )
( 3 )
(1) 38 mm (1.50 in)
GW-00090
( A )
( B )
GW-00145
A-A
AA
( 1 )
GW-00092
( A )
( B )

GW-14
GLASS/WINDOWS/MIRRORS FRONT DOOR GLASS
6) Adjust sothat upperand lower ends ofcenter pil-
lar are the same size.
7) For glass stroke adjustment, close door, raise
glass until positional relationship between glass
and weatherstrip becomes as shown. And secure
the glass so that upper stopper lightly touches the
glass holder.
8) After stabilizer adjustment, carry out glass crimp
adjustment. First, visually ensure positional rela-
tionship between retainer & molding and glass of
the roof side, and then begin with rear sash adjust-
ment. Adjust two adjusting bolts alternately step by
step to obtain dimensionsshown below (cross-sec-
tion A).
NOTE:
If two nuts are loosened at the same time, sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
9) Make the same adjustment of two adjusting bolts
of rear sash.
NOTE:
Do not tiltsash bracket to inner panelduring adjust-
ment. Otherwise smooth regulator operation can-
not be achieved.
(1) Glass tilts too far rearward
(2) Narrow
(3) Wide
(4) Lower B channel
(5) Glass tilts too far forward
(6) Raise B channel
(1) 2.5±0.5 mm (0.098±0.020 in)
(2) 6 mm (0.24 in)
GW-00093
( 1 )
( 2 )
( 2 )
( 3 )
( 3 )
( 4 )
( 5 )
( 6 )
GW-00146
A-A
A
A
( 1 )
6
(0.24)
(1) 2.5±0.5 mm (0.098±0.020 in)
(2) 6 mm (0.24 in)
(1) Sash bracket
(2) Rear sash
(3) Adjust a line parallel
(4) Sash
(5) Inner panel
GW-00146
A-A
A
A
( 1 )
6
(0.24)
GW-00096
( 1 )
( 2 )
( 3 )
( 5 )
( 4 )

GW-15
GLASS/WINDOWS/MIRRORS
FRONT DOOR GLASS
10) Make adjustment of front sash in the same
manner as that of rear sash.
CAUTION:
Although front and rear sashes must, as a rule,
be adjusted in the same manner, in some door
installation, the adjustment in a different man-
ner may be required. However, adjustment of
onesash to the maximumamountand the other
to the minimum amount is not permitted. Such
adjustment may result in application of exces-
sive load to regulator.
11) After adjustments, tighten nuts.
12) After adjustment of glass, if there is a gap be-
tween outer lip of gusset and glass surface, adjust
the gap with adjusting bolt (A) in lower fitting part of
gusset to prevent generation of wind noise.
13) During adjustments, loosen other three clamp-
ing bolts.
14) After adjustment, tighten bolts and nuts.
GW-00097
( A )

GW-16
GLASS/WINDOWS/MIRRORS
FRONT REGULATOR AND MOTOR ASSEMBLY
7. Front Regulator and Motor
Assembly
A: REMOVAL
1) Remove door trim. <Ref. to EI-30, REMOVAL,
Front Door Trim.>
2) Remove sealing cover. <Ref. to EB-13, RE-
MOVAL, Front Sealing Cover.>
3) Remove inner remote. <Ref. to SL-19, REMOV-
AL, Front Inner Remote.>
4) Remove door glass. <Ref. to GW-12, REMOV-
AL, Front Door Glass.>
5) Disconnect motor connector.
6) Loosen four bolts and two nuts to pull out regu-
lator assembly.
7) Loosen screws to remove motor assembly.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust front door glass. <Ref. to GW-13, AD-
JUSTMENT, Front Door Glass.>
C: INSPECTION
1) Make sure that power window motor rotates
properly when battery voltage is applied to termi-
nals of motor connector.
2) Change polarity of battery connections to termi-
nals to ensure that motor rotates in reverse direc-
tion.
GW-00098
GW-00099

GW-17
GLASS/WINDOWS/MIRRORS
REAR DOOR GLASS
8. Rear Door Glass
A: REMOVAL
1) Remove door trim. <Ref. to EI-31, REMOVAL,
Rear Door Trim.>
2) Remove sealing cover. <Ref. to EB-16, RE-
MOVAL, Rear Sealing Cover.>
3) Remove stabilizer.
4) Operate power window switch to move glass as
shown in the figure, and remove two nuts.
5) Loosen two screws to remove weatherstrip.
6) Pull out glass.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Make sure that glass stay is placed securely in
sash.
2) Adjust rear door glass. <Ref. to GW-17, AD-
JUSTMENT, Rear Door Glass.>
C: ADJUSTMENT
NOTE:
Rear door glass, as a rule, should be adjusted in
the same manner as front glass, although they are
different in dimension. Special notes for rear glass
are given below.
1) Adjust glass position using the following dimen-
sions as a guide line.
NOTE:
•If dimensions are smaller than the given dimen-
sions, glass may get caught in weatherstrip during
lifting/lowering operation. In the worst case, it may
cause glass not to be opened fully.
•After adjustment, move glass up and down to
check whether it is caught.
2) Adjust crimp of glass using the following dimen-
sions as a guide line.
CAUTION:
•If crimp of rear glass is higher than neces-
sary, glass may get caught in weatherstrip of
center pillar corner, resulting in early wear of
weatherstrip. Be careful when adjusting.
•After adjustment, move glass up and down to
check whether it is caught.
GW-00085
GW-00087
GW-00102
(1) 38 mm (1.50 in)
(1) 2.5±0.5 mm (0.098±0.020 in)
(2) 6 mm (0.24 in)
GW-00147
AA
A–A
( 1 )
GW-00148
A
A
A–A
( 1 )
( 2 )

GW-18
GLASS/WINDOWS/MIRRORS
REAR REGULATOR AND MOTOR ASSEMBLY
9. Rear Regulator and Motor As-
sembly
A: REMOVAL
1) Remove door trim. <Ref. to EI-30, REMOVAL,
Front Door Trim.>
2) Remove sealing cover. <Ref. to EB-16, RE-
MOVAL, Rear Sealing Cover.>
3) Remove door glass. <Ref. to GW-17, REMOV-
AL, Rear Door Glass.>
4) Secure bolts using screwdriver to remove front
sash adjusting nut.
5) Remove front sash.
6) Disconnect motor connector.
7) Loosen four bolts and two nuts to remove regu-
lator assembly.
8) Loosen screws to remove motor assembly.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust rear door glass. <Ref. to GW-17, AD-
JUSTMENT, Rear Door Glass.>
C: INSPECTION
1) Make sure that power window motor rotates
properly when battery voltage is applied to termi-
nals of motor connector.
2) Change polarity of battery connections to termi-
nals to ensure that motor rotates in reverse direc-
tion.
GW-00105
GW-00098
GW-00099