Subaru 2004 LEGACY User manual

FUJI HEAVY INDUSTRIES LTD. G2320GE7
2004 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 (AUTO A/C)
(DIAGNOSTICS) AC(diag)
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTICS) AB(diag)
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

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G2320GE7
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTICS) CC(diag)
IMMOBILIZER (DIAGNOSTICS) IM(diag)
LAN SYSTEM (DIAGNOSTICS) LAN(diag)

GLASS/WINDOWS/MIRRORS GW
Page
1. General Description ....................................................................................2
2. Power Window System...............................................................................8
3. Power Window Control Switch....................................................................9
4. Front Door Glass.......................................................................................10
5. Front Regulator and Motor Assembly .......................................................15
6. Remote Control Mirror System..................................................................16
7. Scalp Cap..................................................................................................17
8. Outer Mirror Assembly ..............................................................................18
9. Outer Mirror...............................................................................................19
10. Remote Control Mirror Switch...................................................................20
11. Rear Door Glass .......................................................................................22
12. Rear Regulator and Motor Assembly........................................................24
13. Windshield Glass ......................................................................................25
14. Rear Gate Glass .......................................................................................28
15. Rear Window Glass ..................................................................................29
16. Rear Window Defogger System................................................................30
17. Rear Window Defogger.............................................................................31
18. Rear Quarter Glass...................................................................................33
19. Sun Roof Glass.........................................................................................34
20. Rearview Mirror.........................................................................................35
21. Wiper Deicer System ................................................................................36
22. Wiper Deicer Switch..................................................................................37

GW-2
GLASS/WINDOWS/MIRRORS General Description
1. General Description
A: COMPONENT
1. FIXED GLASS (SEDAN MODEL)
(1) Windshield glass (4) Rearview mirror mount (7) Six light glass
(2) Dam rubber (5) Locating pin (8) Bracket
(3) Molding (6) Rear window glass (9) Clip
GW-00331
(2)
(6)
(2)
(7) (8)
(9)
(2)
(3)
(5)
(3)
(8)
(1)
(2)
(3) (4)
(5)
(9)
(9)

GW-3
GLASS/WINDOWS/MIRRORS
General Description
2. FIXED GLASS (WAGON MODEL)
(1) Windshield glass (4) Rearview mirror mount (7) Rear quarter glass
(2) Dam rubber (5) Locating pin (8) Locating pin
(3) Molding (6) Fastener (9) Glass
GW-00314
(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 (6) Stabilizer (Inner) Tightening torque: N ⋅ m (kgf-m, ft-lb)
(2) Door sash (Front) (7) Regulator ASSY T1: 7.4 (0.75, 5.5)
(3) Door sash (Rear) (8) Motor ASSY T2: 13.7 (1.4, 10.1)
(4) Weather strip (9) Mirror gusset T3: 5.9 (0.60, 4.4)
(5) Stabilizer (Outer) (10) Guide ASSY
GW-00256
T2
T1
T1
T3
T3
(8)
(7)
(3)
(2)
(1)
(9)
T2
T2
T2
T1
(6)
(5)
(4)
T3
T1
(10)

GW-5
GLASS/WINDOWS/MIRRORS
General Description
4. REAR DOOR GLASS
(1) Glass (5) Stabilizer (Outer) Tightening torque: N ⋅ m (kgf-m, ft-lb)
(2) Door sash (Front) (6) Stabilizer (Inner) T1: 7.4 (0.75, 5.5)
(3) Door sash (Rear) (7) Regulator ASSY T2: 13.7 (1.4, 10.1)
(4) Weather strip (8) Motor ASSY
GW-00257
T1
T1
(8)
(7)
(1)
(2)
(3)
T2
T1
(6)
(5)
(4)
T2

GW-6
GLASS/WINDOWS/MIRRORS General Description
5. MIRROR
B: CAUTION
• When electrical connectors are disconnected, always conduct an operational check after connecting them
again.
• Avoid impact and damage to the glass.
(1) Outer mirror (3) Scalp cap (5) Rearview mirror
(2) Mirror (4) Side turn signal light (6) Mount
GW-00258
(5)
(6)
(2)
(3)
(4)
(1)

GW-7
GLASS/WINDOWS/MIRRORS
General Description
C: PREPARATION TOOL
1. SPECIAL TOOL
2. GENERAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
61299AE000 SPACER Used for adjusting the upper end position of front
door glass. (Glass thickness: 5 mm (0.197 in))
61299AE010 SPACER Used for adjusting the upper end position of rear
door glass. (Glass thickness: 4 mm (0.157 in))
TOOL NAME REMARKS
Circuit tester Used for checking voltage and continuity.
Piano wire Used for removing the window glass.
Windshield glass knife Used for removing the window glass.
ST61299AE000
ST61299AE010

GW-8
GLASS/WINDOWS/MIRRORS Power Window System
2. Power Window System
A: WIRING DIAGRAM
<Ref. to WI-294, Power Window System.>
B: INSPECTION
Symptom Repair order
All power windows do not operate.
(1) Fuse (SBF-5)
(2) Power window circuit breaker
(3) Power window relay
(4) Wiring harness
(5) Body integrated unit
One window does not operate.
(1) Power window main switch
(2) Power window sub switch
(3) Power window motor
(4) Wiring harness
“Window Lock” does not operate. Power window main switch

GW-9
GLASS/WINDOWS/MIRRORS
Power Window Control Switch
3. Power Window Control
Switch
A: REMOVAL
1. MAIN SWITCH
1) Disconnect the ground cable from battery.
2) Remove the front door trim. <Ref. to EI-48, RE-
MOVAL, Door Trim.>
3) Disconnect the harness connector.
4) Remove the screws from the reverse side of
front door trim to remove the power window main
switch.
2. SUB SWITCH
1) Disconnect the ground cable from battery.
2) Remove the door trim. <Ref. to EI-48, REMOV-
AL, Door Trim.>
3) Disconnect the connector.
4) Remove the screws from the reverse side of
door trim to remove the power window sub switch.
B: INSTALLATION
1. MAIN SWITCH
Install in the reverse order of removal.
2. SUB SWITCH
Install in the reverse order of removal.
C: INSPECTION
1. MAIN SWITCH
Measure switch resistance.
• LHD model
• RHD model
Replace the main switch if faulty.
2. SUB SWITCH
Measure switch resistance.
Replace the sub switch if faulty.
GW-00259
GW-0026
0
Switch position Terminal No. Standard
Driver’s seat
AUTO UP 10 and 2, 7 and 1 Less than 1 Ω
UP 10 and 2, 7 and 1 Less than 1 Ω
DOWN 10 and 1, 7 and 2 Less than 1 Ω
AUTO DOWN 10 and 1, 7 and 2 Less than 1 Ω
Switch position Terminal No. Standard
Driver’s seat
AUTO UP 11 and 1, 14 and 2 Less than 1 Ω
UP 11 and 1, 14 and 2 Less than 1 Ω
DOWN 11 and 2, 14 and 1 Less than 1 Ω
AUTO DOWN 11 and 2, 14 and 1 Less than 1 Ω
Switch position Terminal No. Standard
Passenger’s seat and
rear
UP 2 and 3, 4 and 5 Less than 1 Ω
OFF 1 and 2, 4 and 5 Less than 1 Ω
DOWN 1 and 2, 3 and 4 Less than 1 Ω

GW-10
GLASS/WINDOWS/MIRRORS Front Door Glass
4. Front Door Glass
A: REMOVAL
1) Remove the front door trim. <Ref. to EI-48, RE-
MOVAL, Door Trim.>
2) Remove the sealing cover. <Ref. to EB-20, RE-
MOVAL, Front Sealing Cover.>
3) Remove the outer mirror assembly. <Ref. to
GW-18, REMOVAL, Outer Mirror Assembly.>
4) Remove the clip (A), and remove the front end of
weather strip.
5) Remove the gusset.
6) Remove the stabilizer.
7) Remove the clips (A), and remove the rear end
of weather strip.
8) Remove the screw (A) from the rear end of
weather strip outer to remove weather strip outer.
9) Remove the screws to remove guide assembly.
10) Operate the power window switch to move
glass to position shown in the figure, and then re-
move the two nuts through service holes.
GW-00261
(A)
GW-00262
GW-00263
GW-00264
(A)
GW-00265
(A)
GW-00266

GW-11
GLASS/WINDOWS/MIRRORS
Front Door Glass
11) Remove the door glass.
CAUTION:
• Since the gear may be disengaged, do not
turn regulator in the closing direction after re-
moval of the glass.
• Avoid impact and damage to the glass.
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Make sure that glass stay is placed securely in
sash.
2) Adjust the front door glass. <Ref. to GW-11, AD-
JUSTMENT, Front Door Glass.>
Tightening torque:
Refer to “COMPONENT” of “General Descrip-
tion”. <Ref. to GW-4, FRONT DOOR GLASS,
COMPONENT, General Description.>
C: ADJUSTMENT
NOTE:
Before adjustment, ensure thatall adjusting bolts of
stabilizer, upper stopper and sash are loose and
door glass is raised so that it is in contact with
weather strip.
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 the regulator B-channel in a
position at the top of slotted hole.
3) Lower the door glass 10 — 15 mm (0.39 — 0.59
in) from fully closed position. While applying out-
ward pressure of 45.0±5.0 N (4.5±0.5 kgf, 9.9±1.1
lb) (F) to upper edge of glass above midpoint of two
outer stabilizers, press the inner stabilizer at pres-
sure of 25±5 N (2.5±0.5 kgf, 5.5±1.1 lb) to the
glass, then secure it.
4) For adjustment of clearance between front glass
and center pillar cover, loosen the nuts (A), and
move the glass sash back and forward until clear-
ance becomes the value shown.
GW-00267
(1) Fully closed position
(2) Stabilizer
(3) 10 — 15 mm (0.39 — 0.59 in)
(1) Adjust a line parallel
(2) Sash
(3) Inner panel
(1) 11 mm (0.433 in)
(1) F
(2) A = A
A
(2)
(3)
GW-0006
3
A
GW-00319
(A)
(2) (1)
(3)
BO038
8
AA
A-A
(1) (1)
GW-0006
4

GW-12
GLASS/WINDOWS/MIRRORS Front Door Glass
5) To adjust the upper end and lower end of center
pillar,loosen the stopper bolt(A) ornut (B) securing
door sash, move the stopper position until the
clearance between center pillar cover is equal.
CAUTION:
Perform the measurement of clearance be-
tween center pillar at less than 50 mm (1.969 in)
from upper end of window glass.
6) Adjust so that the upper and lower ends of cen-
ter pillar are the same size.
(1) Glass
(2) Center pillar cover
(3) Check point
(4) 50 mm (1.969 in)
(5) 11 mm (0.433 in)
(A)
GW-00320
GW-00321
(B)
(1)
(4)
(3)
(5)
(2)
GW-00322
(1) Narrow
(2) Wide
(3) Glass tilts too far rearward
(4) Glass tilts too far forward
(5) Stopper adjusting direction
GW-00323
(5)
(4) (1)
(2)
(1)
(2)
(3)
(5)
(5) (5)

GW-13
GLASS/WINDOWS/MIRRORS
Front Door Glass
7) After adjusting the clearance between center pil-
lar, up and down the glass several times to check
glass contact to stopper when glass is fully closed.
Adjust it to contact the front and rear stopper simul-
taneously.
8) For adjustment of the upper and lower ends of
center pillar, loosen the adjusting nut (A) ofB-chan-
nel (B).
9) For glass stroke adjustment, install the ST to
glass, close the door, and raise the glass with reg-
ulator until positional relationship between glass
and weather strip becomes as shown. And secure
the glass so that the upper stopper correctly touch-
es the glass holder.
ST 61299AE000 SPACER
(Glassthickness:5mm(0.197
in) for front door glass)
For preventing wind noise, adjust the glass at the
position where tip of gusset is raised up a little.
10) After stabilizer adjustment, carry out the glass
cohesion adjustment. First, visually ensure the po-
sitional relationship between retainer & molding
and glass of the roof side, and then begin with rear
sash adjustment. Install the ST to glass and adjust
two adjusting bolts alternately step by step to ob-
tain dimensions shown below (cross-section A).
NOTE:
If two nuts are loosened at the same time, the sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
(1) Narrow
(2) Wide
(3) When the stopper of door sash (rear) contacts
first
(4) When the stopper of door sash (front) contacts
first
(5) Raise B channel
(6) Lower B channel
GW-00324
(6)
(5)
(4) (1)
(2)
(1)
(2)
(3)
(A)
GW-00269
(B)
(1) 3.2 — 4.8 mm (0.126 — 0.189 in)
(2) 7 mm (0.276 in)
(3) ST
(A) 0 — 1.5 mm (0 — 0.059 in)
GW-00336
A
A
(2)
(1)
(3)
(A)
GW-00325

GW-14
GLASS/WINDOWS/MIRRORS Front Door Glass
11) Make the same adjustment of two adjusting
bolts of rear sash.
ST 61299AE000 SPACER
(Glassthickness:5mm(0.197
in) for front door glass)
NOTE:
Do not tiltthe sash bracketto inner panel duringad-
justment. Otherwise smooth regulator operation
cannot be achieved.
12) Make adjustment of front sash in the same
manner as that of rear sash.
NOTE:
Although front and rear sashes must, as a rule, be
adjusted in the same manner, in some door instal-
lation, the adjustment in a different manner may be
required. However, adjustment of one sash to the
maximum amount and the other to the minimum
amount is not permitted. Such adjustment may re-
sult in application of excessive load to regulator.
13) After adjustments, tighten the nuts.
14) After adjustment of the glass, close the door. If
there is a gap between 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.
15) During adjustment, loosen the other three
clamping bolts.
16) After adjustment, tighten the bolts and nuts.
(1) 3.2 — 4.8 mm (0.126 — 0.189 in)
(2) 7 mm (0.276 in)
(3) ST
(1) Sash bracket
(2) Rear sash
(3) Adjust a line parallel
(4) Sash
(5) Inner panel
GW-00336
A
A
(2)
(1)
(3)
GW-00270
(1)
(2)
(4) (3)
(5)
GW-00271
(A)

GW-15
GLASS/WINDOWS/MIRRORS
Front Regulator and Motor Assembly
5. Front Regulator and Motor
Assembly
A: REMOVAL
1) Remove the door glass. <Ref. to GW-10, RE-
MOVAL, Front Door Glass.>
2) Disconnect the motor connector.
3) Remove the four bolts and two nuts to remove
regulator assembly.
4) Remove the screws to remove motor assembly.
NOTE:
When removing the motor assembly, secure the
arm correctly, because the regulator arm moves in
the force of balancing spring.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust the front door glass. <Ref. to GW-11, AD-
JUSTMENT, Front Door Glass.>
Tightening torque:
Refer to “COMPONENT” of “General Descrip-
tion”. <Ref. to GW-4, FRONT DOOR GLASS,
COMPONENT, General Description.>
C: INSPECTION
1) Make sure that the power window motor rotates
properly when the battery voltage is applied to the
terminals of motor connector.
2) Change polarity of battery connection to termi-
nals to ensure that the motor rotates in reverse di-
rection.
GW-00273
GW-00274

GW-16
GLASS/WINDOWS/MIRRORS Remote Control Mirror System
6. Remote Control Mirror System
A: WIRING DIAGRAM
<Ref. to WI-306, Remote Control Mirror System.>
B: INSPECTION
Symptom Repair order
All function does not operate. (1) Fuse (F/B No. 6) (2) Mirror switch
(3) Wiring harness
One side of the mirror motor does not operate. (1) Mirror switch (2) Mirror motor
(3) Wiring harness
Mirror heater does not operate. (1) Mirror switch (2) Mirror heater
(3) Wiring harness

GW-17
GLASS/WINDOWS/MIRRORS
Scalp Cap
7. Scalp Cap
A: REPLACEMENT
1) Remove the outer mirror. <Ref. to GW-19, RE-
PLACEMENT, Outer Mirror.>
2) Press-in the upper side clips (A) from inside of
door mirror.
3) Pull the scalp cap frontward of door mirror, re-
move the upper side clips (A) and lower side hooks
(B), and then remove the scalp cap.
4) Insert the lower hooks (B) of scalp cap to door
mirror and push the upper clips (A) in.
5) Install the scalp cap securely.
CAUTION:
Do not remove the scalp cap forcibly. The lower
hooks may be damaged.
GW-00312
(A)
(A)
(A)
GW-00275
(B)
(B)
(A)
GW-00276

GW-18
GLASS/WINDOWS/MIRRORS Outer Mirror Assembly
8. Outer Mirror Assembly
A: REMOVAL
1) Remove the mirror gusset cover.
2) Remove the door trim. <Ref. to EI-48, REMOV-
AL, Door Trim.>
3) Disconnect the mirror connector.
4) Remove the screws to remove mirror assembly.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Check that the rearview mirror moves properly when the battery voltage is applied to terminals.
• Model without mirror heater
• Model with mirror heater
Replace the outer mirror assembly if defective.
(1) Hook
GW-0027
7
: (1)
GW-00278
Switch position Terminal No.
OFF —
UP 6 (+) and 3 (−) or 8 (−)
DOWN 3 (+) or 8 (+) and 6 (−)
LEFT 7 (+) and 3 (−) or 8 (−)
RIGHT 3 (+) or 8 (+) and 7 (−)
Switch position Terminal No.
OFF —
UP 7 (+) and 3 (−) or 9 (−)
DOWN 3 (+) or 9 (+) and 7 (−)
LEFT 8 (+) and 3 (−) or 9 (−)
RIGHT 3 (+) or 9 (+) and 8 (−)