Subaru 2003 Legacy Manuel utilisateur

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

( 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 )

( 4 )

( 5 )

( 6 )

( 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)

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)

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 )

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 )

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

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