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)

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