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2004 Legacy Service Manual Quick Reference Index Body

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2004 Legacy Service Manual Quick Reference Index Body 2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION HVAC SYSTEM AC (HEATER, VENTILATOR AND A/C) HVAC SYSTEM (AUTO A/C) AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AB AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) This service manual has been prepared to provide SUBARU service personnel SEAT BELT SYSTEM SB with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. LIGHTING SYSTEM LI This manual includes the procedures for maintenance, disassembling, reas- sembling, inspection and adjustment of WIPER AND WASHER SYSTEMS WW components and diagnostics for guid- ance of experienced mechanics. Please peruse and utilize this manual ENTERTAINMENT ET fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition. COMMUNICATION SYSTEM COM When replacement of parts during repair work is needed, be sure to use SUBARU genuine parts. GLASS/WINDOWS/MIRRORS GW BODY STRUCTURE BS INSTRUMENTATION/DRIVER INFO IDI SEATS SE SECURITY AND LOCKS SL SUNROOF/T-TOP/CONVERTIBLE TOP SR (SUNROOF) EXTERIOR/INTERIOR TRIM EI All information, illustration and specifi- cations contained in this manual are EXTERIOR BODY PANELS EB based on the latest product information available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD. G2320GE7 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CC CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) LAN SYSTEM (DIAGNOSTICS) LAN(diag) G2320GE7 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 General Description GLASS/WINDOWS/MIRRORS 1. General Description A: COMPONENT 1. FIXED GLASS (SEDAN MODEL) (2) (4) (3) (1) (5) (2) (6) (8) (9) (2) (3) (5) (9) (3) (7) (9) (2) (8) GW-00331 (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-2 General Description GLASS/WINDOWS/MIRRORS 2. FIXED GLASS (WAGON MODEL) (2) (4) (1) (3) (5) (8) (9) (8) (6) (7) (6) (2) GW-00314 (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-3 General Description GLASS/WINDOWS/MIRRORS 3. FRONT DOOR GLASS T3 (9) (4) (1) T1 T3 (6) T3 (5) (10) T1 T1 (7) (3) (2) T2 T1 T2 (8) T2 T2 GW-00256 (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-4 General Description GLASS/WINDOWS/MIRRORS 4. REAR DOOR GLASS (4) (5) T1 (6) (1) T1 (7) (3) T1 T2 (8) (2) T2 GW-00257 (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-5 General Description GLASS/WINDOWS/MIRRORS 5. MIRROR (3) (6) (2) (5) (1) (4) GW-00258 (1) Outer mirror (3) Scalp cap (5) Rearview mirror (2) Mirror (4) Side turn signal light (6) Mount B: CAUTION • When electrical connectors are disconnected, always conduct an operational check after connecting them again. • Avoid impact and damage to the glass. GW-6 General Description GLASS/WINDOWS/MIRRORS C: PREPARATION TOOL 1. SPECIAL 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)) ST61299AE000 61299AE010 SPACER Used for adjusting the upper end position of rear door glass. (Glass thickness: 4 mm (0.157 in)) ST61299AE010 2. GENERAL TOOL 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. GW-7 Power Window System GLASS/WINDOWS/MIRRORS 2. Power Window System A: WIRING DIAGRAM <Ref. to WI-294, Power Window System.> B: INSPECTION Symptom Repair order (1) Fuse (SBF-5) (2) Power window circuit breaker All power windows do not operate. (3) Power window relay (4) Wiring harness (5) Body integrated unit (1) Power window main switch (2) Power window sub switch One window does not operate. (3) Power window motor (4) Wiring harness “Window Lock” does not operate. Power window main switch GW-8 Power Window Control Switch GLASS/WINDOWS/MIRRORS 3. Power Window Control 2. SUB SWITCH Switch 1) Disconnect the ground cable from battery. 2) Remove the door trim. <Ref. to EI-48, REMOV- A: REMOVAL AL, Door Trim.> 1. MAIN SWITCH 3) Disconnect the connector. 4) Remove the screws from the reverse side of 1) Disconnect the ground cable from battery. door trim to remove the power window sub switch. 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. GW-00260 B: INSTALLATION 1. MAIN SWITCH Install in the reverse order of removal. GW-00259 2. SUB SWITCH Install in the reverse order of removal. C: INSPECTION 1. MAIN SWITCH Measure switch resistance. • LHD model Switch position Terminal No. Standard AUTO UP 10 and 2, 7 and 1 Less than 1 Ω UP 10 and 2, 7 and 1 Less than 1 Ω Driver’s seat DOWN 10 and 1, 7 and 2 Less than 1 Ω AUTO DOWN 10 and 1, 7 and 2 Less than 1 Ω • RHD model Switch position Terminal No. Standard AUTO UP 11 and 1, 14 and 2 Less than 1 Ω UP 11 and 1, 14 and 2 Less than 1 Ω Driver’s seat DOWN 11 and 2, 14 and 1 Less than 1 Ω AUTO DOWN 11 and 2, 14 and 1 Less than 1 Ω Replace the main switch if faulty. 2. SUB SWITCH Measure switch resistance. Switch position Terminal No. Standard UP 2 and 3, 4 and 5 Less than 1 Ω Passenger’s seat and OFF 1 and 2, 4 and 5 Less than 1 Ω rear DOWN 1 and 2, 3 and 4 Less than 1 Ω Replace the sub switch if faulty. GW-9 Front Door Glass GLASS/WINDOWS/MIRRORS 4. Front Door Glass 6) Remove the stabilizer. 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. GW-00263 7) Remove the clips (A), and remove the rear end of weather strip. (A) (A) GW-00261 5) Remove the gusset. GW-00264 8) Remove the screw (A) from the rear end of weather strip outer to remove weather strip outer. (A) GW-00265 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-00262 GW-00266 GW-10 Front Door Glass GLASS/WINDOWS/MIRRORS 11) Remove the door glass. sure of 25±5 N (2.5±0.5 kgf, 5.5±1.1 lb) to the glass, then secure it. (1) F (3) A A (2) A = A (2) GW-00267 GW-00063 CAUTION: • Since the gear may be disengaged, do not (1) Fully closed position turn regulator in the closing direction after re- (2) Stabilizer moval of the glass. (3) 10 — 15 mm (0.39 — 0.59 in) • Avoid impact and damage to the glass. B: INSTALLATION 4) For adjustment of clearance between front glass and
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