Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Headlights

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REMOVAL & INSTALLATION



Justy

See Figure 1

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Fig. Fig. 1: Headlight and combination light assembly-Justy

The Justy is equipped with halogen headlamps, where the bulb can be replaced without removing the headlight assembly.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the front grille retaining screws and remove the grille assembly.
  4.  
  5. Remove the screws that secure the front combination light assembly.
  6.  
  7. Disconnect the electrical harness from the combination light and headlight assemblies.
  8.  
  9. Remove the headlight assembly retaining nuts and bolts, then remove the assembly from the vehicle.
  10.  

To install:
  1. Install the headlight assembly and tighten the nuts and bolts to 61 inch lbs. (6.9 Nm).
  2.  
  3. Attach the wire harnesses to the headlight and combination light assemblies.
  4.  
  5. Install the combination light, using the retainer screws.
  6.  
  7. Install the front grille, and secure with the retainer screws.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Test to make sure the headlight work correctly. Check the headlight alignment. Adjust if needed.
  12.  

Sedan, Coupe, Loyale, Wagon and Brat

See Figure 2

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Fig. Fig. 2: Headlight assemblies-Sedan, Coupe, Loyale, Wagon and Brat

WITH 4 HEADLIGHTS

These vehicles are equipped with 4 5 inch rectangular headlights. These headlight do not have replaceable bulbs. The entire headlight must be removed and replaced.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the retainer screws securing the bezel around the headlight assembly. Remove the bezel and place aside.
  4.  
  5. Pull the headlight out enough to access the wire harness at the rear of the light assembly.
  6.  
  7. Disconnect the electrical harness from the headlight assembly.
  8.  

To install:
  1. Attach the wire harness to the rear of the headlight assembly.
  2.  
  3. Position the headlight into the bracket assembly. Make sure the tabs on the headlight seat within the grooves in the bracket assembly.
  4.  
  5. Install the bezel around the headlight, and secure in place with the retainer screws.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Test to make sure the headlight work correctly. Check the headlight alignment. Adjust if needed.
  10.  

WITH 2 HEADLIGHTS

These models are equipped with halogen headlamps, where the bulb can be replaced without removing the headlight assembly.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the front grille retaining screws and remove the grille assembly.
  4.  
  5. Remove the screws that secure the front combination light assembly.
  6.  
  7. Disconnect the electrical harness from the combination light and headlight assemblies.
  8.  
  9. Remove the headlight assembly retaining nuts and bolts, then remove the assembly from the vehicle.
  10.  

To install:
  1. Install the headlight assembly and tighten the nuts and bolts to 61 inch lbs. (7 Nm).
  2.  
  3. Attach the wire harnesses to the headlight and combination light assemblies.
  4.  
  5. Install the combination light, using the retainer screws.
  6.  
  7. Install the front grille, and secure with the retainer screws.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Test to make sure the headlight work correctly. Check the headlight alignment. Adjust if needed.
  12.  

XT

See Figures 3, 4 and 5

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Fig. Fig. 3: Retractable headlight system-XT



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Fig. Fig. 4: Remove the retainer screws to access the headlight-XT



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Fig. Fig. 5: Headlight bracket retainer bolts-XT

The XT is equipped with pop-up headlamps. The headlamp motors are actuated by a switch on the left control wing. If the light fails to raise, it can be manually raised by means of a knob on top of the motor. The knob is covered by a rubber boot. Remove the boot and turn the knob in the direction of the arrow on top of the motor, this will raise the light.

The XT is equipped with a sealed beam type headlight. If the light fails, the entire lens assembly must be replaced.

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the electrical harnesses from the light and the retractor motor.
  4.  
  5. Remove the front grille assembly.
  6.  
  7. Remove the screws that retain the lid on the light assembly and remove the lid.
  8.  
  9. Remove the headlight cover, by removing the retainer screws.
  10.  
  11. Remove the bolts that retain the headlight assembly and motor, and remove the assembly from the vehicle.
  12.  
  13. If needed, remove the motor from the assembly.
  14.  
  15. To remove the headlight, proceed as follows;
    1. Remove the retainer screws securing the bezel around the headlight assembly. Remove the bezel and place aside.
    2.  
    3. Pull the headlight out enough to access the wire harness at the rear of the light assembly.
    4.  
    5. Disconnect the electrical harness from the headlight assembly.
    6.  
    7. To install, attach the wire harness to the rear of the headlight assembly.
    8.  
    9. Position the headlight into the bracket assembly. Make sure the tabs on the headlight seat within the grooves in the bracket assembly.
    10.  
    11. Install the bezel around the headlight, and secure in place with the retainer screws.
    12.  

  16.  

To install:
  1. Install the headlight motor if removed.
  2.  
  3. Install the assembly in place on the vehicle and secure in place with the retainer bolts. Tighten the bolts to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the cover and lid using the retainer screws.
  6.  
  7. Install the front grille.
  8.  
  9. Connect the motor and headlight wire leads.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Test the operation of the headlights. Adjust the lights if needed.
  14.  

Legacy, Impreza and SVX

See Figures 6 and 7

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Fig. Fig. 6: Headlight bracket retainer nuts on front radiator support-Legacy, Impreza and SVX



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Fig. Fig. 7: Headlight bracket retainer bolts located behind the grille assembly

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the front grille retaining screws, then remove the grille and place aside.
  4.  
  5. Remove the screws that secure the front combination light assembly.
  6.  
  7. Disconnect the electrical connectors from the combination light and headlight assemblies.
  8.  
  9. Remove the headlight assembly retaining nuts and bolts at the top and side of the bracket assembly.
  10.  
  11. Remove the headlight assembly from the vehicle.
  12.  

To install:
  1. Install the headlight assembly and tighten the nuts and bolts to 61 inch lbs. (7 Nm).
  2.  
  3. Attach the wire harnesses to the headlight and combination light assemblies.
  4.  
  5. Install the combination light, using the retainer screws.
  6.  
  7. Install the front grille, and secure with the retainer screws.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Test to make sure the headlight work correctly. Check the headlight alignment. Adjust if needed.
  12.  

HALOGEN BULB REPLACEMENT



See Figures 8, 9 and 10

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Fig. Fig. 8: Slide the protective rubber cap back, if equipped-Legacy



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Fig. Fig. 9: After loosening the retainer ring, remove the bulb from the headlight assembly



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Fig. Fig. 10: Disconnect the harness from the rear of the bulb

The 9004 headlight bulb is a halogen type bulb. This type of bulb is very sensitive to oils on the glass lens. When removing or installing a type 9004 bulb, NEVER touch the lens, or bulb life will be severely reduced.

  1. Disconnect the negative battery cable.
  2.  
  3. From inside the engine compartment, slide the protective rubber cap from the rear of the bulb assembly, if equipped.
  4.  
  5. Twist off the headlight bulb retainer ring and slide over the harness plug.
  6.  
  7. Grasp the base of the bulb and pull it out from the headlamp.
  8.  
  9. Unplug the bulb from the harness.
  10.  

To install:
  1. Grasp the base of the bulb with your hand. Plug the wire harness into the bulb.
  2.  
  3. Insert the bulb into the headlamp.
  4.  
  5. Twist the headlight bulb retainer ring on until it locks in place.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Turn ON the headlight switch to make sure all the lights work correctly.
  10.  

AIMING



See Figure 11

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Fig. Fig. 11: Using the built in level to align the headlight-Legacy

  1. Park the vehicle on level ground, so it is perpendicular to, and facing a flat wall about 25 ft. (7.6m) away.
  2.  
  3. Remove any stone shields and switch ON the lights to low beam.
  4.  
  5. The horizontal distance between the light beams on the wall should be the same as between the headlights themselves.
  6.  
  7. The vertical height of the light beams above the ground should be 4 in. (10cm) less than the distance between the ground and the center of the lamp lenses for the lights.
  8.  
  9. If adjustment is needed, proceed as follows:
    1. On 1985-93 models, turn the adjusting screw on the headlight ring. Each headlight will have 2 adjusting screws. One will control the vertical plain, and the other will control the horizontal plain. Adjust in small increments.
    2.  
    3. On 1994-96 models, headlight alignment is made easier because each light assembly is equipped with an adjustment level. Use a suitable wrench or socket to adjust the level indicator nut at the end of the level, until the bubble is in the middle of the sight glass.
    4.  

  10.  
  11. Test to make sure the lights work correctly, and the light pattern is even.
  12.  

 
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