Subaru LEGACY 2003 Service Manual
Engine section 1
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- Service manual (4441 pages) ,
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2003 LEGACY SERVICE MANUAL
ENGINE SECTION 1
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.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FUEL INJECTION (FUEL SYSTEMS)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION)
MECHANICAL
EXHAUST
COOLING
LUBRICATION
SPEED CONTROL SYSTEMS
IGNITION
STARTING/CHARGING SYSTEMS
ENGINE (DIAGNOSTICS)
FUEL INJECTION (FUEL SYSTEMS)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
INTAKE (INDUCTION)
MECHANICAL
EXHAUST
COOLING
FU(H4SO)
EC(H4SO)
IN(H4SO)
ME(H4SO)
EX(H4SO)
CO(H4SO)
LU(H4SO)
SP(H4SO)
IG(H4SO)
SC(H4SO)
EN(H4SO)
FU(H4SOw/oOBD)
EC(H4SOw/oOBD)
IN(H4SOw/oOBD)
ME(H4SOw/oOBD)
EX(H4SOw/oOBD)
CO(H4SOw/oOBD)
G2300GE2
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Table of Contents
Related Manuals for Subaru LEGACY 2003
Summary of Contents for Subaru LEGACY 2003
- Page 1 EC(H4SO) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4SO) MECHANICAL ME(H4SO) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4SO) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING CO(H4SO)
- Page 2 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 LUBRICATION LU(H4SOw/oOBD) SPEED CONTROL SYSTEMS SP(H4SOw/oOBD) IGNITION IG(H4SOw/oOBD) STARTING/CHARGING SYSTEMS SC(H4SOw/oOBD) ENGINE (DIAGNOSTICS) EN(H4SOw/oOBD) G2300GE2...
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Page 3: Table Of Contents
COOLING CO(H4SO) Page General Description ..................2 Radiator Main Fan System................6 Radiator Sub Fan System .................10 Engine Coolant..................14 Water Pump ....................16 Thermostat ....................21 Radiator.....................23 Radiator Cap .....................27 Radiator Main Fan and Fan Motor ............28 Radiator Sub Fan and Fan Motor..............30 Reservoir Tank..................32 Engine Cooling System Trouble in General ..........33... -
Page 4: General Description
GENERAL DESCRIPTION COOLING 1. General Description A: SPECIFICATIONS Electric fan + Forced engine coolant circula- Cooling system tion system 2.0 L MT: Approx. 7.0 (7.4, 6.2) 2.0 L AT: Approx. 6.9 (7.3, 6.1) 2 (US qt, Imp qt) Total engine coolant capacity 2.5 L MT: Approx. - Page 5 GENERAL DESCRIPTION COOLING B: COMPONENT 1. WATER PUMP ( 1 ) ( 2 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) CO-00001 (1) Water pump ASSY (5) Gasket Tightening torque: N·m (kgf-m, ft-lb) (2) Gasket (6) Thermostat cover T1: First 12 (1.2, 8.7) Second 12 (1.2, 8.7)
- Page 6 GENERAL DESCRIPTION COOLING 2. RADIATOR AND RADIATOR FAN ( 5 ) ( 6 ) ( 5 ) ( 8 ) ( 4 ) (10) ( 7 ) ( 3 ) (11) (14) (12) (15) (14) ( 9 ) ( 2 ) (13) (16) (19)
- Page 7 GENERAL DESCRIPTION COOLING C: CAUTION • Be careful not to burn your hands, because each part in the vehicle is hot after running. • Wear working clothing, including a cap, protec- • Be sure to tighten fasteners including bolts and tive goggles, and protective shoes during opera- nuts to the specified torque.
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Page 8: Radiator Main Fan System
RADIATOR MAIN FAN SYSTEM COOLING 2. Radiator Main Fan System A: SCHEMATIC BATTERY SBF-1 IGNITION SWITCH SBF-4 NO. 18 NO. 17 B100 : 14 WITH OBD WITHOUT OBD : 13 WITH OBD : 12 WITHOUT OBD SUB FAN MAIN FAN B134 RELAY RELAY... - Page 9 RADIATOR MAIN FAN SYSTEM COOLING B: INSPECTION DETECTING CONDITION: Condition: • Engine coolant temperature is above 95°C (203°F). • Vehicle speed is below 19 km/h (12 MPH). TROUBLE SYMPTOM: • Radiator main fan does not rotate under the above conditions. Step Value CHECK POWER SUPPLY TO MAIN FAN MO-...
- Page 10 RADIATOR MAIN FAN SYSTEM COOLING Step Value CHECK POWER SUPPLY TO MAIN FAN RE- 10 V Go to step 10. Go to step 9. LAY. 1) Turn ignition switch to ON. 2) Measure voltage between main fan relay terminal and chassis ground. Connector &...
- Page 11 Check poor contact in connector between main tact connector. ARU distributor fan and ECM. service. Is there poor contact in connector between main fan motor and ECM? NOTE: Inspection by SUBARU distributor service is required, because probable cause is deterioration of multiple parts. CO(H4SO)-9...
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Page 12: Radiator Sub Fan System
RADIATOR SUB FAN SYSTEM COOLING 3. Radiator Sub Fan System A: SCHEMATIC BATTERY SBF-1 IGNITION SWITCH SBF-4 NO. 18 NO. 17 B100 : 14 WITH OBD WITHOUT OBD : 13 WITH OBD : 12 WITHOUT OBD SUB FAN MAIN FAN B134 RELAY RELAY... - Page 13 RADIATOR SUB FAN SYSTEM COOLING B: INSPECTION NOTE: Radiator sub fan system is for model with A/C. DETECTING CONDITION: Condition (1): • Engine coolant temperature is below 95°C (203°F). • A/C switch is turned ON. • Vehicle speed is below 19 km/h (12 MPH). Condition (2): •...
- Page 14 RADIATOR SUB FAN SYSTEM COOLING Step Value CHECK POWER SUPPLY TO SUB FAN RE- 10 V Go to step 6. Go to step 7. LAY. 1) Turn ignition switch to OFF. 2) Remove sub fan relay from A/C relay holder. 3) Measure voltage between sub fan relay ter- minal and chassis ground.
- Page 15 Check poor contact in connector between sub tact connector. ARU distributor fan and ECM. service. Is there poor contact in connector between sub fan motor and ECM? NOTE: Inspection by SUBARU distributor service is required, because probable cause is deterioration of multiple parts. CO(H4SO)-13...
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Page 16: Engine Coolant
Approx. 6.7 2 (7.1 US qt, 5.9 Imp qt) CAUTION: The SUBARU Genuine Coolant containing anti- freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Cool- ant, since other coolant may cause corrosion. CO(H4SO)-14... - Page 17 The concentration and safe operating temperature necessary amount of coolant with an undiluted so- of the SUBARU coolant is shown in the diagram. lution of SUBARU genuine coolant (concentration Measuring the temperature and specific gravity of 50).
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Page 18: Water Pump
WATER PUMP COOLING 5. Water Pump 6) Disconnect radiator outlet hose and heater by- pass hose from water pump. A: REMOVAL 1) Disconnect ground cable from battery. CO-00085 7) Lower the vehicle. FU-00009 8) Remove air intake duct. 2) Lift-up the vehicle. 3) Remove under cover. - Page 19 WATER PUMP COOLING 12) Remove V-belts. 17) Remove left-hand belt cover No. 2. <Ref. to ME(H4SO)-41, REMOVAL, V-belt.> 13) Remove timing belt. <Ref. to ME(H4SO)-46, REMOVAL, Timing Belt Assembly.> 14) Remove automatic belt tension adjuster. CO-00019 18) Remove tensioner bracket. CO-00016 15) Remove belt idler No.
- Page 20 WATER PUMP COOLING B: INSTALLATION 4) Install left-hand camshaft sprockets by using ST. ST 18231AA010 CAMSHAFT SPROCKET 1) Install water pump onto left-hand cylinder block. WRENCH NOTE: NOTE: • Replace gasket with a new one. Camshaft sprocket wrench (499207100) is also •...
- Page 21 WATER PUMP COOLING 10) Install reservoir tank. 15) Connect connectors to radiator main fan (A) and sub fan (B) motors. ( B ) ( A ) CO-00087 CO-00084 11) Connect overflow hose. 16) Install under cover. CO-00086 LU-00095 12) Install air intake duct. 17) Lower the vehicle.
- Page 22 WATER PUMP COOLING C: INSPECTION 1) Check water pump bearing for smooth rotation. 2) Check water pump pulley for abnormalities. 3) Using a dial gauge, measure impeller runout in thrust direction while rotating the pulley. “Thrust” runout limit: 0.5 mm (0.020 in) CO-00028 4) Check clearance between impeller and pump case.
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Page 23: Thermostat
THERMOSTAT COOLING 6. Thermostat B: INSTALLATION 1) Install the thermostat in the water pump, and in- A: REMOVAL stall the thermostat cover together with a gasket. 1) Lift-up the vehicle. NOTE: 2) Remove under cover. • Replace gasket with a new one. •... - Page 24 THERMOSTAT COOLING Specified value: Starts to open: With OBD: 80 — 84 ° ° ° ° C (176 — 183 ° ° ° ° F) Without OBD: 76.0 — 80.0 ° ° ° ° C (169 — 176 ° ° ° ° F) Fully opens: With OBD: 95 °...
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Page 25: Radiator
RADIATOR COOLING 7. Radiator 6) Disconnect radiator outlet hose from thermostat cover. A: REMOVAL 1) Disconnect battery ground cable. CO-00105 7) Disconnect ATF cooler hoses from radiator. (AT FU-00009 vehicles only) 2) Lift-up the vehicle. 3) Remove under cover. ( A ) CO-00088 LU-00095 (A) Clip... - Page 26 RADIATOR COOLING 11) Remove reservoir tank. 16) Lift radiator up and away from vehicle. CO-00092 CO-00087 12) Disconnect radiator inlet hose from engine. B: INSTALLATION 1) Attach radiator mounting cushions to holes on the vehicle. CO-00089 13) Remove radiator upper brackets. CO-00093 2) Install radiator while fitting radiator pins to cush- ions.
- Page 27 RADIATOR COOLING 3) Install radiator brackets and tighten bolts. 7) Install air intake duct. Tightening torque: 18 N·m (1.8 kgf-m, 13.0 ft-lb) IN-00059 8) Lift-up the vehicle. 9) Connect ATF cooler hoses. (AT vehicles only) CO-00090 4) Attach power steering hose to the radiator. ( A ) CO-00088 CO-00091...
- Page 28 RADIATOR COOLING 12) Install under cover. C: INSPECTION 1) Remove radiator cap, top off radiator, and attach tester to radiator in place of cap. LU-00095 13) Lower the vehicle. CO-00094 14) Connect battery ground cable. 2) Apply a pressure of 157 kPa (1.6 kg/cm , 23 psi) to radiator to check if: (1) Engine coolant leaks at/around radiator.
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Page 29: Radiator Cap
RADIATOR CAP COOLING 8. Radiator Cap A: INSPECTION 1) Attach radiator cap to tester. CO-00044 2) Increase pressure until tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for five to six seconds. Standard pressure: 93 —... -
Page 30: Radiator Main Fan And Fan Motor
RADIATOR MAIN FAN AND FAN MOTOR COOLING 9. Radiator Main Fan and Fan 7) Disconnect overflow hose. Motor A: REMOVAL 1) Disconnect battery ground cable. CO-00086 8) Remove reservoir tank. FU-00009 2) Lift-up the vehicle. 3) Remove under cover. CO-00087 9) Remove radiator main fan motor assembly. - Page 31 RADIATOR MAIN FAN AND FAN MOTOR COOLING B: INSTALLATION 3) Remove bolts which install fan motor onto shroud. Install in the reverse order of removal. NOTE: When the main fan motor assembly cannot be in- stalled as is, loosen the sub fan motor assembly securing bolts to install it.
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Page 32: Radiator Sub Fan And Fan Motor
RADIATOR SUB FAN AND FAN MOTOR COOLING 10.Radiator Sub Fan and Fan 7) Remove bolts which hold sub fan shroud to radi- ator. Motor 8) Remove radiator sub fan shroud through the un- der side of vehicle. A: REMOVAL 1) Disconnect battery ground cable. CO-00101 FU-00009 B: INSTALLATION... - Page 33 RADIATOR SUB FAN AND FAN MOTOR COOLING 3) Remove bolts which install fan motor onto shroud. CO-00098 D: ASSEMBLY Assemble in the reverse order of disassembly. NOTE: ・Refer to “COMPONENT” for tightening torque. <Ref. to CO(H4SO)-3, COMPONENT, General De- scription.> E: INSPECTION 1) Connect battery positive (+) terminal to terminal No.
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Page 34: Reservoir Tank
RESERVOIR TANK COOLING 11.Reservoir Tank A: REMOVAL 1) Disconnect overflow hose from radiator filler neck position. 2) Remove bolts which install reservoir tank onto radiator main fan shroud. 3) Remove reservoir tank. CO-00087 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 4.9N·m (0.50 kgf-m, 3.6 ft-lb) CO-00087... -
Page 35: Engine Cooling System Trouble In General
ENGINE COOLING SYSTEM TROUBLE IN GENERAL COOLING 12.Engine Cooling System Trouble in General A: INSPECTION Trouble Corrective action Replenish engine coolant, inspect for leakage, and a. Insufficient engine coolant repair. b. Loose timing belt Repair or replace timing belt tensioner. c. - Page 36 ENGINE COOLING SYSTEM TROUBLE IN GENERAL COOLING MEMO: CO(H4SO)-34...