Subaru legacy 2003 Service Manual
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Subaru legacy 2003 Service Manual

Subaru legacy 2003 Service Manual

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2003 LEGACY SERVICE MANUAL

ENGINE SECTION 3

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)
FU(H4DOSTC)
EC(H4DOSTC)
IN(H4DOSTC)
ME(H4DOSTC)
EX(H4DOSTC)
CO(H4DOSTC)
LU(H4DOSTC)
SP(H4DOSTC)
IG(H4DOSTC)
SC(H4DOSTC)
EN(H4DOSTC)
G2300GE4

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  • Page 1: Engine Section

    EC(H4DOSTC) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H4DOSTC) MECHANICAL ME(H4DOSTC) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H4DOSTC) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING CO(H4DOSTC)

  • Page 3: Table Of Contents

    COOLING CO(H4DOSTC) Page General Description ..................2 Radiator Main Fan System................7 Radiator Sub Fan System .................11 Engine Coolant..................15 Water Pump ....................17 Thermostat ....................21 Radiator.....................23 Radiator Cap .....................27 Radiator Main Fan and Fan Motor ............28 Radiator Sub Fan and Fan Motor..............30 Reservoir Tank..................32 Coolant Filler Tank ..................33 Engine Cooling System Trouble in General ..........34...

  • Page 4: General Description

    GENERAL DESCRIPTION COOLING 1. General Description A: SPECIFICATIONS Electric fan + Forced engine coolant circulation sys- Cooling system MT: Approx. 7.7 (8.1, 6.8) 2 (US qt, Imp qt) Total engine coolant capacity AT: Approx. 7.6 (8.0, 6.7) Type Centrifugal impeller type 20 2 (5.3 US gal, 4.4 Imp gal)/min.
  • Page 5 GENERAL DESCRIPTION COOLING B: COMPONENT 1. WATER PUMP ( 5 ) ( 8 ) ( 4 ) ( 7 ) ( 3 ) ( 6 ) ( 2 ) ( 1 ) CO-00201 (1) Thermostat case (5) Gasket Tightening torque: N·m (kgf-m, ft-lb) (2) Gasket (6) Heater by-pass hose T1: First 12 (1.2, 8.7)
  • Page 6 GENERAL DESCRIPTION COOLING 2. RADIATOR AND RADIATOR FAN (19) (18) (17) (10 ) (11) (13) (22) (12) (25) (22) (14) (26) (24) (22) (22) (21) (22) (16) (23) (27) (20) (22) (15) CO-00145 (1) Radiator lower cushion (14) Radiator main fan and main fan (25) ATF outlet hose B (AT vehicles motor ASSY only)
  • Page 7 GENERAL DESCRIPTION COOLING C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove contamination including dirt and corro- sion before removal, installation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
  • Page 8 GENERAL DESCRIPTION COOLING D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977100 (MT CRANK PULLEY Used for fixing crankshaft pulley when loos- model) WRENCH ening and tightening crankshaft pulley bolts. ST-499977100 499977400 (AT CRANK PULLEY Used for fixing crankshaft pulley when loos- model) WRENCH ening and tightening crankshaft pulley bolts.

  • Page 9: Radiator Main Fan System

    RADIATOR MAIN FAN SYSTEM COOLING 2. Radiator Main Fan System A: SCHEMATIC BATTERY SBF-1 NO. 3 IGNITION SWITCH SBF-4 NO. 18 NO. 17 B100 SUB FAN MAIN FAN B137 RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR AIR CONDITIONING RELAY HOLDER B137 2 3 4 5 6 7...
  • Page 10 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 11 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 12 RADIATOR MAIN FAN SYSTEM COOLING Step Value 1 Ω CHECK HARNESS BETWEEN MAIN FAN Go to step 14. Repair open circuit RELAY AND ECM. in harness 1) Turn ignition switch to OFF. between main fan 2) Disconnect connector from ECM. relay and ECM.

  • Page 13: Radiator Sub Fan System

    RADIATOR SUB FAN SYSTEM COOLING 3. Radiator Sub Fan System A: SCHEMATIC BATTERY SBF-1 NO. 3 IGNITION SWITCH SBF-4 NO. 18 NO. 17 B100 SUB FAN MAIN FAN B137 RELAY RELAY MAIN FAN SUB FAN MOTOR MOTOR AIR CONDITIONING RELAY HOLDER B137 2 3 4 5 6 7...
  • Page 14 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 15 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 16 RADIATOR SUB FAN SYSTEM COOLING Step Value 1 Ω CHECK HARNESS BETWEEN SUB FAN RE- Go to step 13. Repair open circuit LAY TERMINAL AND SUB FAN MOTOR in harness CONNECTOR. between sub fan Measure resistance of harness between sub motor and sub fan fan motor connector and sub fan relay termi- relay connector.

  • Page 17: Engine Coolant

    TEMPERATURE Remove radiator cap so that engine coolant will drain faster. The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram. Measuring the temperature and specific gravity of the coolant will provide this information. [Example] If the coolant temperature is 25°C (77°F) and its...
  • Page 18 2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 liters (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU cool- ant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only.

  • Page 19: Water Pump

    WATER PUMP COOLING 5. Water Pump 9) Disconnect water by-pass hose (C) and oil cool- er hose (D). A: REMOVAL 1) Disconnect ground cable from battery. ( C ) ( A ) ( B ) ( D ) CO-00148 10) Lower the vehicle. FU-00009 11) Remove air intake duct.
  • Page 20 WATER PUMP COOLING 15) Remove V-belts. 23) Remove left-hand belt cover No. 2. <Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.> 16) Remove timing belt. <Ref. to ME(H4DOSTC)-47, REMOVAL, Timing Belt Assembly.> 17) Remove automatic belt tension adjuster. 18) Remove belt idler (B). 19) Remove belt idler No.
  • Page 21 WATER PUMP COOLING 2) Install tensioner bracket. 8) Install automatic belt tension adjuster which ten- sion rod is held with pin. <Ref. to ME(H4DOSTC)- Tightening torque: 49, BELT IDLER AND AUTOMATIC BELT TEN- 25 N·m (2.5 kgf-m, 18.1 ft-lb) SION ADJUSTER ASSEMBLY, INSTALLATION, Timing Belt Assembly.>...
  • Page 22 WATER PUMP COOLING 17) Connect water by-pass hose (C) and oil cooler 24) Fill coolant. <Ref. to CO(H4DOSTC)-15, FILL- hose (D). ING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.> C: INSPECTION ( C ) 1) Check water pump bearing for smooth rotation. 2) Check water pump pulley for abnormalities.

  • 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. 3) Drain engine coolant completely.
  • Page 24 THERMOSTAT COOLING C: INSPECTION Replace the thermostat if the valve does not close completely at an ambient temperature or if the fol- lowing test shows unsatisfactory results. Immerse the thermostat and a thermometer in wa- ter. Raise water temperature gradually, and mea- sure the temperature and valve lift when the valve begins to open and when the valve is fully opened.

  • Page 25: Radiator

    RADIATOR COOLING 7. Radiator 7) Disconnect ATF cooler hoses from radiator. (AT vehicles only) A: REMOVAL 1) Disconnect battery ground cable. ( A ) CO-00088 FU-00009 (A) Clip 2) Lift-up the vehicle. 8) Lower the vehicle. 3) Remove under cover. 9) Remove air intake duct.
  • Page 26 RADIATOR COOLING 13) Disconnect radiator inlet hose (A) and engine 17) Lift radiator up and away from vehicle. coolant filler tank hose (B) from radiator. CO-00092 CO-00157 B: INSTALLATION 1) Attach radiator mounting cushions to holes on the vehicle. CO-00158 14) Remove radiator upper brackets.
  • Page 27 RADIATOR COOLING Tightening torque: 6) Install reservoir tank. 18 N·m (1.8 kgf-m, 13.0 ft-lb) Tightening torque: 4.9 N·m (0.50 kgf-m, 3.6 ft-lb) CO-00090 4) Attach power steering hose to the radiator. CO-00087 7) Connect overflow hose. 8) Install air intake duct. CO-00091 5) Connect radiator inlet hose (A) and engine cool- ant filler tank hose (B) to radiator.
  • Page 28 RADIATOR COOLING 11) Connect connectors to radiator main fan motor C: INSPECTION (A) and sub fan motor (B). 1) Remove radiator cap, top off radiator, and attach tester to radiator in place of cap. ( B ) ( A ) CO-00084 CO-00159 12) Connect radiator outlet hose.

  • 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 8) Remove reservoir tank. Motor A: REMOVAL 1) Disconnect battery ground cable. CO-00087 9) Remove radiator main fan motor assembly. FU-00009 2) Lift-up the vehicle. 3) Remove under cover. 4) Disconnect connector of main fan motor.
  • Page 31 RADIATOR MAIN FAN AND FAN MOTOR COOLING C: DISASSEMBLY Tightening torque: 4.4 N·m (0.45 kgf-m, 3.3 ft-lb) 1) Remove clip which holds motor connector onto shroud. CO-00098 CO-00046 Tightening torque: 2) Remove nut which holds fan itself onto fan motor 3.4 N·m (0.35 kgf-m, 2.5 ft-lb) and shroud assembly.

  • Page 32: Radiator Sub Fan And Fan Motor

    RADIATOR SUB FAN AND FAN MOTOR COOLING 10.Radiator Sub Fan and Fan 8) Remove radiator sub fan shroud through the un- der side of vehicle. Motor A: REMOVAL 1) Disconnect battery ground cable. CO-00101 B: INSTALLATION Install in the reverse order of removal. FU-00009 Tightening torque: 2) Lift-up the vehicle.
  • Page 33 RADIATOR SUB FAN AND FAN MOTOR COOLING 2) Remove nut which holds fan itself onto fan motor E: INSPECTION and shroud assembly. 1) Connect battery positive (+) terminal to terminal No. 2, and negative (−) terminal to terminal No. 1 of sub fan motor connector.

  • 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: Coolant Filler Tank

    COOLANT FILLER TANK COOLING 12.Coolant Filler Tank B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL Tightening torque: WARNING: T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb) The radiator is pressurized. Wait until the en- T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb) gine cools down before working on the radia- tor.

  • Page 36: Engine Cooling System Trouble In General

    ENGINE COOLING SYSTEM TROUBLE IN GENERAL COOLING 13.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.

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