Subaru LEGACY 2003 Service Manual
  1. Manuals
  2. Brands
  3. Subaru Manuals
  4. Automobile
  5. 2003 Legacy
  6. Service manual
Subaru LEGACY 2003 Service Manual

Subaru LEGACY 2003 Service Manual

Hide thumbs Also See for LEGACY 2003:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Service Manual, Owner's Manual
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

Advertisement

Table of Contents
loading

Related Manuals for Subaru LEGACY 2003

Summary of Contents for Subaru LEGACY 2003

  • Page 1: Engine Section

    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...

  • Page 3: Table Of Contents

    LUBRICATION LU(H4SO) Page General Description ..................2 Oil Pressure System ...................6 Engine Oil....................8 Oil Pump ....................10 Oil Pan and Strainer..................14 Oil Pressure Switch...................17 Engine Oil Filter..................18 Engine Lubrication System Trouble in General.........19...

  • Page 4: General Description

    GENERAL DESCRIPTION LUBRICATION 1. General Description A: SPECIFICATIONS Lubrication method Forced lubrication Pump type Trochoid type Inner rotor Number of teeth Outer rotor Outer rotor diameter × thickness 78 × 7 mm (3.07 × 0.28 in) STANDARD 0.04 — 0.14 mm (0.0016 — 0.0055 in) Tip clearance between inner and outer rotor LIMIT 0.18 mm (0.0071 in)
  • Page 5 GENERAL DESCRIPTION LUBRICATION B: COMPONENT (13) (16) (15) (14) (12) (17) (11) (18) (24) (10) ( 9 ) ( 8 ) ( 7 ) (19) ( 6 ) (20) (27) ( 5 ) (21) ( 4 ) ( 3 ) ( 2 ) ( 1 ) (22)
  • Page 6 GENERAL DESCRIPTION LUBRICATION C: CAUTION • Wear working clothing, including a cap, protec- tive goggles, and protective shoes during opera- tion. • Remove dirt and corrosion before removal, in- stallation or disassembly. • Keep the disassembled parts in order and pro- tect them from dust or dirt.
  • Page 7 GENERAL DESCRIPTION LUBRICATION D: PREPARATION TOOL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977100 CRANKSHAFT Used for stopping rotation of crankshaft pulley PULLEY when loosening and tightening crankshaft pulley WRENCH bolt. (2500 cc model) ST-499977100 499977400 CRANKSHAFT Used for stopping rotation of crankshaft pulley PULLEY when loosening and tightening crankshaft pulley WRENCH...

  • Page 8: Oil Pressure System

    OIL PRESSURE SYSTEM LUBRICATION 2. Oil Pressure System A: SCHEMATIC BATTERY NO.5 IGNITION RELAY OIL PRESSURE SWITCH (GREEN) B21 (GRAY) A1 A2 A4 A5 A6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 B1 B2 B4 B5 B6 C5 C6 9 10...
  • Page 9 OIL PRESSURE SYSTEM LUBRICATION B: INSPECTION Step Value CHECK COMBINATION METER. Warning light goes on. Go to step 2. Repair or replace 1) Turn ignition switch to ON. (engine OFF) the combination 2) Check other warning lights. meter. <Ref. to Does the warning lights go on? IDI-4, INSPEC- TION, Combina-...

  • Page 10: Engine Oil

    When replenishing oil, it does not matter if the oil to be added is a different brand from that in the engine; however, use oil having the ILSAC LU-00094 or API classification and SAE viscosity No. des- 3) Replace drain plug gasket. ignated by SUBARU. LU(H4SO)-8...
  • Page 11 ENGINE OIL LUBRICATION NOTE: If vehicle is used in desert areas with very high tem- peratures or for other heavy duty applications, the following viscosity oils may be used: API classifica- tion: SL, SJ or SH SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W- 6) Close engine oil filler cap.

  • Page 12: Oil Pump

    OIL PUMP LUBRICATION 4. Oil Pump 9) Remove crankshaft pulley by using ST. ST 499977100 CRANKSHAFT PULLEY A: REMOVAL WRENCH (2500 cc model) 1) Disconnect battery ground cable. ST 499977400 CRANKSHAFT PULLEY WRENCH (2000 cc model) FU-00009 LU-00012 2) Lift-up the vehicle. 3) Remove under cover.
  • Page 13 OIL PUMP LUBRICATION 14) Remove oil pump by using flat bladed screw- CAUTION: driver. Make sure the oil seal lip is not folded. CAUTION: 6) Install oil pump. Be careful not to scratch mating surfaces of Tightening torque: cylinder block and oil pump. 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) LU-00016 LU-00019...
  • Page 14 OIL PUMP LUBRICATION D: ASSEMBLY E: INSPECTION 1) Install front oil seal by using ST. 1. TIP CLEARANCE ST 499587100 OIL SEAL INSTALLER Measure the tip clearance of rotors. If the clearance NOTE: exceeds the limit, replace rotors as a set. Use a new oil seal.
  • Page 15 OIL PUMP LUBRICATION 3. SIDE CLEARANCE Measure clearance between oil pump inner rotor and pump cover. If the clearance exceeds the limit, replace rotor or pump body. Side clearance: Standard 0.02 — 0.07 mm (0.0008 — 0.0028 in) Limit 0.12 mm (0.0047 in) LU-00025 4.

  • Page 16: Oil Pan And Strainer

    OIL PAN AND STRAINER LUBRICATION 5. Oil Pan and Strainer 7) Support engine with a lifting device and wire ropes. A: REMOVAL 1) Set the vehicle on lift arms. 2) Remove front wheels. 3) Disconnect battery ground cable. LU-00028 8) Lift-up the vehicle. CAUTION: When lifting up the vehicle, wire rope must be FU-00009...
  • Page 17 OIL PAN AND STRAINER LUBRICATION 14) Insert oil pan cutter blade between cylinder B: INSTALLATION block-to-oil pan clearance. CAUTION: CAUTION: Before installing oil pan, clean sealant from oil Do not use a screwdriver or similar tool in place pan and engine block. of oil pan cutter.
  • Page 18 OIL PAN AND STRAINER LUBRICATION Tightening torque: 10) Install pitching stopper. 5 N·m (0.5 kgf-m, 3.6 ft-lb) Tightening torque: T1: 50 N·m (5.1 kgf-m, 37 ft-lb) T2: 58 N·m (5.9 kgf-m, 43 ft-lb) LU-00051 4) Lower engine onto front crossmember. 5) Tighten nuts which secure front cushion rubber ME-00218 onto front crossmember.

  • Page 19: Oil Pressure Switch

    OIL PRESSURE SWITCH LUBRICATION 6. Oil Pressure Switch 2) Install oil pressure switch onto engine block. Tightening torque: A: REMOVAL 25 N·m (2.5 kgf-m, 18.1 ft-lb) 1) Remove generator from bracket. <Ref. to SC(H4SO)-14, REMOVAL, Generator.> 2) Disconnect terminal from oil pressure switch. LU-00037 3) Connect terminal of oil pressure switch.

  • Page 20: Engine Oil Filter

    ENGINE OIL FILTER LUBRICATION 7. Engine Oil Filter A: REMOVAL 1) Remove under cover. <Ref. to EI-13, REMOV- AL, Front Under Cover.> 2) Remove oil filter with ST. ST 498547000 OIL FILTER WRENCH LU-00100 B: INSTALLATION 1) Get a new oil filter and thinly apply engine oil to the seal rubber.

  • Page 21: Engine Lubrication System Trouble In General

    ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL LUBRICATION 8. Engine Lubrication System Trouble in General A: INSPECTION Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists. Trouble Possible cause Corrective action Cracked diaphragm or oil leakage within switch Replace. 1) Oil pressure switch failure Broken spring or seized contacts...
  • Page 22 ENGINE LUBRICATION SYSTEM TROUBLE IN GENERAL LUBRICATION MEMO: LU(H4SO)-20...

Table of Contents