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Subaru LEGACY 2003 Service Manual

Engine section 1
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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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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 STARTING/CHARGING SYSTEMS SC(H4SO) Page General Description ..................2 Starter ......................6 Generator ....................14 Battery.......................20...

  • Page 4: General Description

    GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 1. General Description A: SPECIFICATIONS Item Designation Type Reduction type Vehicle model Model M000T83981 M001T86481 Manufacturer Mitsubishi Electric Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW Direction of rotation Counterclockwise (when observed from pinion) Number of pinion teeth Voltage 11 V...
  • Page 5 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS B: COMPONENT 1. STARTER ( 2 ) ( 4 ) (11) (10) ( 9 ) ( 3 ) ( 8 ) ( 1 ) ( 7 ) ( 6 ) (17) ( 5 ) (16) (15) (14) (13) (12)
  • Page 6 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 2. GENERATOR ( 7 ) ( 6 ) ( 5 ) ( 4 ) ( 3 ) ( 2 ) ( 1 ) (13) (12) (11) (10) ( 9 ) ( 8 ) SC-00163 (1) Pulley nut (7) Bearing (13) Terminal...
  • Page 7 GENERAL DESCRIPTION STARTING/CHARGING SYSTEMS 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: Starter

    STARTER STARTING/CHARGING SYSTEMS 2. Starter 4) Disconnect the connector and terminal from starter. A: REMOVAL 1) Disconnect the ground cable from battery. ( A ) ( B ) SC-00006 FU-00009 (A) Terminal (B) Connector 2) Remove the air cleaner case. <Ref.
  • Page 9 STARTER STARTING/CHARGING SYSTEMS C: DISASSEMBLY NOTE: Before removal, confirm the attachment locations 1. STARTER ASSEMBLY of brush holder and rear bracket. 1) Loosen nut which holds terminal M of switch as- sembly, and disconnect connector. ( A ) ( B ) ( B ) ( A ) ( C )
  • Page 10 STARTER STARTING/CHARGING SYSTEMS 5) Remove packing A, three planetary gears, pack- (2) Remove ring, stopper and clutch from shaft. ing B and plate. NOTE: ( A ) Before removal, confirm the inserting location of packing A. ( B ) ( D ) ( C ) ( A ) ( B )
  • Page 11 STARTER STARTING/CHARGING SYSTEMS D: ASSEMBLY • Lever direction Assemble in the reverse order of disassembly. Do the following: NOTE: When assembling, apply grease to the following parts. • Front and rear bracket sleeve bearing • Armature shaft gear • Outer periphery of plunger •...
  • Page 12 STARTER STARTING/CHARGING SYSTEMS 5) Install brush holder in alignment with Yoke’s 3) Depth of segment mold groove. Check the depth of segment mold. Depth of segment mold: 0.5 mm (0.020 in) ( B ) ( C ) SC-00159 ( A ) 6) Install rear bracket.
  • Page 13 STARTER STARTING/CHARGING SYSTEMS 5) Armature ground test 2) Brush movement Using a circuit tester, touch one probe to the com- Be sure brush moves smoothly inside brush holder. mutator segment and the other to shaft. There 3) Brush spring force should be no continuity.
  • Page 14 STARTER STARTING/CHARGING SYSTEMS 2) Disconnect the connector from terminal M, and Three performance tests, no-load test, load test, then connect the positive terminal of battery and and lock test, are presented here; however, if the terminal M using a lead wire and ground terminal to load test and lock test cannot be performed, carry starter body.
  • Page 15 STARTER STARTING/CHARGING SYSTEMS 3) Lock test With starter stalled, or not rotating, measure the torque developed and current draw when the volt- age is adjusted to the specified voltage. Lock test (Standard): Voltage / Current AT: 3.5 V / 940 A or less MT: 4 V / 650 A or less Torque AT: 28.9 N·m (2.95 kgf-m, 21.3 ft-lb) or more...

  • Page 16: Generator

    GENERATOR STARTING/CHARGING SYSTEMS 3. Generator B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: 1) Disconnect the ground cable from battery. Check and adjust the V-belt tension. <Ref. to ME(H4SO)-42, INSPECTION, V-belt.> FU-00009 2) Disconnect the connector and terminal from SC-00032 generator.
  • Page 17 GENERATOR STARTING/CHARGING SYSTEMS 3) Then insert the tip of a flat tip screwdriver into the (1) Remove the bolt, and then remove the bear- gap between stator core and front cover. Pry them ing retainer. apart to disassemble. SC-00081 SC-00080 (2) Firmly install an appropriate tool (such as a fit socket wrench) to bearing inner race.
  • Page 18 GENERATOR STARTING/CHARGING SYSTEMS time because the rectifier cannot withstand (2) Remove the cover B. heat very well. SC-00087 SC-00083 (A) Cover B 8) Remove the IC regulator as follows. (1) Remove the screws which secure IC regula- (3) Separate the brush from connection to re- move.
  • Page 19 GENERATOR STARTING/CHARGING SYSTEMS (3) Remove the nut of terminal B, and then re- D: ASSEMBLY move the rectifier. To assemble, reverse order of disassembly. 1) Pulling up brush Before assembling, press the brush down into brush holder, and then fix them in that position by passing a [1 mm (0.04 in) dia.
  • Page 20 GENERATOR STARTING/CHARGING SYSTEMS E: INSPECTION 2. ROTOR 1) Slip ring surface 1. DIODE Inspect the slip rings for contamination or any CAUTION: roughness of the sliding surface. Repair the slip Never use a mega tester (measuring use for ring surface using a lathe or sand paper. high voltage) or any other similar measure for 2) Slip ring outer diameter this test;...
  • Page 21 GENERATOR STARTING/CHARGING SYSTEMS 3. STATOR 4. BRUSH 1) Continuity test 1) Measure the length of each brush. If wear ex- Inspect the stator coil for continuity between each ceeds the service limit, replace the brush. Each end of the lead wires. If resistance is 1 M Ω or brush has the service limit mark (A) on it.

  • Page 22: Battery

    BATTERY STARTING/CHARGING SYSTEMS 4. Battery • For safety, in case an explosion does occur, wear eye protection or shield your eyes when A: REMOVAL working near any battery. Never lean over a bat- tery. 1) Remove battery cable holder (A) from battery rod.
  • Page 23 BATTERY STARTING/CHARGING SYSTEMS 2) Measuring the specific gravity of the electrolyte 4. QUICK CHARGING in the battery will disclose the state of charge of the Quick charging is a method in which the battery is battery. The relation between the specific gravity charged in a short period of time with a relatively and the state of charge is as shown in figure.
  • Page 24 BATTERY STARTING/CHARGING SYSTEMS MEMO: SC(H4SO)-22...