Subaru Legacy 2003 Service Manual
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Subaru Legacy 2003 Service Manual

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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: Table Of Contents

    FUEL INJECTION (FUEL SYSTEMS) FU(H4SOw/oOBD) Page General Description ..................2 Throttle Body.....................13 Intake Manifold..................14 Engine Coolant Temperature Sensor............26 Crankshaft Position Sensor...............27 Camshaft Position Sensor.................28 Knock Sensor....................29 Throttle Position Sensor................30 Intake Air Temperature and Pressure Sensor...........32 Idle Air Control Solenoid Valve ..............33 Fuel Injector ....................34 Oxygen Sensor ..................40 Engine Control Module................42...

  • Page 4: General Description

    GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Model 64 2 (16.9 US gal, 14.1 Imp gal) Capacity Fuel tank Location Under rear seat Type Impeller Shutoff discharge pressure 370 — 677 kPa (3.77 — 6.9 kg/cm , 53.6 —...
  • Page 5 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) MEMO: FU(H4SOw/oOBD)-3...
  • Page 6 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD ( 2 ) (20) ( 4 ) ( 3 ) ( 7 ) ( 8 ) ( 5 ) ( 2 ) ( 6 ) (22) (13) (20) ( 9 ) ( 4 ) ( 3 ) (14)
  • Page 7 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Intake manifold gasket RH (12) Fuel pipe protector LH (22) Plug cord holder RH (2) Fuel injector pipe (13) Intake air temperature and pres- sure sensor (3) Fuel injector Tightening torque: N.m (kgf-m, ft-lb) (4) O-ring (14) O-ring T1: 1.5 (0.15, 1.1)
  • Page 8 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM ( 3 ) ( 1 ) ( 2 ) ( 4 ) FU-00712 (1) Gasket (4) Throttle body Tightening torque: N·m (kgf-m, ft-lb) (2) Throttle position sensor T1: 1.6 (0.16, 1.2) (3) Idle air control solenoid valve T2: 22 (2.2, 15.9) FU(H4SOw/oOBD)-6...
  • Page 9 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS FU-00414 (1) Crank angle position sensor (3) Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb) (2) Knock sensor (4) Camshaft position sensor support T1: 6.4 (0.65, 4.7) T2: 24 (2.4, 17.4) FU(H4SOw/oOBD)-7...
  • Page 10 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 4. FUEL TANK ( 6 ) (13) (28) (29) (36) (17) (34) (10) (12) (30) (14) (33) (11) (38) (16) ( 7 ) (37) ( 5 ) (31) (15) ( 9 ) ( 8 ) (22) (21) (27)
  • Page 11 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Heat sealed cover (16) Joint pipe (31) Gasket (2) Fuel tank band (17) Evaporation hose B (32) Cap (3) Protector LH (Front) (18) Jet pump hose A (33) Gasket (4) Protector RH (Front) (19) Fuel return tube (34) Fuel cut valve plate (5) Fuel tank...

  • Page 12: Fuel Line

    GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 5. FUEL LINE ( 7 ) ( 8 ) (13) ( 1 ) (11) (12) (10) ( 1 ) ( 1 ) ( 9 ) (18) ( 1 ) ( 4 ) ( 1 ) ( 6 ) ( 1 ) (14)
  • Page 13 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 6. FUEL FILLER PIPE ( 5 ) ( 4 ) ( 6 ) ( 1 ) ( 7 ) ( 2 ) ( 3 ) FU-00628 (1) Fuel filler pipe ASSY (5) Filler ring Tightening torque: N·m (kgf-m, ft-lb) (2) Clip (6) Filler cap...
  • Page 14 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) C: CAUTION • Be careful not to burn your hands, because each part on 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.

  • Page 15: Throttle Body

    THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 6) Disconnect air by-pass hose from purge control solenoid valve. A: REMOVAL ( B ) ( A ) 1) Disconnect battery ground cable. ( C ) FU-00716 FU-00009 (A) Throttle position sensor (B) Idle air control solenoid valve 2) Remove air cleaner case.

  • Page 16: Intake Manifold

    INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold NOTE: Do not disconnect power steering hose. A: REMOVAL 1) Release fuel pressure. <Ref. to FU(H4SOw/ oOBD)-45, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.> 2) Open fuel flap lid, and remove fuel filler cap. 3) Disconnect battery ground cable.
  • Page 17 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (7) Place power steering pump and tank on the 12) Remove air cleaner case stay RH and engine right side wheel apron. harness bracket, and disconnect engine harness connectors from bulkhead harness connectors. FU-00430 FU-00258 8) Disconnect spark plug cords from spark plugs.
  • Page 18 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Disconnect connector from oil pressure switch. 19) Remove bolts which hold intake manifold onto cylinder heads and then remove intake manifold. FU-00146 FU-00260 17) Disconnect connector from camshaft position sensor. B: INSTALLATION 1) Install intake manifold onto cylinder heads. NOTE: Always use new gaskets.
  • Page 19 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3) Connect connector to camshaft position sensor. 7) Connect connectors to engine coolant tempera- ture sensor. FU-00147 FU-00145 4) Connect connector to oil pressure switch. 8) Install air cleaner case stay RH and engine har- ness bracket, and connect engine harness connec- tors to bulkhead connectors.
  • Page 20 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 11) Connect PCV hose to intake manifold. (4) Install power steering pipes onto right side intake manifold protector. FU-00719 FU-00718 12) Connect spark plug cords to spark plugs. (5) Install front V-belt. 13) Install power steering pump and tank on brack- ets.
  • Page 21 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 17) Connect connector to fuel pump relay. 3) Remove ignition coil and ignitor assembly. FU-00431 FU-00722 18) Connect battery ground cable. 4) Disconnect connector from intake air tempera- ture and pressure sensor. FU-00009 FU-00723 C: DISASSEMBLY 5) Remove intake air temperature and pressure 1) Disconnect engine ground terminal from intake...
  • Page 22 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 8) Disconnect pressure regulator vacuum hose 12) Disconnect connector from purge control sole- from intake manifold. noid valve. FU-00265 FU-00728 9) Remove fuel pipe protector LH. 13) Disconnect air by-pass hose from purge control solenoid valve.
  • Page 23 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Remove purge control solenoid valve. (1) Remove fuel injector securing clip. FU-00730 FU-00733 17) Remove bolt which installs injector pipe on in- (2) Remove fuel injector while lifting up fuel in- take manifold as shown in figure. jector pipe.
  • Page 24 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 23) Remove fuel injector pipe. D: ASSEMBLY 1) Install fuel pipe assembly and pressure regula- tor, etc. to intake manifold. ( A ) FU-00735 24) Remove bolt which installs fuel pipes on intake ( B ) FU-00737 manifold.
  • Page 25 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 4) Install fuel injector pipe. NOTE: Do not forget to install the fuel injector securing clip. FU-00735 FU-00733 5) Connect left side fuel hose to injector pipe, and tighten clamp screw. 7) Tighten bolt which installs injector pipe on intake manifold.
  • Page 26 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 9) Tighten bolt which install injector pipe on intake 14) Hold engine harness by harness band (A) and manifold. harness bracket (B). Tightening torque: 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) ( A ) ( A ) ( B ) FU-00795 NOTE:...
  • Page 27 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 17) Connect pressure regulator vacuum hose to in- 20) Install intake air temperature and pressure sen- take manifold. sor. Tightening torque: 3.4 N·m (0.35 kgf-m, 2.5 ft-lb) FU-00265 18) Install throttle body to intake manifold. FU-00724 NOTE: Replace gasket with a new one.

  • Page 28: Engine Coolant Temperature Sensor

    ENGINE COOLANT TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 4. Engine Coolant Temperature Sensor A: REMOVAL 1) Disconnect battery ground cable. FU-00009 2) Remove air intake duct and air cleaner assem- bly. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake Duct.> and <Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner Case.>...

  • Page 29: Crankshaft Position Sensor

    CRANKSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 5. Crankshaft Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect battery ground cable. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) FU-00009 FU-00058 2) Remove bolt which install crankshaft position sensor to cylinder block.

  • Page 30: Camshaft Position Sensor

    CAMSHAFT POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 6. Camshaft Position Sensor 5) Remove camshaft position sensor and camshaft position sensor support as a unit. A: REMOVAL 6) Remove camshaft position sensor itself. 1) Disconnect battery ground cable. FU-00179 FU-00009 B: INSTALLATION 2) Disconnect connector from camshaft position Install in the reverse order of removal.

  • Page 31: Knock Sensor

    KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install knock sensor to cylinder block. A: REMOVAL Tightening torque: 1) Disconnect battery ground cable from battery 24 N·m (2.4 kgf-m, 17.4 ft-lb) ground terminal. NOTE: The extraction area of the knock sensor cord must be positioned at a 60°...

  • Page 32: Throttle Position Sensor

    THROTTLE POSITION SENSOR FUEL INJECTION (FUEL SYSTEMS) 8. Throttle Position Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect battery ground cable. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) CAUTION: When installing throttle position sensor, adjust to the specified data.
  • Page 33 TION TOOL, General Description.> (4) Connect Subaru Select Monitor to the data link connector (A). ( A ) FU-00435 5) Turn ignition switch to ON, and Subaru Select Monitor switch to ON. 6) Select {2. Each System Check} in Main Menu. FU(H4SOw/oOBD)-31...

  • Page 34: Intake Air Temperature And Pressure Sensor

    INTAKE AIR TEMPERATURE AND PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Intake Air Temperature and 4) Remove intake air temperature and pressure sensor. Pressure Sensor A: REMOVAL NOTE: This sensor is installed on AT vehicles only. 1) Disconnect battery ground cable. FU-00745 B: INSTALLATION Install in the reverse order of removal.

  • Page 35: Idle Air Control Solenoid Valve

    IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 10.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL Always use new gasket. 1) Disconnect battery ground cable. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) FU-00009 2) Disconnect connector from idle air control sole- FU-00747...

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