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Subaru LEGACY 2003 Service Manual

Engine section 2
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2003 LEGACY SERVICE MANUAL

ENGINE SECTION 2

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(H6DO)
EC(H6DO)
IN(H6DO)
ME(H6DO)
EX(H6DO)
CO(H6DO)
LU(H6DO)
SP(H6DO)
IG(H6DO)
SC(H6DO)
EN(H6DO)
G2300GE3

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Summary of Contents for Subaru LEGACY 2003

  • Page 1: Engine Section

    EC(H6DO) (AUX. EMISSION CONTROL DEVICES) INTAKE (INDUCTION) IN(H6DO) MECHANICAL ME(H6DO) This service manual has been prepared to provide SUBARU service personnel EXHAUST EX(H6DO) with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. COOLING CO(H6DO)

  • Page 3: Table Of Contents

    EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) EC(H6DO) Page General Description ..................2 Front Catalytic Converter ................3 Rear Catalytic Converter................6 Canister.......................7 Purge Control Solenoid Valve ..............8 EGR Valve ....................10 Two-way valve ..................12...

  • Page 4: General Description

    GENERAL DESCRIPTION EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 1. General Description A: 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. •...

  • Page 5: Front Catalytic Converter

    FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 2. Front Catalytic Converter 9) Separate front exhaust pipe from rear exhaust pipe. A: REMOVAL CAUTION: 1) Set the vehicle on the lift. Be careful, exhaust pipe is hot. 2) Remove battery. 3) Remove air cleaner case and air intake duct.
  • Page 6 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 12) Separate front catalytic converter (RH) from 3) Tighten nuts which hold front exhaust pipe onto front exhaust pipe. cylinder heads. Tightening torque: 30 N·m (3.1 kgf-m, 22.4 ft-lb) RH side LH side EX-00062 B: INSTALLATION...
  • Page 7 FRONT CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6) Connect connector to rear oxygen sensor con- nector. EX-00058 7) Install front oxygen (A/F) sensor harness to the clips attached to the cylinder head covers. 8) Install under cover. 9) Lower the vehicle. 10) Connect front oxygen (A/F) sensor connector.

  • Page 8: Rear Catalytic Converter

    REAR CATALYTIC CONVERTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3. Rear Catalytic Converter A: REMOVAL The front and rear catalytic converter are integrated into one unit. Therefore, the removal and installa- tion procedures are the same as the those for the front catalytic converter.

  • Page 9: Canister

    CANISTER EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 4. Canister A: REMOVAL 1) Lift-up the vehicle. 2) Loosen two clamps which hold two canister hos- es, and disconnect evaporation hoses from canis- ter. EC-00127 3) Remove canister from body. EC-00128 B: INSTALLATION Install in the reverse order of removal.

  • Page 10: Purge Control Solenoid Valve

    PURGE CONTROL SOLENOID VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5. Purge Control Solenoid Valve (5) Remove power steering tank from the bracket by pulling it upward. A: REMOVAL 1) Disconnect battery ground cable. ME-00451 (6) Place power steering pump on the right side FU-00009 wheel apron.
  • Page 11 PURGE CONTROL SOLENOID VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 5) Take out purge control solenoid valve through the bottom of the intake manifold. B: INSTALLATION Install in the reverse order of removal. Tightening torque: 19 N·m (1.9 kgf-m, 14 ft-lb) EC-00110 CAUTION: Carefully connect the evaporation hoses.

  • Page 12: Egr Valve

    EGR VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 6. EGR Valve 6) Disconnect connector from EGR valve. A: REMOVAL 1) Disconnect battery ground cable. EC-00114 B: INSTALLATION FU-00009 NOTE: Replace old gaskets with new one. 2) Remove air intake chamber. <Ref. to IN(H6DO)- 1) Connect connector EGR valve.
  • Page 13 EGR VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 3) Install EGR pipe to EGR valve and cylinder head. Tightening torque: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) EC-00112 4) Install starter. <Ref. to SC(H6DO)-6, INSTALLA- TION, Starter.> 5) Install air intake chamber. <Ref. to IN(H6DO)-6, INSTALLATION, Air Intake Chamber.>...

  • Page 14: Two-Way Valve

    TWO-WAY VALVE EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES) 7. Two-way valve A: REMOVAL 1) Lift-up the vehicle. 2) Disconnect hoses from two-way valve. EC-00129 3) Remove two-way valve with bracket as a single unit from body. EC-00130 4) Remove two-way valve from bracket. B: INSTALLATION Install in the reverse order of removal.