Subaru 2003 LEGACY Service Manual
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Subaru 2003 LEGACY Service Manual

Subaru 2003 LEGACY Service Manual

Engine section 3
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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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Summary of Contents for Subaru 2003 LEGACY

  • Page 1: Engine Section

    2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 3 FUEL INJECTION (FUEL SYSTEMS) FU(H4DOSTC) EMISSION CONTROL 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)

  • Page 3: Table Of Contents

    MECHANICAL ME(H4DOSTC) Page General Description ..................2 Compression .....................21 Idle Speed ....................22 Ignition Timing...................23 Intake Manifold Vacuum................24 Engine Oil Pressure ..................25 Fuel Pressure....................26 Valve Clearance..................27 Engine Assembly ..................31 Engine Mounting ..................40 Preparation for Overhaul................41 V-belt......................42 Crankshaft Pulley ..................44 Belt Cover ....................46 Timing Belt Assembly................47 Camshaft Sprocket..................55 Crankshaft Sprocket..................56...

  • Page 4: V-Belt

    CAMSHAFT SPROCKET MECHANICAL 16.Camshaft Sprocket shaft sprocket LH is identified by a projection used to monitor camshaft position sensor. A: REMOVAL 1) Remove the V-belt. <Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME(H4DOSTC)-44, REMOVAL, Crank- shaft Pulley.>...

  • Page 5: Crankshaft Sprocket

    CRANKSHAFT SPROCKET MECHANICAL 17.Crankshaft Sprocket 6) Install the V-belt. <Ref. to ME(H4DOSTC)-42, INSTALLATION, V- A: REMOVAL belt.> 1) Remove the V-belt. C: INSPECTION <Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.> 1) Check the sprocket teeth for abnormal wear and 2) Remove the crankshaft pulley. scratches.

  • Page 6: Camshaft

    CAMSHAFT MECHANICAL 18.Camshaft 9) Remove the belt cover No. 2 (RH). A: REMOVAL 1) Remove the V-belt. <Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.> 2) Remove the crankshaft pulley. <Ref. to ME(H4DOSTC)-44, REMOVAL, Crank- shaft Pulley.> 3) Remove the belt cover. <Ref. to ME(H4DOSTC)-46, REMOVAL, Belt Cov- er.>...
  • Page 7 CAMSHAFT MECHANICAL B: INSTALLATION Fluid packing: Part No. 004403007 1) Camshaft installation: THREE BOND 1215 or equivalent Apply engine oil to the cylinder head at camshaft bearing location before installing the camshaft. In- stall the camshaft so that each valves is close to or in contact with “base circle”...
  • Page 8 CAMSHAFT MECHANICAL 3) Camshaft oil seal installation: 7) Similarly, install the parts on right-hand side. Apply grease to the new oil seal lips and press onto 8) Install the belt cover No. 2 (RH). the front end of camshaft by using ST1 and ST2. Tightening torque: NOTE: 5 N·m (0.5 kgf-m, 3.6 ft-lb)
  • Page 9 CAMSHAFT MECHANICAL <Ref. to ME(H4DOSTC)-46, INSTALLATION, Belt Tightening torque: Cover.> T1: 10 N·m (1.0 kgf-m, 7.2 ft-lb) 15) Install the crankshaft pulley. T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb) <Ref. to ME(H4DOSTC)-44, INSTALLATION, Crankshaft Pulley.> 16) Install the V-belt. <Ref. to ME(H4DOSTC)-42, INSTALLATION, V- belt.>...
  • Page 10 CAMSHAFT MECHANICAL Cam base circle diameter A: 37.0 mm (1.457 in) ME-00120 6) Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, re- place the caps and cylinder head as a set. If neces- sary replace the camshaft.

  • Page 11: Cylinder Head Assembly

    CYLINDER HEAD ASSEMBLY MECHANICAL 19.Cylinder Head Assembly 11) Remove the cylinder head gasket. NOTE: A: REMOVAL Do not scratch the mating surface of cylinder head 1) Remove the V-belt. and cylinder block. <Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.> 12) Similarly, remove the right side cylinder head. 2) Remove the crankshaft pulley.
  • Page 12 CYLINDER HEAD ASSEMBLY MECHANICAL 6) Install the camshaft sprocket. <Ref. to ME(H4DOSTC)-55, INSTALLATION, Camshaft Sprocket.> 7) Install the timing belt assembly. <Ref. to ME(H4DOSTC)-49, INSTALLATION, Tim- ing Belt Assembly.> 8) Install the belt cover. <Ref. to ME(H4DOSTC)-46, INSTALLATION, Belt Cover.> 9) Install the crankshaft pulley.
  • Page 13 CYLINDER HEAD ASSEMBLY MECHANICAL D: ASSEMBLY (11) (11) (12) (10) (12) (10) ME-00003 (1) Exhaust valve (5) Intake valve oil seal (9) Valve lifter (2) Intake valve (6) Valve spring (10) Exhaust valve oil seal (3) Cylinder head (7) Retainer (11) Intake valve guide (4) Valve spring seat (8) Retainer key...
  • Page 14 CYLINDER HEAD ASSEMBLY MECHANICAL 1) Installation of valve spring and valve: NOTE: (1) Coat the stem of each valve with engine oil Uneven torque for the cylinder head nuts can and insert the valve into valve guide. cause warping. When reassembling, pay special attention to the torque so as to tighten evenly.
  • Page 15 CYLINDER HEAD ASSEMBLY MECHANICAL 3. VALVE GUIDE (3) Turn the cylinder head upside down and place ST as shown in the figure. 1) Check the clearance between valve guide and ST 18251AA020 VALVE GUIDE ADJUSTER stem. The clearance can be checked by measuring the outside diameter of valve stem and the inside diameter of valve guide with outside and inside mi- crometers respectively.
  • Page 16 CYLINDER HEAD ASSEMBLY MECHANICAL (7) Ream the inside of valve guide with ST. Valve overall length: Gently rotate the reamer clockwise while press- Intake ing it lightly into the valve guide, and return it 104.4 mm (4.110 in) also rotating clockwise. After reaming, clean the Exhaust valve guide to remove chips.
  • Page 17 CYLINDER HEAD ASSEMBLY MECHANICAL 5. VALVE SPRINGS Color of spring part: Intake [Silver] 1) Check the valve springs for damage, free length, Exhaust [Silver] and tension. Replace the valve spring if it is not within specifications presented in the table. 2) To measure the squareness of valve spring, stand the spring on a surface plate and measure its deflection at the top using a try square.
  • Page 18 CYLINDER HEAD ASSEMBLY MECHANICAL Standard: CAUTION: 0.019 — 0.057 mm (0.0007 — 0.0022 in) Make sure the reaction liquid does not contact your skin. If contact with skin occurs, immedi- Limit: ately wash the affected area with large quanti- 0.100 mm (0.0039 in) ties of water.

  • Page 19: Cylinder Block

    CYLINDER BLOCK MECHANICAL 20.Cylinder Block 16) Remove the oil cooler. (MT vehicles) A: REMOVAL NOTE: Before conducting this procedure, drain the engine oil completely if applicable. 1) Remove the intake manifold. <Ref. to FU(H4DOSTC)-15, REMOVAL, Intake ( A ) Manifold.> ( B ) 2) Remove the V-belt.
  • Page 20 CYLINDER BLOCK MECHANICAL 23) Remove the oil pump from cylinder block. NOTE: Use a flat-bladed screwdriver as shown in the fig- Be careful not to scratch the mating surface of cyl- ure when removing the oil pump. inder block and oil pump. ME-00138 ( 1 ) ( 3 )
  • Page 21 CYLINDER BLOCK MECHANICAL 24) Remove the service hole cover and service 29) Back off the bolts which connect cylinder block hole plugs using hexagon wrench [14 mm (0.55 on the side of #1 and #3 cylinders two or three in)]. turns.
  • Page 22 CYLINDER BLOCK MECHANICAL ( 5 ) ( 1 ) ( 4 ) ( 2 ) ( 4 ) ( 3 ) ( 1 ) ( 5 ) ME-00143 (1) Cylinder block (3) Crankshaft (5) Piston (2) Rear oil seal (4) Crankshaft bearing 32) Remove the rear oil seal.
  • Page 23 CYLINDER BLOCK MECHANICAL B: INSTALLATION ( 1 ) ( 4 ) ( 1 ) ( 3 ) ( 2 ) ( 3 ) ME-00144 (1) Crankshaft bearing (3) Cylinder block (4) Rear oil seal (2) Crankshaft 1) Remove oil in the mating surface of bearing and NOTE: cylinder block before installation.
  • Page 24 CYLINDER BLOCK MECHANICAL 4) Tighten the 10 mm cylinder block connecting 7) Further tighten the RH side bolts (E — J) to 90° bolts in alphabetical sequence shown in the figure. in alphabetical sequence. (LH side) Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) ( G ) ( E ) ( J )
  • Page 25 CYLINDER BLOCK MECHANICAL 11) Position the second ring gap at 180° on the re- 13) Position the upper rail gap at (G) in the figure. verse side for the top ring gap. 180˚ ˚ ME-00638 ME-00635 NOTE: 12) Position the expander rail gap at (C) in the fig- •...
  • Page 26 CYLINDER BLOCK MECHANICAL ( 5 ) ( 5 ) ( 4 ) ( 4 ) ( 3 ) ( 3 ) ( 1 ) ( 2 ) ( 2 ) ( 1 ) ME-00155 (1) Piston (4) Gasket Tightening torque ： ： ： ： N·m (kgf-m, ft-lb) (2) Piston pin (5) Service hole plug T: 70 (7.1, 51.4)
  • Page 27 CYLINDER BLOCK MECHANICAL 16) Installing piston pin: NOTE: (1) Apply a coat of engine oil to ST3, and then Use a new gasket. insert the ST3 into service hole to align piston pin hole with connecting rod small end. ST3 499017100 PISTON PIN GUIDE ME-00140 ME-00158...
  • Page 28 CYLINDER BLOCK MECHANICAL ( 5 ) ( 6 ) ( 3 ) ( 4 ) ( 2 ) ( 7 ) ( 3 ) ( 1 ) ( 2 ) ( 1 ) ME-00161 (1) Piston (5) Service hole plug Tightening torque ：...
  • Page 29 CYLINDER BLOCK MECHANICAL 22) Apply fluid packing to the matching surfaces, (2) Apply fluid packing to the matching surface and then install the oil separator cover. of oil pump. Fluid packing: Fluid packing: Part No. 004403007 Part No. 004403007 THREE BOND 1215 or equivalent THREE BOND 1215 or equivalent ( A ) ME-00163...
  • Page 30 CYLINDER BLOCK MECHANICAL 27) Install the water pump and gasket. 30) Install the oil filter using ST. ST 18332AA000 OIL FILTER WRENCH Tightening torque: 31) Install the water by-pass pipe between oil cool- First; 12 N·m (1.2 kgf-m, 8.7 ft-lb) er and water pump.
  • Page 31 CYLINDER BLOCK MECHANICAL C: DISASSEMBLY ( 1 ) ( 2 ) ( 2 ) ( 5 ) ( 4 ) ( 3 ) ( 6 ) ME-00168 (1) Connecting rod cap (3) Top ring (5) Oil ring (2) Connecting rod bearing (4) Second ring (6) Circlip 1) Remove the connecting rod cap.
  • Page 32 CYLINDER BLOCK MECHANICAL D: ASSEMBLY ( 3 ) ( 1 ) ( 1 ) ( 2 ) ( 4 ) ( 5 ) ( 6 ) ( 8 ) ( 7 ) ME-00169 (1) Connecting rod bearing (5) Second ring Tightening torque: N·m (kgf-m, ft-lb) (2) Connecting rod (6) Top ring...
  • Page 33 CYLINDER BLOCK MECHANICAL Standard diameter: Taper: A: 92.005 — 92.015 mm (3.6222 — 3.6226 Standard 0.015 mm (0.0006 in) B: 91.995 — 92.005 mm (3.6218 — 3.6222 Limit 0.050 mm (0.0020 in) Out-of-roundness: Standard 0.010 mm (0.0004 in) Limit 0.050 mm (0.0020 in) ( A ) ( B ) ( A )
  • Page 34 CYLINDER BLOCK MECHANICAL Piston grade point H: Limit of cylinder enlarging (boring): 38.7 mm (1.524 in) 0.5 mm (0.020 in) Piston outer diameter: 3. PISTON AND PISTON PIN Standard 1) Check the pistons and piston pins for damage, A: 91.985 — 91.995 mm (3.6214 — 3.6218 cracks, and wear and the piston ring grooves for wear and damage.
  • Page 35 CYLINDER BLOCK MECHANICAL 4) Check the circlip installation groove on piston for 2) Clean up the piston ring groove and piston ring. burr (A). If necessary, remove the burr from groove 3) Squarely place the piston ring and oil ring in cyl- so that the piston pin can lightly move.
  • Page 36 CYLINDER BLOCK MECHANICAL 5. CONNECTING ROD 4) Inspect the connecting rod bearing for scar, peeling, seizure, melting, wear, etc. 1) Replace the connecting rod, if the large or small 5) Measure the oil clearance on individual connect- end thrust surface is damaged. ing rod bearings by means of plastigauge.
  • Page 37 CYLINDER BLOCK MECHANICAL 6) Inspect the bushing at connecting rod small end, 6. CRANKSHAFT AND CRANKSHAFT and replace if worn or damaged. Also measure the BEARING piston pin clearance at connecting rod small end. 1) Clean the crankshaft completely and check for Clearance between piston pin and bushing: cracks by means of red lead check etc., and re- Standard...
  • Page 38 CYLINDER BLOCK MECHANICAL Unit: mm (in) Crank journal diameter Crank pin diameter #1, #3, #5 #2, #4 59.992 — 60.008 59.992 — 60.008 51.984 — 52.000 Journal O.D. (2.3619 — 2.3625) (2.3619 — 2.3625) (2.0466 — 2.0472) Standard Bearing size 1.998 —...

  • Page 39: Engine Trouble In General

    ENGINE TROUBLE IN GENERAL MECHANICAL 21.Engine Trouble in General A: INSPECTION NOTE: “RANK” shown in the chart refers to the possibility of reason for the trouble in order (“Very often” to “Rarely”) A — Very often B — Sometimes C — Rarely TROUBLE PROBLEM PARTS, ETC.
  • Page 40 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 4) Engine stalls after initial • Engine control system <Ref. to EN(H4DOSTC)-2, Basic Diagnostic Procedure.> combustion. • Intake system • Loosened or cracked intake duct • Loosened or cracked PCV hose •...
  • Page 41 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 3. Low output, hesitation and • Engine control system <Ref. to EN(H4DOSTC)-2, Basic Diagnostic Procedure.> poor acceleration • Intake system • Loosened or cracked intake duct • Loosened or cracked PCV hose •...
  • Page 42 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 5. Engine does not return to • Engine control system <Ref. to EN(H4DOSTC)-2, Basic Diagnostic Procedure.> idle. • Intake system • Loosened or cracked vacuum hose • Others •...
  • Page 43 ENGINE TROUBLE IN GENERAL MECHANICAL TROUBLE PROBLEM PARTS, ETC. POSSIBLE CAUSE RANK 10. Excessive fuel consump- • Engine control system <Ref. to EN(H4DOSTC)-2, Basic Diagnostic Procedure.> tion • Intake system • Dirty air cleaner element • Belt • Defective timing •...

  • Page 44: Engine Noise

    ENGINE NOISE MECHANICAL 22.Engine Noise A: INSPECTION Type of sound Condition Possible cause • Valve mechanism is defective. • Incorrect valve clearance Sound increases as engine Regular clicking sound • Worn valve rocker speed increases. • Worn camshaft • Broken valve spring •...
  • Page 45 ENGINE NOISE MECHANICAL MEMO: ME(H4DOSTC)-96...

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