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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: Valve Clearance

    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

    MECHANICAL ME(H4SO) Page General Description ..................2 Compression .....................23 Idle Speed ....................24 Ignition Timing...................25 Intake Manifold Vacuum................26 Engine Oil Pressure ..................27 Fuel Pressure....................28 Valve Clearance..................29 Engine Assembly ..................32 Engine Mounting ..................39 Preparation for Overhaul................40 V-belt......................41 Crankshaft Pulley ..................43 Belt Cover ....................45 Timing Belt Assembly................46 Camshaft Sprocket..................51 Crankshaft Sprocket..................53...

  • Page 4: Engine Assembly

    ENGINE ASSEMBLY MECHANICAL 9. Engine Assembly 11) Disconnect the following connectors and ca- bles. A: REMOVAL (1) Front oxygen (A/F) sensor connector 1) Set the vehicle on lift arms. 2) Open the front hood fully, and then support with the hood stay. 3) Lower the fuel pressure.
  • Page 5 ENGINE ASSEMBLY MECHANICAL (4) Engine harness connectors (7) Pressure switch FU-00017 12) Disconnect the following hoses. (1) Brake booster vacuum hose ME-00207 (5) Generator connector, terminal and A/C ME-00329 compressor connector (2) Heater inlet outlet hose ( B ) ( A ) ME-00208 ME-00330 (A) Generator connector and terminal...
  • Page 6 ENGINE ASSEMBLY MECHANICAL (3) Remove the pipe with bracket. 15) Remove the nuts which hold lower side of transmission to engine. ME-00331 ME-00210 (4) Remove the bolts which install power steer- ing pump bracket. 16) Remove the nuts which install front cushion rubber onto front crossmember.
  • Page 7 ENGINE ASSEMBLY MECHANICAL 18) Remove the pitching stopper. 21) Support the transmission with a garage jack. CAUTION: Before moving the engine away from transmis- sion, check to be sure no work has been over- looked. Doing this is very important in order to facilitate re-installation and because the trans- mission lowers under its own weight.
  • Page 8 ENGINE ASSEMBLY MECHANICAL 24) Remove the engine from vehicle. 3) Tighten the bolts which hold upper side of trans- mission to engine. (1) Slightly raise the engine. (2) Raise the transmission with garage jack. Tightening torque: (3) Move the engine horizontally until main 50 N·m (5.1 kgf-m, 36.9 ft-lb) shaft is withdrawn from clutch cover.
  • Page 9 ENGINE ASSEMBLY MECHANICAL 9) Install the torque converter clutch onto drive (3) Tighten the bolts which install power steer- plate. (AT vehicles) ing pump bracket, and then install the spark plug cords. (1) Tighten the bolts which hold torque convert- er clutch to drive plate.
  • Page 10 ENGINE ASSEMBLY MECHANICAL 11) Tighten the nuts which hold lower side of trans- 18) Install the air cleaner case stay. mission to engine. Tightening torque: Tightening torque: 16 N·m (1.6 kgf-m, 11.6 ft-lb) 50 N·m (5.1 kgf-m, 36.9 ft-lb) 19) Install the A/C pressure hoses. <Ref. to AC-42, INSTALLATION, Flexible Hose.>...

  • Page 11: Engine Mounting

    ENGINE MOUNTING MECHANICAL 10.Engine Mounting A: REMOVAL 1) Remove engine assembly. <Ref. ME(H4SO)-32, REMOVAL, Engine Assembly.> 2) Remove the engine mounting from engine as- sembly. B: INSTALLATION Install in the reverse order of removal. Tightening torque: Engine mounting; 34 N·m (3.5 kgf-m, 25.3 ft-lb) C: INSPECTION Make sure there are no cracks or other damage.

  • Page 12: Preparation For Overhaul

    PREPARATION FOR OVERHAUL MECHANICAL 11.Preparation for Overhaul A: PROCEDURE 1) After removing the engine from body, secure it in the ST shown below. ST1 498457000 ENGINE STAND ADAPTER ST2 498457100 ENGINE STAND ADAPTER ST3 499817100 ENGINE STAND ME-00221 2) In this section the procedures described under each index are all connected and stated in order.

  • Page 13: V-Belt

    V-BELT MECHANICAL 12.V-belt 4) Remove the A/C belt tensioner. A: REMOVAL 1. FRONT SIDE BELT NOTE: Perform the following procedures 1) to 4) with the engine installed to body. 1) Remove the V-belt cover. ME-00225 ME-00606 2) Loosen the lock bolt (A). 3) Loosen the slider bolt (B).
  • Page 14 V-BELT MECHANICAL B: INSTALLATION C: INSPECTION 1) Replace the belts, if cracks, fraying or wear is 1. FRONT SIDE BELT found. 1) Wipe off any oil or water on the belt and pulley. 2) Check the drive belt tension and adjust it if nec- 2) Install the belt (C), and tighten the slider bolt so essary by changing the generator installing position as to obtain the specified belt tension.

  • Page 15: Crankshaft Pulley

    CRANKSHAFT PULLEY MECHANICAL 13.Crankshaft Pulley 3) Confirm that the tightening angle of crankshaft pulley bolt is 45 degrees or more. If the tightening A: REMOVAL angle of crankshaft pulley bolt is less than 45 de- grees, conduct the following procedures. 1) Remove the V-belt.
  • Page 16 CRANKSHAFT PULLEY MECHANICAL (2) Apply engine oil to the crankshaft pulley bolt 5) Install the A/C belt. seat and thread. (3) Tighten the bolts temporarily with tightening torque of 44 N·m (4.5 kgf-m, 33 ft-lb). (4) Tighten the crankshaft pulley bolts. Tightening torque: 177 N·m (18.0 kgf-m, 130.2 ft-lb) ME-00228...

  • Page 17: Belt Cover

    BELT COVER MECHANICAL 14.Belt Cover A: REMOVAL 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- MOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. ME(H4SO)-43, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover (LH). 4) Remove the front belt cover. ( B ) ( A ) ME-00229 (A) Belt cover (LH)

  • Page 18: Timing Belt Assembly

    TIMING BELT ASSEMBLY MECHANICAL 15.Timing Belt Assembly ST 499987500 CRANKSHAFT SOCKET A: REMOVAL 1. TIMING BELT 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- MOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. ME(H4SO)-43, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME(H4SO)-45, REMOVAL, Belt Cover.>...
  • Page 19 TIMING BELT ASSEMBLY MECHANICAL Specified data: 2) Remove the automatic belt tension adjuster as- sembly. : 46.8 tooth length : 43.7 tooth length ME-00238 ME-00234 B: INSTALLATION 6) Remove the belt idler (No. 2). 1. AUTOMATIC BELT TENSION ADJUST- 7) Remove the belt idler No. 2. ER ASSEMBLY AND BELT IDLER 1) Preparation for installation of automatic belt ten- sion adjuster assembly;...
  • Page 20 TIMING BELT ASSEMBLY MECHANICAL (3) With a 2 mm (0.08 in) dia. stopper pin or a 2 2. TIMING BELT mm (0.08 in) (nominal) dia. hex bar wrench in- 1) Preparation for the installation of automatic belt serted into the stopper pin hole in the cylinder, tension adjuster assembly.
  • Page 21 TIMING BELT ASSEMBLY MECHANICAL 4) Install the belt idler (No. 2). (2) Check and adjust the clearance between timing belt and timing belt guide by using thick- Tightening torque: ness gauge. 39 N·m (4.0 kgf-m, 28.9 ft-lb) Clearance: 1.0 ± ± ± ± 0.5 mm (0.039 ± ± ± ± 0.020 in) ME-00235 5) After ensuring that the marks on timing belt and ME-00246...
  • Page 22 TIMING BELT ASSEMBLY MECHANICAL C: INSPECTION • Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into 1. TIMING BELT the cylinder. Doing so may damage the cylinder. 4) Measure the extension of rod beyond the body. 1) Check the timing belt teeth for breaks, cracks, and wear.

  • Page 23: Camshaft Sprocket

    CAMSHAFT SPROCKET MECHANICAL 16.Camshaft Sprocket B: INSTALLATION 1) Install the camshaft sprocket No. 1. To lock the A: REMOVAL camshaft, use ST. 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- ST 499207400 CAMSHAFT SPROCKET MOVAL, V-belt.> WRENCH 2) Remove crankshaft pulley.

  • Page 24: Crankshaft Sprocket

    CAMSHAFT SPROCKET MECHANICAL 6) Install crankshaft pulley. <Ref. ME(H4SO)-43, INSTALLATION, CRANKSHAFT PULLEY.> 7) Install the V-belt. <Ref. to ME(H4SO)-42, IN- STALLATION, V-belt.> C: INSPECTION 1) Check the sprocket teeth for abnormal wear and scratches. 2) Make sure there is no free play between sprock- et and key.

  • Page 25: Crankshaft Sprocket

    CRANKSHAFT SPROCKET MECHANICAL 17.Crankshaft Sprocket C: INSPECTION 1) Check the sprocket teeth for abnormal wear and A: REMOVAL scratches. 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- 2) Make sure there is no free play between sprock- MOVAL, V-belt.> et and key. 2) Remove crankshaft pulley.

  • Page 26: Valve Rocker Assembly

    VALVE ROCKER ASSEMBLY MECHANICAL 18.Valve Rocker Assembly B: INSTALLATION 1) Installation of valve rocker assembly A: REMOVAL (1) Temporarily tighten the bolts (a) through (d) 1) Remove the V-belt. <Ref. to ME(H4SO)-41, RE- equally as shown in the figure. MOVAL, V-belt.> NOTE: 2) Remove crankshaft...
  • Page 27 VALVE ROCKER ASSEMBLY MECHANICAL D: ASSEMBLY 2) If oil clearance exceeds the limit, replace the valve rocker arm or shaft, whichever shows greater 1) Install the adjuster screw and nut to valve rocker. amount of wear. 2) Arrange the valve rocker arms, springs and shaft supports in assembly order and insert valve rocker Rocker arm inside diameter: shaft.

  • Page 28: Camshaft

    CAMSHAFT MECHANICAL 19.Camshaft (1) Remove the bolts (a) through (b) in alpha- betical sequence. A: REMOVAL 1) Remove the V-belt. <Ref. to ME(H4SO)-42, IN- STALLATION, V-belt.> 2) Remove crankshaft pulley. <Ref. ( a ) ME(H4SO)-43, REMOVAL, Crankshaft Pulley.> 3) Remove the belt cover. <Ref. to ME(H4SO)-45, REMOVAL, Belt Cover.>...
  • Page 29 CAMSHAFT MECHANICAL 16) Remove the plug from rear side of camshaft. (3) Install the valve rocker assembly. NOTE: • Do not remove the oil seal unless necessary. • Do not scratch the journal surface when remov- ing oil seal. B: INSTALLATION 1) Apply a coat of engine oil to the camshaft jour- nals, and then install the camshaft.
  • Page 30 CAMSHAFT MECHANICAL (6) Tighten the bolts (o) through (v) in alphabet- 6) Install the rocker cover and connect PCV hose. ical sequence. 7) Install the oil level gauge guide. (LH side only) 8) Install the camshaft position sensor support. (LH Tightening torque: side only) 10 N·m (1.0 kgf-m, 7.2 ft-lb)
  • Page 31 CAMSHAFT MECHANICAL C: INSPECTION Cam base circle diameter A: IN: 34.00 mm (1.3386 in) 1. CAMSHAFT EX: 34.00 mm (1.3386 in) 1) Measure the bend, and repair or replace if nec- essary. Limit: 0.025 mm (0.0010 in) ME-00276 2. CAMSHAFT SUPPORT Measure the thrust clearance of camshaft with dial gauge.

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