Subaru 2003 LEGACY Service Manual
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Subaru 2003 LEGACY 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 2003 LEGACY

  • Page 1: Engine Section

    2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 1 FUEL INJECTION (FUEL SYSTEMS) FU(H4SO) EMISSION CONTROL 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)
  • 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(H4SO) Page General Description ..................2 Throttle Body.....................14 Intake Manifold..................15 Engine Coolant Temperature Sensor............26 Crankshaft Position Sensor...............27 Camshaft Position Sensor.................28 Knock Sensor....................29 Throttle Position Sensor................30 Pressure Sensor ..................32 Intake Air Temperature Sensor ..............33 Idle Air Control Solenoid Valve ..............34 EGR Valve ....................35 Fuel Injector ....................36 Front Oxygen (A/F) Sensor ...............41...

  • Page 4: General Description

    GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 1. General Description A: SPECIFICATIONS Model Specification 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(H4SO)-3...
  • Page 6 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) B: COMPONENT 1. INTAKE MANIFOLD (19) (21) (23) (19) (15) (10) (20) (11) (22) (14) (18) (17) (20) (12) (17) (13) (16) (18) (16) (17) FU-00377 FU(H4SO)-4...
  • Page 7 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Intake manifold gasket RH (11) Intake manifold (21) Plug cord holder RH (2) Fuel injector pipe (12) Intake manifold gasket LH (22) Accelerator cable bracket (3) Fuel injector (13) Fuel pipe protector LH (23) EGR valve (4) O-ring (14) Plug cord holder LH...
  • Page 8 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 2. AIR INTAKE SYSTEM FU-00247 (1) Gasket (5) Throttle body Tightening torque: N·m (kgf-m, ft-lb) (2) Throttle position sensor (6) Intake air temperature sensor T1: 1.6 (0.16, 1.2) (3) Idle air control solenoid valve (7) Grommet T2: 22 (2.2, 15.9) (4) Pressure sensor...
  • Page 9 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) 3. CRANKSHAFT POSITIOM, CAMSHAFT POSITION AND KNOCK SENSORS FU-00414 (1) Crankshaft position sensor (4) Camshaft position sensor support Tightening torque: N·m (kgf-m, ft-lb) (2) Knock sensor T1: 6.4 (0.65, 4.7) (3) Camshaft position sensor T2: 24 (2.4, 17.4) FU(H4SO)-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 shield 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 (29) (28) (30) (31) (32) (26) (25) (27) ( 1 ) (24) ( 1 ) (17) ( 1 ) (19) (23) (18) ( 1 ) (20) (22) ( 1 ) (16) (21) ( 7 ) ( 3 )
  • Page 13 GENERAL DESCRIPTION FUEL INJECTION (FUEL SYSTEMS) (1) Clamp (12) Damper valve (Delivery) (23) Evaporation pipe ASSY (2) Fuel return hose A (13) Bracket (24) Purge hose (3) Damper valve (Return) (14) Fuel delivery hose C (25) Evaporation hose C (4) Fuel return hose B (15) Fuel pipe ASSY (26) Canister drain hose (5) Clip...
  • Page 14 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 15 24082AA210 CARTRIDGE Troubleshooting for electrical system. (Newly adopted tool) ST24082AA210 22771AA030 SUBARU SELECT Troubleshooting for electrical systems. MONITOR KIT • English: 22771AA030 (Without printer) • German: 22771AA070 (Without printer) • French: 22771AA080 (Without printer) • Spanish: 22771AA090 (Without printer) ST22771AA030...

  • Page 16: Throttle Body

    THROTTLE BODY FUEL INJECTION (FUEL SYSTEMS) 2. Throttle Body 7) Remove the bolts (B) which install throttle body to the intake manifold. A: REMOVAL 1) Disconnect the ground cable from battery. FU-00253 B: INSTALLATION FU-00009 1) Install in the reverse order of removal. 2) Remove the air cleaner case.

  • Page 17: Intake Manifold

    INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 3. Intake Manifold NOTE: Do not disconnect the power steering hose. A: REMOVAL 1) Release the fuel pressure. <Ref. to FU(H4SO)- 48, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.> 2) Open the fuel flap lid, and remove the fuel filler cap.
  • Page 18 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (7) Place the power steering pump on the right 12) Remove the air cleaner case stay RH and en- side wheel apron. gine harness bracket, and disconnect the engine harness connectors from the bulkhead harness connectors.
  • Page 19 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 16) Disconnect the connector from the oil pressure 19) Disconnect the fuel hoses from the fuel pipes. switch. WARNING: • Do not spill fuel. • Catch fuel from hoses in a container or cloth. ( A ) ( B ) FU-00146...
  • Page 20 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 2) Connect the fuel hoses. 5) Connect the connector to the oil pressure switch. ( A ) ( B ) ( C ) FU-00259 FU-00146 6) Connect the connector to the crankshaft position (A) Fuel delivery hose sensor.
  • Page 21 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 9) Install the air cleaner case stay RH and engine 14) Install the power steering pump and reservoir harness bracket, and connect the engine harness tank to bracket. connectors to the bulkhead connectors. (1) Install the reservoir tank to bracket. FU-00258 FU-00020 10) Connect the brake booster hose.
  • Page 22 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) (5) Install the front side V-belt. <Ref. to 19) Connect the battery ground cable to battery. ME(H4SO)-42, INSTALLATION, V-belt.> (6) Install the resonator chamber. Tightening torque: 33 N·m (3.4 kgf-m, 24.6 ft-lb) FU-00009 C: DISASSEMBLY 1) Disconnect the engine ground terminal from the intake manifold.
  • Page 23 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 6) Disconnect the pressure regulator vacuum hose 10) Disconnect the connector from the purge con- from the intake manifold. trol solenoid valve. FU-00265 FU-00269 7) Remove the fuel pipe protector LH. 11) Disconnect the air by-pass hose from the purge control solenoid valve.
  • Page 24 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 15) Remove the bolt which installs injector pipe on 18) Loosen the clamp which holds the front left side the intake manifold as shown in figure. fuel hose to the injector pipe and remove the pipe. FU-00272 FU-00171 16) Remove the two bolts which hold fuel pipes on...
  • Page 25 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) D: ASSEMBLY 6) Install the fuel injectors. 1) Install the fuel pipe assembly and pressure reg- NOTE: ulator, etc. to the intake manifold. Replace the O-rings with new ones. 2) Tighten the bolt which installs the fuel pipes on the intake manifold.
  • Page 26 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) Tightening torque: NOTE: 19 N·m (1.94 kgf-m, 13.7 ft-lb) Connect the evaporation hose as shown in the fig- ure. FU-00284 FU-00285 8) Tighten the two bolts which install the fuel pipes on the left side of intake manifold. (A) To fuel pipe Tightening torque: (B) To intake manifold...
  • Page 27 INTAKE MANIFOLD FUEL INJECTION (FUEL SYSTEMS) 15) Install the fuel pipe protector LH. 21) Install the engine ground terminal to the intake manifold. Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) Tightening torque: 19 N·m (1.94 kgf-m, 13.7 ft-lb) FU-00266 FU-00287 16) Connect the pressure regulator vacuum hose to the intake manifold.

  • Page 28: Engine Coolant Temperature Sensor

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

  • 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 the ground cable from battery. T: 6.4 N·m (0.65 kgf-m, 4.7 ft-lb) FU-00009 FU-00058 2) Remove the bolt which install crankshaft position sensor to the cylinder block.

  • Page 30: Camshaft Position Sensor

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

  • Page 31: Knock Sensor

    KNOCK SENSOR FUEL INJECTION (FUEL SYSTEMS) 7. Knock Sensor B: INSTALLATION 1) Install the knock sensor to the cylinder block. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 24 N·m (2.4 kgf-m, 17.4 ft-lb) 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 CAUTION: When installing throttle position sensor, adjust A: REMOVAL to the specified data. 1) Disconnect the ground cable from battery. FU-00290 FU-00009 C: ADJUSTMENT 2) Disconnect the connector from the throttle posi- 1) Turn the ignition switch to OFF.
  • Page 33 Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) ( A ) EN-00710 5) Turn the ignition switch to ON, and the Subaru Select Monitor switch to ON. FU-00291 6) Select the {2. Each System Check} in Main 4) When using Subaru Select Monitor;...

  • Page 34: Pressure Sensor

    PRESSURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 9. Pressure Sensor B: INSTALLATION Install in the reverse order of removal. A: REMOVAL Tightening torque: 1) Disconnect the ground cable from battery. 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) FU-00009 FU-00295 2) Disconnect the connector from the pressure sensor.

  • Page 35: Intake Air Temperature Sensor

    INTAKE AIR TEMPERATURE SENSOR FUEL INJECTION (FUEL SYSTEMS) 10.Intake Air Temperature Sen- A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Disconnect the connector from the intake air temperature sensor. 3) Remove the intake air temperature sensor from air cleaner case.

  • Page 36: Idle Air Control Solenoid Valve

    IDLE AIR CONTROL SOLENOID VALVE FUEL INJECTION (FUEL SYSTEMS) 11.Idle Air Control Solenoid B: INSTALLATION Install in the reverse order of removal. Valve NOTE: A: REMOVAL Always use new gasket. 1) Disconnect the ground cable from battery. Tightening torque: 1.6 N·m (0.16 kgf-m, 1.2 ft-lb) FU-00009 2) Disconnect the connector from the idle air con- FU-00299...

  • Page 37: Egr Valve

    EGR VALVE FUEL INJECTION (FUEL SYSTEMS) 12.EGR Valve A: REMOVAL 1) Disconnect the ground cable from battery. FU-00009 2) Disconnect the connector from EGR valve. FU-00210 3) Remove the EGR valve from intake manifold. FU-00211 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) FU-00211...

  • Page 38: Fuel Injector

    FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 13.Fuel Injector (3) Remove the bolts which install the power steering pump to the bracket. A: REMOVAL 1. RH SIDE 1) Release the fuel pressure. <Ref. to FU(H4SO)- 48, RELEASING OF FUEL PRESSURE, OPERA- TION, Fuel.>...
  • Page 39 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 7) Remove the fuel pipe protector RH. (1) Remove the fuel injector securing clip. FU-00267 FU-00305 8) Disconnect the connector from fuel injector. (2) Remove the fuel injector while lifting up the fuel injector pipe. FU-00303 FU-00306 9) Remove the bolt which holds the injector pipe to...
  • Page 40 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 4) Remove the two bolts which install the washer 9) Remove the spark plug cords from the spark tank on the body. plugs (#2 and #4 cylinders). FU-00190 FU-00307 5) Disconnect the connector from the front window 10) Remove the fuel pipe protector LH.
  • Page 41 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) 13) Remove the bolt which holds the fuel pipe on B: INSTALLATION the left side intake manifold. 1. RH SIDE Install in the reverse order of removal. NOTE: Replace O-rings with new ones. ( A ) FU-00170 ( B ) 14) Remove the fuel injector from the intake mani-...
  • Page 42 FUEL INJECTOR FUEL INJECTION (FUEL SYSTEMS) Tightening torque: Tightening torque: 19 N·m (1.9 kgf-m, 13.7 ft-lb) 5.0 N·m (0.51 kgf-m, 3.7 ft-lb) FU-00267 FU-00170 Tightening torque: Tightening torque: 33 N·m (3.4 kgf-m, 24.3 ft-lb) 19 N·m (1.94 kgf-m, 13.7 ft-lb) FU-00261 FU-00309 2.

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