Subaru 2003 Legacy User manual

FUJI HEAVY INDUSTRIES LTD. G2300GE3
2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
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.
FUEL INJECTION (FUEL SYSTEMS) FU(H6DO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(H6DO)
INTAKE (INDUCTION) IN(H6DO)
MECHANICAL ME(H6DO)
EXHAUST EX(H6DO)
COOLING CO(H6DO)
LUBRICATION LU(H6DO)
SPEED CONTROL SYSTEMS SP(H6DO)
IGNITION IG(H6DO)
STARTING/CHARGING SYSTEMS SC(H6DO)
ENGINE (DIAGNOSTICS) EN(H6DO)

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

EC(H6DO)-2
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
GENERAL DESCRIPTION
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.
•Keep the disassembled parts in order and pro-
tect them from dust or dirt.
•Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
•Be careful not to burn your hands, because each
part on the vehicle is hot after running.
•Be sure to tighten fasteners including bolts and
nuts to the specified torque.
•Placeshopjacks orsafetystands at thespecified
points.
•Before disconnecting electrical connectors of
sensors or units, be sure to disconnect ground ca-
ble from battery.

EC(H6DO)-3
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
FRONT CATALYTIC CONVERTER
2. Front Catalytic Converter
A: REMOVAL
1) Set the vehicle on the lift.
2) Remove battery.
3) Remove air cleaner case and air intake duct.
<Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner.>
and <Ref. to IN(H6DO)-7, REMOVAL, Air Intake
Duct.>
4) Disconnect front oxygen (A/F) sensor connec-
tors.
5) Lift-up the vehicle.
6) Remove under cover.
7) Remove front oxygen (A/F) sensor harness from
the clips attached to both right and left cylinder
head covers.
8) Disconnect connector from rear oxygen sensor
connector.
9) Separate front exhaust pipe from rear exhaust
pipe.
CAUTION:
Be careful, exhaust pipe is hot.
10) Remove nuts which hold front exhaust pipe
onto cylinder heads.
11) Remove front exhaust pipe from hanger brack-
et.
CAUTION:
Be careful not to pull down front exhaust pipe.
EX-00056
LH side
RH side
EX-00058
EX-00059
EX-00060
RH side LH side
EX-00061

EC(H6DO)-4
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
FRONT CATALYTIC CONVERTER
12) Separate front catalytic converter (RH) from
front exhaust pipe.
B: INSTALLATION
NOTE:
Replace gaskets with new ones.
1) Install front catalytic converter (RH) to front ex-
haust pipe.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
2) Install front exhaust pipe assembly to the vehi-
cle. And temporarily tighten bolt which installs front
exhaust pipe to hanger bracket.
3) Tighten nuts which hold front exhaust pipe onto
cylinder heads.
Tightening torque:
30 N·m (3.1 kgf-m, 22.4 ft-lb)
4) Tighten bolts which secure front exhaust pipe
assembly to rear exhaust pipe.
Tightening torque:
18 N·m (1.8 kgf-m, 13.0 ft-lb)
5) Tighten bolt which holds front exhaust pipes to
hanger bracket.
Tightening torque:
35 N·m (3.6 kgf-m, 26.0 ft-lb)
EX-00062
EX-00062
EX-00061
EX-00060
RH side LH side
EX-00059
EX-00061

EC(H6DO)-5
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
FRONT CATALYTIC CONVERTER
6) Connect connector to rear oxygen sensor con-
nector.
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.
11) Install air cleaner case and air intake duct.
<Ref. to IN(H6DO)-5, INSTALLATION, Air Clean-
er.> and <Ref. to IN(H6DO)-7, INSTALLATION, Air
Intake Duct.>
12) Install battery.
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
EX-00058
EX-00056
LH side
RH side

EC(H6DO)-6
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
REAR CATALYTIC CONVERTER
3. Rear Catalytic Converter
A: REMOVAL
The frontand rearcatalytic converter are integrated
into one unit. Therefore, the removal and installa-
tion procedures are the same as the those for the
frontcatalyticconverter.<Ref.to EC(H6DO)-3, RE-
MOVAL, Front Catalytic Converter.>
B: INSTALLATION
The frontand rearcatalytic converter are integrated
into one unit. Therefore, the removal and installa-
tion procedures are the same as the ones de-
scribed under front catalytic converter. <Ref. to
EC(H6DO)-4, INSTALLATION, Front Catalytic
Converter.>
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
(A) Front catalytic converter RH
(B) Front catalytic converter LH
(C) Rear catalytic converter
(A) Front catalytic converter RH
(B) Front catalytic converter LH
(C) Rear catalytic converter
EC-00108
( A )
( B )
( C )
EC-00108
( A )
( B )
( C )

EC(H6DO)-7
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
CANISTER
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.
3) Remove canister from body.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
23 N·m (2.3 kgf-m, 17 ft-lb)
C: INSPECTION
Make sure the canister and canister hoses are not
cracked or loose.
EC-00127
EC-00128
EC-00128

EC(H6DO)-8
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
PURGE CONTROL SOLENOID VALVE
5. Purge Control Solenoid Valve
A: REMOVAL
1) Disconnect battery ground cable.
2) Remove power steering pump from bracket.
(1) Remove air intake duct and air cleaner
case. <Ref. to IN(H6DO)-5, REMOVAL, Air
Cleaner.> and <Ref. to IN(H6DO)-7, REMOV-
AL, Air Intake Duct.>
(2) Remove V-belt. <Ref. to ME(H6DO)-28,
REMOVAL, V-belt.>
(3) Remove power steering oil pipe with brack-
et.
(4) Remove bolts which install power steering
pump bracket.
CAUTION:
Do not separate hose and pipe from the pump
main unit.
(5) Remove power steering tank from the
bracket by pulling it upward.
(6) Place power steering pump on the right side
wheel apron.
3) Disconnect connector and hoses from purge
control solenoid valve.
4) Remove bolt which installs purge control sole-
noid valve onto intake manifold.
(A) Power steering pump
(B) Generator
(C) A/C compressor
FU-00009
ME-00449
ME-00482
( A ) ( B ) ( C )
(A) Cloth
ME-00451
ME-00483
( A )
EC-00109
EC-00110

EC(H6DO)-9
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
PURGE CONTROL SOLENOID VALVE
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)
CAUTION:
Carefully connect the evaporation hoses.
C: INSPECTION
Make sure hoses are not cracked or loose.
A: To fuel pipe
B: To intake manifold
EC-00110
EC-00111
B
A

EC(H6DO)-10
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
EGR VALVE
6. EGR Valve
A: REMOVAL
1) Disconnect battery ground cable.
2) Remove air intake chamber. <Ref. to IN(H6DO)-
6, REMOVAL, Air Intake Chamber.>
3) Remove starter. <Ref. to SC(H6DO)-6, REMOV-
AL, Starter.>
4) Remove EGR pipe from EGR valve and cylinder
head.
5) Remove EGR valve from intake manifold.
6) Disconnect connector from EGR valve.
B: INSTALLATION
NOTE:
Replace old gaskets with new one.
1) Connect connector EGR valve.
2) Install EGR valve to intake manifold.
Tightening torque:
19 N·m (1.9 kgf-m, 14 ft-lb)
FU-00009
EC-00112
EC-00113
EC-00114
EC-00114
EC-00113

EC(H6DO)-11
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
EGR VALVE
3) Install EGR pipe to EGR valve and cylinder
head.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
4) Install starter. <Ref. toSC(H6DO)-6, INSTALLA-
TION, Starter.>
5) Install air intake chamber. <Ref. to IN(H6DO)-6,
INSTALLATION, Air Intake Chamber.>
6) Connect battery ground cable.
C: INSPECTION
1) Check the EGR valve for proper valve move-
ment.
2) Check the EGR pipe, etc., for blockages or
cracks.
EC-00112

EC(H6DO)-12
EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
TWO-WAY VALVE
7. Two-way valve
A: REMOVAL
1) Lift-up the vehicle.
2) Disconnect hoses from two-way valve.
3) Remove two-way valve with bracket as a single
unit from body.
4) Remove two-way valve from bracket.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Make sure that hoses are not cracked or loose.
EC-00129
EC-00130