Subaru 2003 Legacy User manual

FUJI HEAVY INDUSTRIES LTD. G2300GE2
2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
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.
FUEL INJECTION (FUEL SYSTEMS) FU(H4SO)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(H4SO)
INTAKE (INDUCTION) IN(H4SO)
MECHANICAL ME(H4SO)
EXHAUST EX(H4SO)
COOLING CO(H4SO)
LUBRICATION LU(H4SO)
SPEED CONTROL SYSTEMS SP(H4SO)
IGNITION IG(H4SO)
STARTING/CHARGING SYSTEMS SC(H4SO)
ENGINE (DIAGNOSTICS) EN(H4SO)
FUEL INJECTION (FUEL SYSTEMS) FU(H4SOw/oOBD)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(H4SOw/oOBD)
INTAKE (INDUCTION) IN(H4SOw/oOBD)
MECHANICAL ME(H4SOw/oOBD)
EXHAUST EX(H4SOw/oOBD)
COOLING CO(H4SOw/oOBD)

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
G2300GE2
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)

FUEL INJECTION (FUEL SYSTEMS)
FU(H4SOw/oOBD)
Page
1. General Description ....................................................................................2
2. Throttle Body.............................................................................................13
3. Intake Manifold..........................................................................................14
4. Engine Coolant Temperature Sensor........................................................26
5. Crankshaft Position Sensor.......................................................................27
6. Camshaft Position Sensor.........................................................................28
7. Knock Sensor............................................................................................29
8. Throttle Position Sensor............................................................................30
9. Intake Air Temperature and Pressure Sensor...........................................32
10. Idle Air Control Solenoid Valve .................................................................33
11. Fuel Injector ..............................................................................................34
12. Oxygen Sensor .........................................................................................40
13. Engine Control Module..............................................................................42
14. Main Relay ................................................................................................43
15. Fuel Pump Relay.......................................................................................44
16. Fuel...........................................................................................................45
17. Fuel Tank..................................................................................................48
18. Fuel Filler Pipe ..........................................................................................55
19. Fuel Pump.................................................................................................59
20. Fuel Level Sensor .....................................................................................61
21. Fuel Sub Level Sensor..............................................................................62
22. Fuel Filter ..................................................................................................64
23. Fuel Cut Valve...........................................................................................65
24. Fuel Damper Valve ...................................................................................66
25. Fuel Delivery, Return and Evaporation Lines............................................67
26. Fuel System Trouble in General ...............................................................70

FU(H4SOw/oOBD)-2
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
Model
Fuel tank Capacity 64 2(16.9 US gal, 14.1 Imp gal)
Location Under rear seat
Fuel pump
Type Impeller
Shutoff discharge pressure 370 —677 kPa (3.77 —6.9 kg/cm2, 53.6 —98 psi)
Discharge flow More than 65 2(17.2 US gal, 14.3 Imp gal)/h
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter Cartridge type

FU(H4SOw/oOBD)-3
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
MEMO:

FU(H4SOw/oOBD)-4
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
FU-00711
( 1 )
( 2 )
( 2 )
( 3 )
( 3 )
( 4 )
( 4 )
( 5 )
( 5 )
( 6 )
( 7 ) ( 8 )
( 9 )
(10)
(20)
(22)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(18)
(18)
(19)
(19)
(19)
(21)
(21)
(20)
T5
T6
T6
T6 T5
T5
T5
T5
T5
T5
T5
T1
T1
T1
T3
T3
T3 T4
T4
T2

FU(H4SOw/oOBD)-5
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
(1) Intake manifold gasket RH (12) Fuel pipe protector LH (22) Plug cord holder RH
(2) Fuel injector pipe (13) Intake air temperature and pres-
sure sensor
(3) Fuel injector Tightening torque: N.m (kgf-m, ft-lb)
(4) O-ring (14) O-ring T1:1.5 (0.15, 1.1)
(5) O-ring (15) Plug cord holder LH T2: 3.4 (0.35, 2.5)
(6) Plug (16) Fuel pipe protector RH T3:5.0 (0.51, 3.7)
(7) PCV valve (17) Fuel pipe ASSY T4:17 (1.7, 12)
(8) Purge control solenoid valve (18) Fuel hose T5:19 (0.19, 1.4)
(9) Nipple (19) Clip T6:25 (2.6, 18.8)
(10) Intake manifold (20) Clip
(11) Intake manifold gasket LH (21) Guide pin

FU(H4SOw/oOBD)-6
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
2. AIR INTAKE SYSTEM
(1) Gasket (4) Throttle body Tightening torque: N·m (kgf-m, ft-lb)
(2) Throttle position sensor T1: 1.6 (0.16, 1.2)
(3) Idle air control solenoid valve T2: 22 (2.2, 15.9)
FU-00712
( 1 ) ( 2 )
( 4 )
( 3 )
T1 T2
T1

FU(H4SOw/oOBD)-7
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
3. CRANKSHAFT POSITION, CAMSHAFT POSITION AND KNOCK SENSORS
(1) Crank angle position sensor (3) Camshaft position sensor Tightening torque: N·m (kgf-m, ft-lb)
(2) Knock sensor (4) Camshaft position sensor support T1: 6.4 (0.65, 4.7)
T2: 24 (2.4, 17.4)
FU-00414
T1
(1)
(2)
T1
T1 (3)
(4)
T2

FU(H4SOw/oOBD)-8
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
4. FUEL TANK
FU-00626
( 1 )
( 2 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(31)
(33)
(37)
(38)
(36)
(30)
(34)
(11)
(10) (12)
(13)
(14)
(14)
(14)
(15)
(16)
(17)
(18)
(19) (20)
(26)
(24)
(25)
(23)
(32)
(21)
(22)
(21)
(27)
(30)
(30)
(30)
(35)
(29) (28)
T3
T3 T3
T3
T1
T1
T4
T2
T2
T2
T2

FU(H4SOw/oOBD)-9
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
(1) Heat sealed 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 (20) Retainer (35) Fuel delivery tube
(6) Fuel pump plate (21) Quick connector (36) Seal
(7) Fuel pump ASSY (22) Jet pump hose B (37) Fuel pump holder
(8) Fuel level sensor (23) Fuel sub level sensor gasket (38) Grommet
(9) Fuel filter (24) Jet pump filter
(10) Fuel pump with filter (25) Fuel sub level sensor Tightening torque: N·m (kgf-m, ft-lb)
(11) Fuel cut valve gasket (26) Protector LH (Rear) T1:4.4 (0.45, 3.3)
(12) Fuel cut valve (27) Protector RH (Rear) T2: 18 (1.8, 13.0)
(13) Evaporation hose A (28) Fuel filler hose T3: 33 (3.4, 25)
(14) Clip (29) Air vent hose T4: 5.9 (0.6, 4.3)
(15) Evaporation hose C (30) Clamp

FU(H4SOw/oOBD)-10
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
5. FUEL LINE
(1) Clamp (10) Two-way valve (19) Dumper valve (Delivery)
(2) Fuel delivery hose A (11) Canister hose B (20) Bracket
(3) Evaporation hose A (12) Canister hose C (21) Dumber valve (Return)
(4) Clip (13) Canister bracket (22) Fuel return hose B
(5) Fuel delivery hose B (14) Fuel pipe ASSY
(6) Fuel return hose A (15) Evaporation hose B Tightening torque: N·m (kgf-m, ft-lb)
(7) Drain hose (16) Fuel return hose C T: 7.4
±
±±
±
2.0 (0.75
±
±±
±
0.2, 5.4
±
±±
±
1.4)
(8) Canister (17) Fuel delivery hose C
(9) Canister hose A (18) Grommet
FU-00713
( 1 ) ( 1 )
( 1 )
( 1 )
( 1 )
( 1 )
( 1 )
( 1 )
( 1 ) ( 1 ) ( 1 )
( 1 ) ( 1 )
( 1 )
( 2 )
( 3 )
( 4 )
( 4 )
( 5 )
( 6 )
( 7 )
( 8 )
( 9 )
(10)
(11) (12)
(13)
(14)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
T

FU(H4SOw/oOBD)-11
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
6. FUEL FILLER PIPE
(1) Fuel filler pipe ASSY (5) Filler ring Tightening torque: N·m (kgf-m, ft-lb)
(2) Clip (6) Filler cap T:7.4 (0.75, 5.4)
(3) Clamp (7) Filler pipe protector
(4) Filler pipe packing
FU-00628
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 ) T
T

FU(H4SOw/oOBD)-12
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
C: 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.
•Place shopjacks or safety stands at thespecified
points.
•Before disconnecting electrical connectors of
sensors or units, be sure to disconnect ground ca-
ble from battery.
•Place “NO FIRE”signs near the working area.
•Be careful not to spill fuel on the floor.
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA210 CARTRIDGE Troubleshooting for electrical systems.
22771AA030 SELECT MONI-
TOR KIT Troubleshooting for electrical systems. •English: 22771AA030 (Without printer)
•German: 22771AA070 (Without printer)
•French: 22771AA080 (Without printer)
•Spanish: 22771AA090 (Without printer)
ST24082AA210
ST22771AA030

FU(H4SOw/oOBD)-13
FUEL INJECTION (FUEL SYSTEMS)
THROTTLE BODY
2. Throttle Body
A: REMOVAL
1) Disconnect battery ground cable.
2) Remove air cleaner case.
3) Disconnect accelerator cable (A).
4) Disconnect cruise control cable (B). (With cruise
control model)
5) Disconnect connectors from idle air control sole-
noid valve, throttle position sensor.
6) Disconnect air by-pass hose from purge control
solenoid valve.
7) Disconnect engine coolant hoses from throttle
body.
8) Remove boltswhich installthrottle body to intake
manifold.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Always use a new gasket.
Tightening torque:
Throttle body;
22 N·m (2.2 kgf-m, 15.9 ft-lb)
Air cleaner case;
6.5 N·m (0.66 kgf-m, 4.8 ft-lb)
FU-00009
FU-00714
FU-00715
( A )
( B )
(A) Throttle position sensor
(B) Idle air control solenoid valve
(C) Air by-pass hose
FU-00716
( B )
( A )
( C )
FU-00717

FU(H4SOw/oOBD)-14
FUEL INJECTION (FUEL SYSTEMS) INTAKE MANIFOLD
3. Intake Manifold
A: REMOVAL
1) Release fuel pressure. <Ref. to FU(H4SOw/
oOBD)-45, RELEASING OF FUEL PRESSURE,
OPERATION, Fuel.>
2) Open fuel flap lid, and remove fuel filler cap.
3) Disconnect battery ground cable.
4) Remove air intake duct and air cleaner assem-
bly. <Ref. to IN(H4SO)-7, REMOVAL, Air Intake
Duct.> and <Ref. to IN(H4SO)-6, REMOVAL, Air
Cleaner Case.>
5) Disconnect accelerator cable (A).
6) Disconnect cruise control cable (B). (With cruise
control model)
7) Remove power steering pump and tank from
brackets.
(1) Remove resonator chamber.
<Ref. to IN(H4SO)-8, REMOVAL, Resonator
Chamber.>
(2) Remove front V-belt.
<Ref. to ME(H4SO)-41, REMOVAL, V-belt.>
(3) Remove bolts which hold power steering
pipes onto intake manifold protector.
NOTE:
Do not disconnect power steering hose.
(4) Remove bolts which install power steering
pump bracket.
(5) Disconnect connector from power steering
pump switch.
(6) Remove power steering tank from the
bracket by pulling it upwards.
FU-00009
FU-00715
( A )
( B )
FU-00718
FU-00139
FU-00428
FU-00429

FU(H4SOw/oOBD)-15
FUEL INJECTION (FUEL SYSTEMS)
INTAKE MANIFOLD
(7) Place power steering pump and tank on the
right side wheel apron.
8) Disconnect spark plug cords from spark plugs.
9) Disconnect PCV hose from intake manifold.
10) Disconnect engine coolant hose from throttle
body.
11) Disconnect brake booster hose.
12) Remove air cleaner case stay RH and engine
harness bracket, and disconnect engine harness
connectors from bulkhead harness connectors.
13) Disconnect connectors from engine coolant
temperature sensor.
14) Disconnect knock sensor connector.
15) Disconnect connector from crankshaft position
sensor.
FU-00430
FU-00719
FU-00717
FU-00720
FU-00258
FU-00145
FU-00062
FU-00515

FU(H4SOw/oOBD)-16
FUEL INJECTION (FUEL SYSTEMS) INTAKE MANIFOLD
16) Disconnect connector from oil pressure switch.
17) Disconnect connector from camshaft position
sensor.
18) Disconnect fuel hoses from fuel pipes.
WARNING:
•Do not spill fuel.
•Catch fuel from hoses in a container or cloth.
19) Remove bolts which hold intake manifold onto
cylinder heads and then remove intake manifold.
B: INSTALLATION
1) Install intake manifold onto cylinder heads.
NOTE:
Always use new gaskets.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
2) Connect fuel hoses.
(A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
FU-00146
FU-00147
FU-00259
( A )
( B )
( C )
(A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
FU-00260
FU-00260
FU-00259
( A )
( B )
( C )

FU(H4SOw/oOBD)-17
FUEL INJECTION (FUEL SYSTEMS)
INTAKE MANIFOLD
3) Connect connector to camshaft position sensor.
4) Connect connector to oil pressure switch.
5) Connect connector to crankshaft position sen-
sor.
6) Connect knock sensor connector.
7) Connect connectors to engine coolant tempera-
ture sensor.
8) Install air cleaner case stay RH and engine har-
ness bracket, and connect engine harness connec-
tors to bulkhead connectors.
9) Connect brake booster hose.
10) Connect engine coolant hose to throttle body.
FU-00147
FU-00146
FU-00515
FU-00062
FU-00145
FU-00258
FU-00720
FU-00717

FU(H4SOw/oOBD)-18
FUEL INJECTION (FUEL SYSTEMS) INTAKE MANIFOLD
11) Connect PCV hose to intake manifold.
12) Connect spark plug cords to spark plugs.
13) Install power steering pump and tank on brack-
ets.
(1) Install power steering tank on bracket.
(2) Connect connector to power steering pump
switch.
(3) Tighten bolts which install power steering
pump on bracket.
Tightening torque:
22 N·m (2.2 kgf-m, 16 ft-lb)
(4) Install power steering pipes onto right side
intake manifold protector.
(5) Install front V-belt.
<Ref. to ME(H4SO)-42, INSTALLATION, V-
belt.>
(6) Install resonator chamber.
Tightening torque:
33 N·m (3.4 kgf-m, 24.6 ft-lb)
14) Connect accelerator cable (A).
<Ref. to SP(H4SO)-10, INSTALLATION, Accelera-
tor Control Cable.>
15) Connect cruise control cable (B). (With cruise
control models)
16) Install air intake duct and air cleaner assembly.
<Ref. to IN(H4SO)-7, INSTALLATION, Air Intake
Duct.> and <Ref. to IN(H4SO)-6, INSTALLATION,
Air Cleaner Case.>
FU-00719
FU-00429
FU-00428
FU-00139
FU-00718
FU-00261
FU-00715
( A )
( B )