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)

LUBRICATION LU(H4SO)
Page
1. General Description ....................................................................................2
2. Oil Pressure System ...................................................................................6
3. Engine Oil....................................................................................................8
4. Oil Pump ...................................................................................................10
5. Oil Pan and Strainer..................................................................................14
6. Oil Pressure Switch...................................................................................17
7. Engine Oil Filter.........................................................................................18
8. Engine Lubrication System Trouble in General.........................................19

LU(H4SO)-2
LUBRICATION GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
Lubrication method Forced lubrication
Oil pump
Pump type Trochoid type
Number of teeth Inner rotor 9
Outer rotor 10
Outer rotor diameter ×thickness 78 ×7 mm (3.07 ×0.28 in)
Tip clearance between inner and outer rotor STANDARD 0.04 —0.14 mm (0.0016 —0.0055 in)
LIMIT 0.18 mm (0.0071 in)
Side clearance between inner rotor and pump
case STANDARD 0.02 —0.07 mm (0.0008 —0.0028 in)
LIMIT 0.12 mm (0.0047 in)
Case clearance between outer rotor and pump
case STANDARD 0.10 —0.175 mm (0.0039 —0.0069 in)
LIMIT 0.20 mm (0.0079 in)
Capacity at
80°C (176°F)
600 rpm - Discharge pressure 98 kPa (1.0 kg/cm2, 14 psi)
- Discharge quantity 3.2 2(3.4 US qt, 2.8 Imp qt)/min.
5,000 rpm - Discharge pressure 294 kPa (3.0 kg/cm2, 43 psi)
- Discharge quantity 32.6 2(8.61 US gal, 7.17 Imp gal)/min.
Relief valve operation pressure 490 kPa (5.0 kg/cm2, 71 psi)
Oil filter
Type Full-flow filter type
Filtration area 760 cm2(118 sq in)
By-pass valve opening pressure 157 kPa (1.6 kg/cm2, 22.7 psi)
Outer diameter ×width 80 ×75 mm (3.15 ×2.95 in)
Installation screw type M 20 ×1.5
Oil pressure
switch
Type Immersed contact point type
Working voltage —wattage 12 V —3.4 W or less
Warning light activation pressure 14.7 kPa (0.15 kg/cm2, 2.1 psi)
Proof pressure More than 981 kPa (10 kg/cm2, 142 psi)
Oil capacity (when replacing oil) Approx. 4.0 2(4.2 US qt, 3.5 Imp qt)

LU(H4SO)-3
LUBRICATION
GENERAL DESCRIPTION
B: COMPONENT
(1) Plug (13) Oil pressure switch (25) Drain plug
(2) Gasket (14) Oil filler duct (26) Metal gasket
(3) Relief valve spring (15) O-ring (27) Gasket
(4) Relief valve (16) Oil filler cap
(5) Oil seal (17) O-ring Tightening torque: N·m (kgf-m, ft-lb)
(6) Oil pump case (18) Baffle plate T1: 5 (0.5, 3.6)
(7) Inner rotor (19) O-ring T2: 6.4 (0.65, 4.7)
(8) Outer rotor (20) Oil strainer T3: 10 (1.0, 7.2)
(9) Oil pump cover (21) Oil level gauge guide T4: 25 (2.5, 18.1)
(10) Oil filter (22) O-ring T5: 44 (4.5, 33)
(11) O-ring (23) Oil pan
(12) Oil pump ASSY (24) Oil level gauge
LU-00168
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 ) ( 7 )
( 8 ) ( 9 )
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(25) (23)
(26) (22)
(21)
(27)
(24)
T5
T5
T3
T1
T2
T2
T4
T2
T1
T1
T2
T1

LU(H4SO)-4
LUBRICATION GENERAL DESCRIPTION
C: CAUTION
•Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
•Remove dirt and corrosion before removal, in-
stallation 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 in the vehicle is hot after running.
•Be sure to tighten fasteners including bolts and
nuts to the specified torque.
•Placeshopjacksorsafetystandsatthespecified
points.
•Before disconnecting electrical connectors of
sensors or units, be sure to disconnect ground ca-
ble from battery.

LU(H4SO)-5
LUBRICATION
GENERAL DESCRIPTION
D: PREPARATION TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
499977100 CRANKSHAFT
PULLEY
WRENCH
Used for stopping rotation of crankshaft pulley
when loosening and tightening crankshaft pulley
bolt. (2500 cc model)
499977400 CRANKSHAFT
PULLEY
WRENCH
Used for stopping rotation of crankshaft pulley
when loosening and tightening crankshaft pulley
bolt. (2000 cc model)
498547000 OIL FILTER
WRENCH Used for removing and installing oil filter.
499587100 OIL SEAL
INSTALLER Used for installing oil pump oil seal.
ST-499977100
ST-499977400
ST-498547000
ST-499587100

LU(H4SO)-6
LUBRICATION OIL PRESSURE SYSTEM
2. Oil Pressure System
A: SCHEMATIC
LU-00158
(GREEN)
i12
123 456
7 8 9 10 11 12 13 14
B21 (GRAY)
12 34
56
78
9
10 11 12
13 14 15 16
17 18 19 20
B36
B4 B5 B6
A4 A5 A6
C5 C6
F6
D4 D5 D6
F1
H1
C4
G6
G1
C2
K1
M1M2
K6
L1
D1 D2
A1 A2
B1 B2
I6
J6
L2
I1
J1
H6
M4M5M6
L4 L5 L6
N5 N6
O4 O5 O6
N4
P4 P5
N2
O1 O2
P1 P2
N3
O3
P3 P6
A3
B3
C3 E4 E5 E6E1 E2
OIL PRESSURE
WARNING LIGHT 3
14
B5
5
i1
B36
E2
E11
B21
OIL PRESSURE
SWITCH
NO.5
IGNITION
RELAY
SMJ
COMBINATION
METER
i12
BATTERY

LU(H4SO)-7
LUBRICATION
OIL PRESSURE SYSTEM
B: INSPECTION
Step Value Yes No
1 CHECK COMBINATION METER.
1) Turn ignition switch to ON. (engine OFF)
2) Check other warning lights.
Does the warning lights go on?
Warning light goes on. Go to step 2. Repair or replace
the combination
meter. <Ref. to
IDI-4, INSPEC-
TION, Combina-
tion Meter
System.>
2 CHECK HARNESS CONNECTOR BETWEEN
COMBINATION METER AND OIL PRES-
SURE SWITCH.
1) Turn ignition switch to OFF.
2) Disconnect connector from the oil pressure
switch.
3) Turn ignition switch ON.
4) Measure the voltage of harness between
the combination meter connector and chas-
sis ground.
Connector & terminal
(E11) No. 1 — Chassis ground:
Does the measured value exceed the spec-
ified value?
10 V Replace oil pres-
sure switch. Go to step 3.
3 CHECK COMBINATION METER.
1) Turn ignition switch to OFF.
2) Remove the combination meter.
3) Measure the resistance of the combination
meter.
Terminal
(i12) No. 3 — (i12) No. 14:
Is the measured value less than the speci-
fied value?
10 ΩReplace the har-
ness connector
between combina-
tion meter and oil
pressure switch.
Repair or replace
the combination
meter and the oil
pressure switch
warning light bulb.

LU(H4SO)-8
LUBRICATION ENGINE OIL
3. Engine Oil
A: INSPECTION
1) Park vehicle on a level surface.
2) Remove oil level gauge and wipe it clean.
3) Reinsertthelevel gauge allthe way. Be sure that
the level gauge is correctly inserted and in the
proper orientation.
4) Remove it again and note the reading. If the en-
gine oil level is below the “L”line, add oil to bring
the level up to the “F”line.
5) After turning off the engine, wait a few minutes
for the oil to drain back into the oil pan before
checking the level.
6) Just after driving or while the engineis warm, en-
gine oil level may show in the range between the
“F”line and the notch mark. This is caused by ther-
mal expansion of the engine oil.
7) To prevent overfilling the engine oil, do not add
oil above the “F”line when the engine is cold.
B: REPLACEMENT
1) Open engine oil filler cap forquick draining of the
engine oil.
2) Drain engine oil by loosening engine oil drain
plug.
3) Replace drain plug gasket.
4) Tighten engine oil drain plug after draining en-
gine oil.
Tightening torque:
44 N·m (4.5 kgf-m, 33 ft-lb)
5) Fill engine oil through filler pipe up to upper point
on level gauge. Make sure that vehicle is placed
level when checking oil level. Use engine oil of
proper quality and viscosity, selected in accor-
dance with the table in figure.
Recommended oil
API classification SL, SJ with the “Energy
Conserving” logo is printed (if you cannot
obtain the oilwith SL, SJ orSH grades, you
may use SG, SF grades “ENERGY CON-
SERVING” oil.)
ACEA specification, A1, A2 or A3
CCMC specification, G4 or G5
New API certification mark (Star burse
mark) label is on the container.
Oil amount for preparation (when replacing en-
gine oil):
Approx. 4.0 2(4.2 US qt, 3.5 Imp qt)
The proper viscosity helps vehicle get good cold
and hot starting by reducing viscous friction and
thus increasing cranking speed.
CAUTION:
When replenishing oil, it does not matter if the
oil to be added is a different brand from that in
the engine; however, use oil having the ILSAC
or API classification and SAE viscosity No. des-
ignated by SUBARU.
(A) Oil level gauge
(B) Engine oil filler cap
(C) Upper level
(D) Lower level
(E) Approx. 1.0 2(1.1 US qt, 0.9 Imp qt)
LU-00138
(A) (B)
(C)
(D)
(E)
LU-00094
LU-00094
LU-00008
SAE Viscosity No. and Applicable Temperature
(˚F) 0403015–15
–20–30
(˚C) 32 10486595
–4–22
10W-30, 10W-40
5W-30 PREFERRED

LU(H4SO)-9
LUBRICATION
ENGINE OIL
NOTE:
If vehicle is usedin desert areas with veryhigh tem-
peratures or for other heavy duty applications, the
following viscosity oils may be used: API classifica-
tion: SL, SJ or SH
SAE Viscosity No.: 30, 40, 10W-50, 20W-40, 20W-
50.
6) Close engine oil filler cap.
7) Start engine and warm it up for a time.
8) After engine stops, recheck the oil level. If nec-
essary, add engine oil up to upper level on level
gauge.
(A) Oil level gauge
(B) Engine oil filler cap
(C) Upper level
(D) Lower level
(E) Approx. 1.0 2(1.1 US qt, 0.9 Imp qt)
LU-00138
(A) (B)
(C)
(D)
(E)

LU(H4SO)-10
LUBRICATION OIL PUMP
4. Oil Pump
A: REMOVAL
1) Disconnect battery ground cable.
2) Lift-up the vehicle.
3) Remove under cover. <Ref. to EI-13, REMOV-
AL, Front Under Cover.>
4) Lower the vehicle.
5) Remove radiator. <Ref. to CO(H4SO)-23, RE-
MOVAL, Radiator.>
6) Remove crankshaft position sensor.
7) Remove V-belts. <Ref. to ME(H4SO)-41, RE-
MOVAL, V-belt.>
8) Remove rear side V-belt tensioner.
9) Remove crankshaft pulley by using ST.
ST 499977100 CRANKSHAFT PULLEY
WRENCH (2500 cc model)
ST 499977400 CRANKSHAFT PULLEY
WRENCH (2000 cc model)
10) Remove water pump. <Ref. to CO(H4SO)-16,
REMOVAL, Water Pump.>
11) Remove timing belt guide. (MT vehicle)
12) Remove crankshaft sprocket.
13) Remove bolts which install oil pump onto cylin-
der block.
NOTE:
To disassemble and check oil pump, loosen relief
valve plug before removing the pump.
FU-00009
LU-00046
LU-00011
LU-00012
LU-00014
LU-00015

LU(H4SO)-11
LUBRICATION
OIL PUMP
14) Remove oil pump by using flat bladed screw-
driver.
CAUTION:
Be careful not to scratch mating surfaces of
cylinder block and oil pump.
B: INSTALLATION
Install in the reverse order of removal.
Do the following:
1) Apply fluid gasket to matching surfaces of oil
pump.
Fluid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
2) Replace O-ring (A) with a new one.
3) Apply engine oil to the inside of the oil seal.
4) Be careful not to scratch oil seal when installing
oil pump on cylinder block.
5) Position the oil pump, aligning the notched area
with the crankshaft, and push the oil pump straight.
CAUTION:
Make sure the oil seal lip is not folded.
6) Install oil pump.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
C: DISASSEMBLY
Remove screws which secure oil pump cover and
disassemble oil pump. Inscribe alignment marks on
inner and outer rotors so that they can be replaced
in their original positions during reassembly.
LU-00016
LU-00017
( A )
LU-00018
(A) Oil seal
(B) Pump case
(C) Inner rotor
(D) Outer rotor
(E) Pump cover
(F) Relief valve
(G) Relief valve spring
(H) Plug
(I) Gasket
LU-00019
T
T
LU-00020
( A )
( B ) ( C )
( D )
( E )
( F ) ( G ) ( H )
( I )

LU(H4SO)-12
LUBRICATION OIL PUMP
D: ASSEMBLY
1) Install front oil seal by using ST.
ST 499587100 OIL SEAL INSTALLER
NOTE:
Use a new oil seal.
2) Apply engine oil to inner and outer rotors.
3) Install inner and outer rotors in their original po-
sitions.
4) Install oil relief valve and relief valve spring.
5) Install oil pump cover.
Tightening torque:
T1: 5 N·m (0.5 kgf-m, 3.6 ft-lb)
T2: 44 N·m (4.5 kgf-m, 33 ft-lb)
E: INSPECTION
1. TIP CLEARANCE
Measure thetip clearance ofrotors.If the clearance
exceeds the limit, replace rotors as a set.
Tip clearance:
Standard
0.04 — 0.14 mm (0.0016 — 0.0055 in)
Limit
0.18 mm (0.0071 in)
2. CASE CLEARANCE
Measure the clearance betweenthe outer rotor and
the cylinder block rotor housing. If the clearance
exceeds the limit, replace the rotor.
Case clearance:
Standard
0.10 — 0.175 mm (0.0039 — 0.0069 in)
Limit
0.20 mm (0.0079 in)
LU-00021
ST
T1
T2
LU-00022
LU-00023
LU-00024

LU(H4SO)-13
LUBRICATION
OIL PUMP
3. SIDE CLEARANCE
Measure clearance between oil pump inner rotor
and pump cover. If the clearance exceeds the limit,
replace rotor or pump body.
Side clearance:
Standard
0.02 — 0.07 mm (0.0008 — 0.0028 in)
Limit
0.12 mm (0.0047 in)
4. OIL RELIEF VALVE
Check the valve for fitting condition and damage,
and the relief valve spring for damage and deterio-
ration. Replace the parts if defective.
Relief valve spring:
Free length
72.8 mm (2.866 in)
Installed length
54.7 mm (2.154 in)
Load when installed
81.3 N (8.29 kgf, 18.28 lb)
5. OIL PUMP CASE
Check the oil pump case for worn shaft hole,
clogged oil passage, worn rotor chamber, cracks,
and other faults.
6. OIL SEAL
Check the oil seal lips for deformation, hardening,
wear, etc. and replace if defective.
LU-00025

LU(H4SO)-14
LUBRICATION OIL PAN AND STRAINER
5. Oil Pan and Strainer
A: REMOVAL
1) Set the vehicle on lift arms.
2) Remove front wheels.
3) Disconnect battery ground cable.
4) Remove air intake duct and air cleaner case.
<Ref. to IN(H4SO)-7, REMOVAL, Air Intake Duct.>
and <Ref. to IN(H4SO)-6, REMOVAL, Air Cleaner
Case.>
5) Remove pitching stopper.
6) Remove radiator upper brackets.
7) Support engine with a lifting device and wire
ropes.
8) Lift-up the vehicle.
CAUTION:
When lifting up the vehicle, wire rope must be
raised at the same time.
9) Remove under cover. <Ref. to EI-13, REMOV-
AL, Front Under Cover.>
10) Drain engine oil.
Set container under the vehicle, and remove drain
plug from oil pan.
11) Remove front and center exhaust pipes. <Ref.
to EX(H4SO)-5, REMOVAL, Front Exhaust Pipe.>
or <Ref. to EX(H4SOw/oOBD)-9, REMOVAL, Front
Exhaust Pipe.>
12) Remove nuts which secure front cushion rub-
ber onto front crossmember.
13) Remove bolts which secure oil pan on cylinder
block while raising up engine.
FU-00009
ME-00213
LU-00097
LU-00028
LU-00098
LU-00030

LU(H4SO)-15
LUBRICATION
OIL PAN AND STRAINER
14) Insert oil pan cutter blade between cylinder
block-to-oil pan clearance.
CAUTION:
Do not use a screwdriver or similar tool in place
of oil pan cutter.
15) Remove oil strainer.
16) Remove baffle plate.
B: INSTALLATION
CAUTION:
Before installing oil pan, clean sealant from oil
pan and engine block.
1) Install baffle plate.
Tightening torque:
6.4 N·m (0.65 kgf-m, 4.7 ft-lb)
2) Install oil strainer onto baffle plate.
CAUTION:
Replace O-ring with a new one.
Tightening torque:
10 N·m (1.0 kgf-m, 7 ft-lb)
3) Apply fluid gasket to mating surfaces and install
oil pan.
Fluid gasket:
Part No. 004403007
THREE BOND 1215 or equivalent
LU-00051
LU-00032
LU-00033
LU-00033
LU-00032
LU-00034

LU(H4SO)-16
LUBRICATION OIL PAN AND STRAINER
Tightening torque:
5 N·m (0.5 kgf-m, 3.6 ft-lb)
4) Lower engine onto front crossmember.
5) Tighten nuts which secure front cushion rubber
onto front crossmember.
Tightening torque:
69 N·m (7.0 kgf-m, 51 ft-lb)
6) Install front and center exhaust pipes.
<Ref. to EX(H4SO)-6, INSTALLATION, Front Ex-
haust Pipe.>or <Ref. to EX(H4SOw/oOBD)-10, IN-
STALLATION, Front Exhaust Pipe.>
7) Install under cover. <Ref. to EI-13, INSTALLA-
TION, Front Under Cover.>
8) Lower the vehicle.
CAUTION:
When lowering vehicle, wire rope must be re-
leased at the same time.
9) Remove lifting device and steel cables.
10) Install pitching stopper.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
11) Install radiator upper brackets.
12) Install air intake duct and air cleaner case.
<Ref. to IN(H4SO)-7, INSTALLATION, Air Intake
Duct.> and <Ref. to IN(H4SO)-6, INSTALLATION,
Air Cleaner Case.>
13) Install front wheels.
14) Connect battery ground cable.
15) Fill engine oil. <Ref. to LU(H4SO)-8, INSPEC-
TION, Engine Oil.>
C: INSPECTION
By visual check make sure oil pan, oil strainer, oil
strainer stay and baffle plate are not damaged.
LU-00051
LU-00030
LU-00028
ME-00218
T2 T1
LU-00097
FU-00009

LU(H4SO)-17
LUBRICATION
OIL PRESSURE SWITCH
6. Oil Pressure Switch
A: REMOVAL
1) Remove generator from bracket. <Ref. to
SC(H4SO)-14, REMOVAL, Generator.>
2) Disconnect terminal from oil pressure switch.
3) Remove oil pressure switch.
B: INSTALLATION
1) Apply fluid gasket to oil pressure switch threads.
Fluid gasket:
Part No. 004403042
THREE BOND 1324 or equivalent
2) Install oil pressure switch onto engine block.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
3) Connect terminal of oil pressure switch.
4) Install generator on bracket. <Ref. to
SC(H4SO)-14, INSTALLATION, Generator.>
C: INSPECTION
Make sure oil does not leak or seep from where the
oil pressure switch is installed.
LU-00036
LU-00037
LU-00038
LU-00037
LU-00036

LU(H4SO)-18
LUBRICATION ENGINE OIL FILTER
7. Engine Oil Filter
A: REMOVAL
1) Remove under cover. <Ref. to EI-13, REMOV-
AL, Front Under Cover.>
2) Remove oil filter with ST.
ST 498547000 OIL FILTER WRENCH
B: INSTALLATION
1) Get a new oil filter and thinly apply engine oil to
the seal rubber.
2) Install oil filter by turning it by hand, being careful
not to damage seal rubber.
3) Tighten more (approximately 2/3 to 3/4 turn) af-
ter the seal rubber contacts the cylinder block. Do
not tighten excessively, or oil may leak.
C: INSPECTION
1) After installing oil filter, run engine and make
sure that no oil is leaking around seal rubber.
NOTE:
The filter element and filter case are integrated
therefore, interior cleaning is not necessary.
2) Check the engine oil level. <Ref. to LU(H4SO)-8,
INSPECTION, Engine Oil.>
LU-00100