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(H4SO)
Page
1. General Description ....................................................................................2
2. Throttle Body.............................................................................................14
3. Intake Manifold..........................................................................................15
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. Pressure Sensor .......................................................................................32
10. Intake Air Temperature Sensor.................................................................33
11. Idle Air Control Solenoid Valve .................................................................34
12. EGR Valve ................................................................................................35
13. Fuel Injector ..............................................................................................36
14. Front Oxygen (A/F) Sensor.......................................................................41
15. Rear Oxygen Sensor.................................................................................43
16. Engine Control Module..............................................................................45
17. Main Relay ................................................................................................46
18. Fuel Pump Relay.......................................................................................47
19. Fuel...........................................................................................................48
20. Fuel Tank..................................................................................................51
21. Fuel Filler Pipe ..........................................................................................58
22. Fuel Pump.................................................................................................62
23. Fuel Level Sensor .....................................................................................64
24. Fuel Sub Level Sensor..............................................................................65
25. Fuel Filter ..................................................................................................67
26. Fuel Cut Valve...........................................................................................68
27. Fuel Damper Valve ...................................................................................69
28. Fuel Delivery, Return and Evaporation Lines............................................70
29. Fuel System Trouble in General ...............................................................73

FU(H4SO)-2
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
Model Specification
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(H4SO)-3
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
MEMO:

FU(H4SO)-4
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
B: COMPONENT
1. INTAKE MANIFOLD
FU-00377
(20)
(21)
(5)
(6)
(7)
(8) (9)
(10)
(3)
(2)
(4)
(17) (17)
(17)
(20)
(22)
(18)
(18) (14)
(16)
(16)
(13)
(12)
(1)
(19)
(15)
(11)
(4)
(3)
(5)
(6)
T2
T2
T1 T1
T1
T1
T1
T1
T5
T4
T4
T4
T2
T5
T4
T4
T3
T3
T5
T5
T5
(23)
T4
T4
T4 (2)
T2
T4
(19)

FU(H4SO)-5
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
(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
(5) O-ring (15) Fuel pipe protector RH Tightening torque: N·m (kgf-m, ft-lb)
(6) O-ring (16) Fuel pipe ASSY T1: 1.5 (0.15, 1.1)
(7) Plug (17) Fuel hose T2: 5.0 (0.51, 3.7)
(8)PCVvalve (18)Clip T3: 17 (1.7, 12.5)
(9) Purge control solenoid valve (19) Clip T4: 19 (1.9, 13.7)
(10) Nipple (20) Guide pin T5: 25 (2.5, 18.1)

FU(H4SO)-6
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
2. AIR INTAKE SYSTEM
(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 (8) Air cleaner case
FU-00247
(2)
(3)
(4)
(5)
(1)
T1
T1
T1
T2
(8)
(6)
(7)

FU(H4SO)-7
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
3. CRANKSHAFT POSITIOM, CAMSHAFT POSITION AND KNOCK SENSORS
(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-00414
T1
(1)
(2)
T1
T1 (3)
(4)
T2

FU(H4SO)-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(H4SO)-9
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
(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 (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 (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) Vent hose T4: 5.9 (0.6, 4.3)
(15) Evaporation hose C (30) Clamp

FU(H4SO)-10
FUEL INJECTION (FUEL SYSTEMS) GENERAL DESCRIPTION
5. FUEL LINE
B2M4171A
FU-00627
( 9 ) ( 8 )
( 7 )
( 6 )
( 5 )
( 4 )
( 4 )
( 3 )
( 3 )
( 2 )
( 1 )
( 1 )
( 1 )
( 1 )
( 1 ) ( 1 ) ( 1 ) ( 1 )
( 1 )
( 1 )
( 1 )
( 1 )
( 1 )
( 1 )
( 1 )
( 1 )
(23)
(22)
(21)
(14)
(13)
(11)
(12)
(15)
(10)
(20)
(19)
(18)
(17)
(16)
(32)
(31)
(30)
(29)
(28)
(27)
(26)
(25)
(24)

FU(H4SO)-11
FUEL INJECTION (FUEL SYSTEMS)
GENERAL DESCRIPTION
(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 (16) Evaporation hose B (27) Canister
(6) Fuel pipe ASSY (17) Two-way valve hose (28) Front canister bracket
(7) Grommet (18) Two-way valve (29) Rear canister bracket
(8) Evaporation hose A (19) Two-way valve bracket (30) Canister bracket spacer
(9) Fuel return hose C (20) Two-way valve drain hose (31) Cushion
(10) Fuel delivery hose A (21) Drain hose (32) Canister bracket plate
(11) Fuel delivery hose B (22) Fuel pipe connector

FU(H4SO)-12
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) Fuel filler pipe protector
(4) Filler pipe packing
FU-00628
( 1 )
( 2 )
( 3 )
( 4 )
( 5 )
( 6 )
( 7 ) T
T

FU(H4SO)-13
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 negative
terminal 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
(Newly adopted
tool)
CARTRIDGE Troubleshooting for electrical system.
22771AA030 SUBARU SELECT
MONITOR KIT Troubleshooting for electrical systems. •English: 22771AA030 (Without printer)
•German: 22771AA070 (Without printer)
•French: 22771AA080 (Without printer)
•Spanish: 22771AA090 (Without printer)
ST24082AA210
ST22771AA030

FU(H4SO)-14
FUEL INJECTION (FUEL SYSTEMS) THROTTLE BODY
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the air cleaner case. <Ref. to
IN(H4SO)-6, REMOVAL, Air Cleaner Case.>
3) Disconnect the accelerator cable (A).
4) Disconnect the cruise control cable (B). (With
cruise control model)
5) Disconnect the connectors from idle air control
solenoid valve, throttle position sensor and pres-
sure sensor.
6) Disconnect the engine coolant hoses (A) from
the throttle body.
7) Remove the bolts (B) which install throttle body
to the intake manifold.
B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
Replace the gasket with a new one.
Tightening torque:
Throttle body;
22 N·m (2.2 kgf-m, 15.9 ft-lb)
2) Adjust the accelerator cable play. <Ref. to
SP(H4SO)-10, REMOVAL, Accelerator Control
Cable.>
(A) Throttle position sensor
(B) Pressure sensor
(C) Idle air control solenoid valve
FU-00009
FU-00251
(B)
(A)
FU-00378
(B)
(A)
(C)
FU-00253
(B)
(B)
(A) (A)

FU(H4SO)-15
FUEL INJECTION (FUEL SYSTEMS)
INTAKE MANIFOLD
3. Intake Manifold
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.
3) Disconnect the ground cable from battery.
4) Remove the 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) Disconnect the accelerator cable (A).
6) Disconnect the cruise control cable (B). (With
cruise control model)
7) Remove the power steering pump and reservoir
tank from bracket.
(1) Remove the resonator chamber. <Ref. to
IN(H4SO)-8, REMOVAL, Resonator Chamber.>
(2) Remove the front side V-belt. <Ref. to
ME(H4SO)-41, REMOVAL, V-belt.>
(3) Remove the bolts which hold power steering
pipes onto the intake manifold protector.
NOTE:
Do not disconnect the power steering hose.
(4) Remove the bolts which install power steer-
ing pump bracket.
(5) Disconnect the connector from the power
steering pump switch.
(6) Remove the power steering tank from the
bracket by pulling it upwards.
FU-00009
FU-00251
(B)
(A)
FU-00255
FU-00139
FU-00017
FU-00020

FU(H4SO)-16
FUEL INJECTION (FUEL SYSTEMS) INTAKE MANIFOLD
(7) Place the power steering pump on the right
side wheel apron.
8) Disconnect the spark plug cords from the spark
plugs.
9) Disconnect the PCV hose from the intake mani-
fold.
10) Disconnect the engine coolant hose (A) from
the throttle body.
11) Disconnect the brake booster hose.
12) Remove the air cleaner case stay RH and en-
gine harness bracket, and disconnect the engine
harness connectors from the bulkhead harness
connectors.
13) Disconnect the connectors from the engine
coolant temperature sensor.
14) Disconnect the knock sensor connector.
15) Disconnect the connector from the crankshaft
position sensor.
FU-00021
FU-00141
FU-00361
(A) (A)
FU-00143
FU-00258
FU-00145
FU-00062
FU-00056

FU(H4SO)-17
FUEL INJECTION (FUEL SYSTEMS)
INTAKE MANIFOLD
16) Disconnect the connector from the oil pressure
switch.
17) Disconnect the connector from the camshaft
position sensor.
18) Remove the EGR pipe from intake manifold.
19) Disconnect the fuel hoses from the fuel pipes.
WARNING:
•Do not spill fuel.
•Catch fuel from hoses in a container or cloth.
20) Remove the bolts which hold intake manifold
onto the cylinder heads.
21) Remove the intake manifold.
B: INSTALLATION
1) Install the intake manifold onto the cylinder
heads.
NOTE:
Replace the gaskets with new ones.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
FU-00146
FU-00147
FU-00148
(A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
FU-00259
( A )
( B )
( C )
FU-00260
FU-00260

FU(H4SO)-18
FUEL INJECTION (FUEL SYSTEMS) INTAKE MANIFOLD
2) Connect the fuel hoses.
3) Connect the EGR pipe to intake manifold.
Tightening torque:
34 N·m (3.4 kgf-m, 24.6 ft-lb)
4) Connect the connector to the camshaft position
sensor.
5) Connect the connector to the oilpressure switch.
6) Connect the connectorto the crankshaftposition
sensor.
7) Connect the knock sensor connector.
8) Connect the connectors to the engine coolant
temperature sensor.
(A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
FU-00259
( A )
( B )
( C )
FU-00148
FU-00147
FU-00146
FU-00056
FU-00062
FU-00145