Subaru 2004 LEGACY User manual

FUJI HEAVY INDUSTRIES LTD. G2320GE2
2004 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 2.0)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.0)
INTAKE (INDUCTION) IN(H4SO 2.0)
MECHANICAL ME(H4SO 2.0)
EXHAUST EX(H4SO 2.0)
COOLING CO(H4SO 2.0)
LUBRICATION LU(H4SO 2.0)
SPEED CONTROL SYSTEMS SP(H4SO 2.0)
IGNITION IG(H4SO 2.0)
STARTING/CHARGING SYSTEMS SC(H4SO 2.0)
ENGINE (DIAGNOSTICS) EN(H4SO 2.0)
(diag)
FUEL INJECTION (FUEL SYSTEMS) FU(H4SO 2.5)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(H4SO 2.5)
INTAKE (INDUCTION) IN(H4SO 2.5)
MECHANICAL ME(H4SO 2.5)
EXHAUST EX(H4SO 2.5)
COOLING CO(H4SO 2.5)

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE SECTION 1
G2320GE2
LUBRICATION LU(H4SO 2.5)
SPEED CONTROL SYSTEMS SP(H4SO 2.5)
IGNITION IG(H4SO 2.5)
STARTING/CHARGING SYSTEMS SC(H4SO 2.5)
ENGINE (DIAGNOSTICS) EN(H4SO 2.5)
(diag)

EXHAUST EX(H4SO 2.0)
Page
1. General Description ....................................................................................2
2. Front Exhaust Pipe......................................................................................7
3. Center Exhaust Pipe.................................................................................10
4. Rear Exhaust Pipe....................................................................................11
5. Muffler.......................................................................................................13

EX(H4SO 2.0)-2
EXHAUST General Description
1. General Description
A: COMPONENT
• 2.0 L model
EX-02020
T7
(19)
(20) (21)
(22)
(19)
(19)
(18)
(17)
(16)
(15)
(14) (8)
(8)
T3
T1
T2
T5
T1
T4
T4
T1
T1
(13)
(1)
(2)
(7)
T3
T1
(5)
(10)
(23)
(24)
(4)
(11)
(6)
(3)
(9)
(12)
T6

EX(H4SO 2.0)-3
EXHAUST
General Description
(1) Front catalytic converter upper
cover (11) Center exhaust pipe lower cover (23) Rear exhaust pipe upper cover
(12) Gasket (24) Rear exhaust pipe lower cover
(2) Front catalytic converter (13) Front catalytic converter lower
cover
(3) Center exhaust pipe Tightening torque: N
⋅ m (kgf-m, ft-lb)
(4) Center exhaust pipe upper cover (14) Front oxygen (A/F) sensor T1: 13 (1.3, 9.4)
(5) Rear catalytic converter upper
cover (15) Gasket T2: 18 (1.8, 13.0)
(16) Spring T3: 21 (2.1, 15.2)
(6) Rear catalytic converter (17) Chamber T4: 30 (3.1, 22.4)
(7) Rear oxygen sensor (18) Rear exhaust pipe T5: 35 (3.6, 26.0)
(8) Gasket (19) Cushion rubber T6: 40.8 (4.2, 30.1)
(9) Front exhaust pipe (20) Self-locking nut T7: 48 (4.9, 35.4)
(10) Rear catalytic converter lower
cover (21) Gasket
(22) Muffler

EX(H4SO 2.0)-4
EXHAUST General Description
• 2.5 L model
(14) (8)
(8)
T3
T1
T2
T5
T1
T4
T4
T1
T1
(13)
(1)
(2)
(5)
(10)
(4)
(11)
(6)
(3)
(9)
(12)
T6
EX-02012
T7
(19)
(20)
(21)
(21)
(23)
(19)
(19)
(19)
(18)
(17)
(16)
(15)
(19)
(22)
T7
(20)
(7)
T3
T1
(24)
(25)

EX(H4SO 2.0)-5
EXHAUST
General Description
(1) Front catalytic converter upper
cover (11) Center exhaust pipe lower cover (23) Muffler (LH)
(12) Gasket (24) Rear exhaust pipe upper cover
(2) Front catalytic converter (13) Front catalytic converter lower
cover (25) Rear exhaust pipe lower cover
(3) Center exhaust pipe
(4) Center exhaust pipe upper cover (14) Front oxygen (A/F) sensor Tightening torque: N
⋅ m (kgf-m, ft-lb)
(5) Rear catalytic converter upper
cover (15) Gasket T1: 13 (1.3, 9.4)
(16) Spring T2: 18 (1.8, 13.0)
(6) Rear catalytic converter (17) Chamber T3: 21 (2.1, 15.2)
(7) Rear oxygen sensor (18) Rear exhaust pipe T4: 30 (3.1, 22.4)
(8) Gasket (19) Cushion rubber T5: 35 (3.6, 26.0)
(9) Front exhaust pipe (20) Self-locking nut T6: 40.8 (4.2, 30.1)
(10) Rear catalytic converter lower
cover (21) Gasket T7: 48 (4.9, 35.4)
(22) Muffler (RH)

EX(H4SO 2.0)-6
EXHAUST General Description
B: CAUTION
• Wear work clothing, including a cap, protective
goggles and protective shoes during operation.
• Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
• Keep the disassembled parts in order and pro-
tect them from dust and 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 yourself, because each
part on the vehicle is hot after running.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or rigid racks at the specified
points.
• Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.

EX(H4SO 2.0)-7
EXHAUST
Front Exhaust Pipe
2. Front Exhaust Pipe
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the front oxygen (A/F) sensor con-
nector.
3) Lift-up the vehicle.
4) Disconnect the rear oxygen sensor connector.
5) Separate the center exhaust pipe from rear ex-
haust pipe.
6) Remove the under cover.
7) Remove the nuts which hold front exhaust pipe
onto cylinder heads.
CAUTION:
Be careful not to pull down the front and center
exhaust pipe assembly.
8) Remove the bolt which holds center exhaust
pipe to hanger bracket.
9) Remove the front and center exhaust pipe as-
sembly from the vehicle.
CAUTION:
• Be careful not to let the front and center ex-
haust pipe assembly fall off when removing as
it is quite heavy.
• After removing the front and center exhaust
pipe assembly, do not apply excessive pulling
force on the rear exhaust pipe.
10) Separate the front exhaust pipe from center ex-
haust pipe.
IN-00203
ME-00859
FU-01116
EX-00214
EX-00215
EX-00216
EX-00217

EX(H4SO 2.0)-8
EXHAUST Front Exhaust Pipe
11) Remove the front oxygen (A/F)sensor and rear
oxygen sensor. <Ref. to FU(H4SO 2.0)-32, RE-
MOVAL, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO 2.0)-33, REMOVAL, Rear Oxygen Sen-
sor.> or <Ref. to FU(H4SO 2.5)-34, REMOVAL,
Front Oxygen (A/F) Sensor.> <Ref. to FU(H4SO
2.5)-35, REMOVAL, Rear Oxygen Sensor.>
B: INSTALLATION
1) Install the front oxygen (A/F) sensor and rear ox-
ygen sensor. <Ref. to FU(H4SO 2.0)-32, INSTAL-
LATION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO 2.0)-33, INSTALLATION, Rear Oxygen
Sensor.>or<Ref.toFU(H4SO2.5)-34,INSTALLA-
TION, Front Oxygen (A/F) Sensor.> <Ref. to
FU(H4SO 2.5)-35, INSTALLATION, Rear Oxygen
Sensor.>
2) Install the front exhaust pipe to center exhaust
pipe.
NOTE:
Use a new gasket.
Tightening torque:
40.8 N
⋅ m (4.2 kgf-m, 30.1 ft-lb)
3) Install the front and center exhaust pipe assem-
bly to the vehicle.
4) Temporarily tighten the bolt which holds the cen-
ter exhaust pipe to hanger bracket.
5) Install the nuts to cylinder head which hold front
exhaust pipe.
Tightening torque:
30 N
⋅ m (3.1 kgf-m, 22.4 ft-lb)
6) Install the under cover.
7) Tighten the bolts which install the center exhaust
pipe to rear exhaust pipe.
Tightening torque:
18 N
⋅ m (1.8 kgf-m, 13.0 ft-lb)
8) Tighten the bolt which holds the center exhaust
pipe to hanger bracket.
Tightening torque:
35 N
⋅ m (3.6 kgf-m, 26.0 ft-lb)
EX-00217
EX-00216
EX-00215
EX-00214
EX-00216

EX(H4SO 2.0)-9
EXHAUST
Front Exhaust Pipe
9) Connect the rear oxygen sensor connector.
10) Lower the vehicle.
11) Connect the front oxygen (A/F) sensor connec-
tor.
12) Connect the battery ground cable to 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.
FU-01116
ME-00859
IN-00203

EX(H4SO 2.0)-10
EXHAUST Center Exhaust Pipe
3. Center Exhaust Pipe
A: REMOVAL
After removing the center and front exhaust pipes
as one unit, separate them. Refer to “Front Exhaust
Pipe” for removal procedure. <Ref. to EX(H4SO
2.0)-7, REMOVAL, Front Exhaust Pipe.>
B: INSTALLATION
Install the center exhaust pipe and front exhaust
pipe as one unit. Refer to “Front Exhaust Pipe” for
installation procedure. <Ref. to EX(H4SO 2.0)-8,
INSTALLATION, Front Exhaust Pipe.>
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(H4SO 2.0)-11
EXHAUST
Rear Exhaust Pipe
4. Rear Exhaust Pipe
A: REMOVAL
1) Separate the rear exhaust pipe from center ex-
haust pipe.
2) Separate the rear exhaust pipe from muffler.
CAUTION:
Be careful not to pull down the rear exhaust
pipe.
•LHside
• RH side (2.5 L model)
3) Apply a coat of spray type lubricant to mating
area of cushion rubber.
4) Remove the rear exhaust pipe bracket from
cushion rubber.
B: INSTALLATION
1) Apply a coat of spray type lubricant to mating
area of cushion rubber.
2) Install the rear exhaust pipe bracket to cushion
rubber.
3) Install the rear exhaust pipe to muffler.
NOTE:
Use a new gasket and self-locking nut.
Tightening torque:
48 N
⋅ m (4.9 kgf-m, 35.4 ft-lb)
•LHside
EX-00214
EX-00222
EX-00218
EX-00219
EX-00219
EX-00222

EX(H4SO 2.0)-12
EXHAUST Rear Exhaust Pipe
• RH side (2.5 L model)
4) Install the rear exhaust pipe to center exhaust
pipe.
Tightening torque:
18 N
⋅ m (1.8 kgf-m, 13.0 ft-lb)
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
cracked.
EX-00218
EX-00214

EX(H4SO 2.0)-13
EXHAUST
Muffler
5. Muffler
A: REMOVAL
1) Separate the muffler from rear exhaust pipe.
•LHside
• RH side (2.5 L model)
2) Apply a coat of spray type lubricant to mating
area of cushion rubber.
•LHside
• RH side (2.5 L model)
3) Remove the front and rear cushion rubber, and
then remove the muffler.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Use a new gasket and self-locking nut.
Tightening torque:
48 N
⋅ m (4.9 kgf-m, 35.4 ft-lb)
•LHside
• RH side (2.5 L model)
C: INSPECTION
1) Make sure there are no exhaust leaks from con-
nections and welds.
2) Make sure there are no holes or rusting.
3) Make sure the cushion rubber is not worn or
cracked.
EX-00222
EX-00218
EX-00220
EX-00221
EX-00222
EX-00218

EX(H4SO 2.0)-14
EXHAUST Muffler