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