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)

FUEL INJECTION
(FUEL SYSTEMS)
FU(H4SO 2.0)
Page
1. General Description ....................................................................................2
2. Throttle Body.............................................................................................10
3. Intake Manifold..........................................................................................11
4. Engine Coolant Temperature Sensor........................................................20
5. Crankshaft Position Sensor.......................................................................21
6. Camshaft Position Sensor.........................................................................22
7. Knock Sensor............................................................................................23
8. Throttle Position Sensor............................................................................25
9. Manifold Absolute Pressure Sensor..........................................................26
10. Intake Air Temperature Sensor.................................................................27
11. EGR Valve ................................................................................................28
12. Fuel Injector ..............................................................................................29
13. Front Oxygen (A/F) Sensor.......................................................................32
14. Rear Oxygen Sensor.................................................................................33
15. Engine Control Module (ECM)..................................................................34
16. Main Relay................................................................................................35
17. Fuel Pump Relay.......................................................................................36
18. Electronic Throttle Control Relay ..............................................................37
19. Fuel...........................................................................................................38
20. Fuel Tank..................................................................................................39
21. Fuel Filler Pipe..........................................................................................45
22. Fuel Pump.................................................................................................47
23. Fuel Level Sensor .....................................................................................49
24. Fuel Sub Level Sensor..............................................................................50
25. Fuel Filter..................................................................................................51
26. Fuel Damper Valve ...................................................................................52
27. Fuel Delivery, Return and Evaporation Lines............................................53
28. Fuel System Trouble in General ...............................................................56

FU(H4SO 2.0)-2
FUEL INJECTION (FUEL SYSTEMS) General Description
1. General Description
A: 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 441 — 686 kPa (4.50 — 7.00 kg/cm2, 64.0 — 99.5 psi)
Discharge 75 2(19.8 US gal, 16.5 Imp gal)/h or more
[12 V at 300 kPa (3.06 kg/cm2, 43.5 psi)]
Fuel filter In-tank type

FU(H4SO 2.0)-3
FUEL INJECTION (FUEL SYSTEMS)
General Description
B: COMPONENT
1. INTAKE MANIFOLD
FU-02056
(3)
(12)
(10)
(14)
(19) (11)
(13)
(8)
(7)
(9)
(16)
(16)
(16)
(3)
(18)
(18)
(12)
(15)
(18)
(6)
(2)
(2)
(17)
(5)
(1)
(9)
(8)
(10)
T2
T1
T1
T1
T1
T1
T1
T5
T4
T4
T4
T2
T5
T4
T4
T3
T3
T5
T5
T5
(4)
T4
T4
T4
(7)
T2
T4
(17)
T2
T6
T2
T2
(12)

FU(H4SO 2.0)-4
FUEL INJECTION (FUEL SYSTEMS) General Description
2. AIR INTAKE SYSTEM
(1) Intake manifold (10) O-ring (19) PCV valve
(2) Gasket (11) Purge control solenoid valve
(3) Guide pin (12) Plug cord holder Tightening torque: N
⋅ m (kgf-m, ft-lb)
(4) EGR valve (EC, EK, K4 model) (13) Nipple (LHD model) T1: 1.5 (0.15, 1.1)
(5) Fuel pipe protector RH (14) Nipple (RHD model) T2: 6.4 (0.65, 4.7)
(6) Fuel pipe protector LH (15) Fuel pipe ASSY T3: 17 (1.7, 12.5)
(7) Fuel injector pipe (16) Fuel hose T4: 19 (1.9, 13.7)
(8) Fuel injector (17) Clip T5: 25 (2.5, 18.1)
(9) O-ring (18) Clamp T6: 23 (2.3, 17.0)
(1) Gasket (4) O-ring Tightening torque: N
⋅ m (kgf-m, ft-lb)
(2) Throttle body T1: 2.0 (0.20, 1.5)
(3) Manifold absolute pressure sensor T2: 8 (0.8, 5.8)
FU-02057
T2
(3)
(4)
T1
(2)
(1)

FU(H4SO 2.0)-5
FUEL INJECTION (FUEL SYSTEMS)
General Description
3. CRANKSHAFT POSITION, 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 2.0)-6
FUEL INJECTION (FUEL SYSTEMS) General Description
4. FUEL TANK
FU-01080
T4
T1
T4
T3
T3
T3
T2
T3 T3
T4
T1
(16)
(14)
(15)
(15)
(17)
(18)
(19)
(17)
(6)
(22)
(5)
(4)
(3)
(23)
(24) (25)
(2)
(20)
(21)
(11)
(12)
(13)
(8)
(7)
(10)
(9)
(1)
T2 T3
(22)

FU(H4SO 2.0)-7
FUEL INJECTION (FUEL SYSTEMS)
General Description
(1) Fuel tank (12) Fuel sub level sensor upper plate (22) Retainer
(2) Fuel tank band RH (13) Fuel sub level sensor gasket (23) Heat shield cover
(3) Fuel tank band LH (14) Fuel filler hose (24) Fuel tank protector RH (Front)
(4) Delivery tube (15) Clamp (25) Fuel tank protector LH (Front)
(5) Return tube (16) Vent hose
(6) Jet pump tube (17) Clip Tightening torque: N
⋅ m (kgf-m, ft-lb)
(7) Fuel pump assembly (18) Fuel tank protector RH (Rear) T1: 4.4 (0.45, 3.3)
(8) Fuel pump upper plate (19) Fuel tank protector LH (Rear) T2: 9.0 (0.92, 6.6)
(9) Fuel pump gasket (20) Stopper RH T3: 17.5 (1.78, 12.9)
(10) Fuel level sensor (21) Stopper LH T4: 33 (3.4, 25)
(11) Fuel sub level sensor

FU(H4SO 2.0)-8
FUEL INJECTION (FUEL SYSTEMS) General Description
5. FUEL LINE
FU-01081
(1)
(1)
(1)
(1)
(9) (32)
(30) (31)
(11)
(15)
(1)
(1)
(16)
(1)
(20)
(19)
(14)
(13)
(12)
(1) (22)
(22)
(10)
(29)
(17)
(26)
(25)
(24)
(18) (23)
(1)
(21)
(34)
(28)
(27)
T2
T1
T3
T2
T2
T2
(33)
B
A
A
B
(1)
(3) (2)
(4) (5)
(6)
(7)
(8)

FU(H4SO 2.0)-9
FUEL INJECTION (FUEL SYSTEMS)
General Description
C: 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.
• Place “NO FIRE” signs near the working area.
• Be careful not to spill fuel on the floor.
D: PREPARATION TOOL
(1) Clip (14) Two-way valve hose A (27) Filler cap
(2) Fuel return hose (15) Purge hose A (28) Tether
(3) Evaporation hose A (16) Purge hose B (29) Clip
(4) Fuel delivery hose A (17) Two-way valve hose B (30) Fuel hose
(5) Fuel delivery hose B (18) Canister drain hose B (31) Purge hose C
(6) Fuel damper (19) Two-way valve drain hose (32) Connector
(7) Fuel damper holder (20) Two-way valve (33) Purge pipe
(8) Fuel damper bracket (21) Two-way valve hose C (34) Two-way valve bracket
(9) Fuel pipe ASSY (22) Connector
(10) Clamp (23) Evaporation hose holder Tightening torque: N
⋅ m (kgf-m, ft-lb)
(11) Canister (24) Fuel filler pipe ASSY T1: 4.4 (0.45, 3.2)
(12) Canister protector (Sedan model) (25) Filler pipe packing T2: 7.5 (0.76, 5.53)
(13) Canister drain hose A (26) Filler ring T3: 8.3 (0.85, 6.1)
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
24082AA230 CARTRIDGE Troubleshooting for electrical system.
22771AA030 SUBARU SELECT
MONITOR KIT Troubleshooting for electrical system. • English: 22771AA030 (Without printer)
• German: 22771AA070 (Without printer)
• French: 22771AA080 (Without printer)
• Spanish: 22771AA090 (Without printer)
ST24082AA23
0
ST22771AA03
0

FU(H4SO 2.0)-10
FUEL INJECTION (FUEL SYSTEMS) Throttle Body
2. Throttle Body
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the air intake chamber. <Ref. to
IN(H4SO 2.0)-8, REMOVAL, Air Intake Chamber.>
3) Disconnectthe connectors from thethrottle posi-
tion sensor and manifold absolutepressure sensor.
4) Disconnect the engine coolant hoses from throt-
tle body.
5) Remove the bolts which secure throttle body to
intake manifold.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Use a new gasket.
Tightening torque:
8 N
⋅ m (0.8 kgf-m, 5.8 ft-lb)
(A) Throttle position sensor
(B) Manifold absolute pressure sensor
IN-00203
FU-02058
(A)
(B)
FU-02059

FU(H4SO 2.0)-11
FUEL INJECTION (FUEL SYSTEMS)
Intake Manifold
3. Intake Manifold
A: REMOVAL
1) Release the fuel pressure.
<Ref. to FU(H4SO 2.0)-38, RELEASING OF FUEL
PRESSURE, PROCEDURE, Fuel.>
2) Open the fuel filler flap lid, and remove the fuel
filler cap.
3) Disconnect the ground cable from battery.
4) Remove the air cleaner case and air intake
chamber. <Ref. to IN(H4SO 2.0)-6, REMOVAL, Air
Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, REMOV-
AL, Air Intake Chamber.>
5) Disconnect the spark plug cords from spark
plugs.
6) Disconnect the engine coolant hoses from throt-
tle body.
7) Disconnect the PCV hose from intake manifold.
8) Disconnect the brake booster hose.
9) Disconnect the engine harness connectors from
bulkhead harness connectors.
10) Disconnect the connectors from engine coolant
temperature sensor.
11) Disconnect the knock sensor connector.
12) Disconnect the connector from crankshaftposi-
tion sensor.
13) Disconnect the connector from power steering
pump switch (A).
IN-00203
FU-02060
FU-0208
9
FU-02061
FU-00055
FU-01334
FU-0005
6

FU(H4SO 2.0)-12
FUEL INJECTION (FUEL SYSTEMS) Intake Manifold
14) Disconnect the connector from oil pressure
switch (B).
15) Disconnect the connector from camshaft posi-
tion sensor.
16) Remove the EGR pipe from intake manifold.
(EC, EK, K4 model)
17) Disconnect the fuel hoses from fuel pipes.
WARNING:
• Be careful not to spill fuel.
• Catch the fuel from hoses using a container
or cloth.
18) Remove the bolts which secure intakemanifold
to cylinder head.
19) Remove the intake manifold.
B: INSTALLATION
1) Install the intake manifold onto cylinder heads.
NOTE:
Use a new gasket.
Tightening torque:
25 N
⋅ m (2.5 kgf-m, 18.1 ft-lb)
2) Connect the fuel hoses.
FU-01087
(B)
(A)
FU-01335
FU-0014
8
(A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
FU-02062
(A)
(C)
(B)
FU-0026
0
FU-0026
0

FU(H4SO 2.0)-13
FUEL INJECTION (FUEL SYSTEMS)
Intake Manifold
NOTE:
If fuel hoses or clamps are damaged, replace them
with new ones.
Tightening torque (Hose clamp screw):
1.25 N
⋅ m (0.13 kgf-m, 0.94 ft-lb)
3) Install the EGR pipe to intake manifold. (EC, EK,
K4 model)
Tightening torque:
34 N
⋅ m (3.4 kgf-m, 24.6 ft-lb)
4) Connect the connector to camshaft position sen-
sor.
5) Connect the connector to power steering pump
switch (A).
6) Connect the connector to oilpressure switch (B).
7) Connect the connector to crankshaft position
sensor.
8) Connect the knock sensor connector.
9) Connect the connectors to engine coolant tem-
perature sensor.
10) Connect the PCV hose to intake manifold.
(A) Fuel delivery hose
(B) Return hose
(C) Evaporation hose
FU-02062
(A)
(C)
(B)
FU-0014
8
FU-01335
FU-01087
(B)
(A)
FU-0005
6
FU-01334
FU-00055

FU(H4SO 2.0)-14
FUEL INJECTION (FUEL SYSTEMS) Intake Manifold
11) Connect the brake booster hose.
12) Connect the engine harness connectors to
bulkhead harness connectors.
13) Connect the engine coolant hoses to throttle
body.
14) Connect the spark plug cords to spark plugs.
15) Install the air cleaner case and air intake cham-
ber. <Ref. to IN(H4SO 2.0)-7, INSTALLATION, Air
Cleaner Case.> <Ref. to IN(H4SO 2.0)-8, INSTAL-
LATION, Air Intake Chamber.>
16) Install the fuse of fuel pump to main fuse box.
17) Connect the battery ground cable to battery.
C: DISASSEMBLY
1) Disconnect the engine ground terminal from in-
take manifold.
2) Remove the ignition coil & ignitor ASSY. <Ref. to
IG(H4SO 2.0)-8, REMOVAL, Ignition Coil & Ignitor
ASSY.>
3) Remove the throttle body. <Ref. to FU(H4SO
2.0)-10, REMOVAL, Throttle Body.>
4) Remove the EGR valve. (EC, EK, K4 model)
<Ref. to FU(H4SO 2.0)-28, REMOVAL, EGR
Valve.>
5) Disconnect the pressure regulator vacuum hose
from intake manifold.
6) Remove the fuel pipe protector LH.
FU-0208
9
FU-02061
FU-02060
IN-00203
FU-02063
FU-02064
FU-02065

FU(H4SO 2.0)-15
FUEL INJECTION (FUEL SYSTEMS)
Intake Manifold
7) Remove the fuel pipe protector RH.
8) Disconnect the connectors from fuel injector.
9) Remove the purge control solenoid valve. <Ref.
to EC(H4SO 2.0)-7, REMOVAL, Purge Control So-
lenoid Valve.>
10) Remove the harness band (A) and bolts (B),
(C) which secure engine harness to intake mani-
fold.
11) Remove the engine harness from intake mani-
fold.
12) Remove the bolts which install injector pipe on
the intake manifold as shown in the figure.
• RH side
•LHside
13) Remove the fuel injector.
FU-02066
FU-02067
FU-02068
(A) (A)
(A)
(B)
FU-02069
(C)
FU-02070
FU-02071
FU-02072
FU-02073

FU(H4SO 2.0)-16
FUEL INJECTION (FUEL SYSTEMS) Intake Manifold
(1) Remove the clip which secures fuel injector
from injector pipe.
(2) Remove the fuel injector with lifting up the
fuel injector pipe.
14) Loosen theclamp which holds fuel injector pipe
LH to fuel hose, and then disconnect the pipe from
fuel hose.
15) Loosen theclamp which holds fuel injector pipe
RH to fuel hose, and then disconnect the pipe from
fuel hose.
16) Remove the fuel injector pipe.
17) Remove the bolt which installs fuel pipes on in-
take manifold.
18) Remove the fuel pipe assembly and pressure
regulator, from intake manifold.
D: ASSEMBLY
1) Install the fuel pipe assembly and pressure reg-
ulator to intake manifold.
NOTE:
• Use a new gasket.
• When assembling thenipple, apply liquid gasket.
Liquid gasket:
THREE BOND 1105 (Part No. 004403010)
2) Tighten the bolt which installs fuel pipes on in-
take manifold.
Tightening torque:
6.4 N
⋅ m (0.65 kgf-m, 4.7 ft-lb)
3) Connect the fuel injector pipe RH to fuel hose,
and tighten the clamp screw.
FU-02074
FU-0207
5
FU-0207
6
FU-0207
7
FU-0207
7
FU-0207
6

FU(H4SO 2.0)-17
FUEL INJECTION (FUEL SYSTEMS)
Intake Manifold
4) Connect the fuel injector pipe LH to fuel hose,
and tighten the clamp screw.
5) Install the fuel injectors.
6) Install the clip which secures fuel injector.
7) Tighten the bolts which install injectorpipe on in-
take manifold.
• RH side
Tightening torque:
19 N
⋅ m (1.9 kgf-m, 13.7 ft-lb)
Tightening torque:
6.4 N
⋅ m (0.65 kgf-m, 4.7 ft-lb)
•LHside
Tightening torque:
19 N
⋅ m (1.9 kgf-m, 13.7 ft-lb)
Tightening torque:
6.4 N
⋅ m (0.65 kgf-m, 4.7 ft-lb)
8) Install the engine harness onto intake manifold.
FU-0207
5
FU-02074
FU-02070
FU-02071
FU-02078
FU-02073

FU(H4SO 2.0)-18
FUEL INJECTION (FUEL SYSTEMS) Intake Manifold
9) Secure the engine harness with harness band
(A) and bolts (B), (C).
Tightening torque:
(B): 16 N
⋅ m (1.6 kgf-m, 11.8 ft-lb)
(C): 6.4 N
⋅ m (0.65 kgf-m, 4.7 ft-lb)
10) Install the purge control solenoid valve. <Ref.
to EC(H4SO 2.0)-7, INSTALLATION, Purge Con-
trol Solenoid Valve.>
11) Connect the connectors to fuel injector.
12) Install the fuel pipe protector RH.
Tightening torque:
19 N
⋅ m (1.9 kgf-m, 13.7 ft-lb)
13) Install the fuel pipe protector LH.
Tightening torque:
19 N
⋅ m (1.9 kgf-m, 13.7 ft-lb)
14) Connect the pressure regulator vacuum hose
to intake manifold.
15) Install the EGR valve. (EC, EK, K4 model)
<Ref. to FU(H4SO 2.0)-28, INSTALLATION, EGR
Valve.>
16) Install the throttle body to intake manifold.
<Ref. to FU(H4SO 2.0)-10, INSTALLATION, Throt-
tle Body.>
17) Install the ignition coil & ignitor ASSY. <Ref. to
IG(H4SO 2.0)-8, INSTALLATION, Ignition Coil &
Ignitor ASSY.>
18) Install the engine ground terminal to intake
manifold.
FU-02068
(A) (A)
(A)
(B)
FU-02069
(C)
FU-02067
FU-02066
FU-02065
FU-02064