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)