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)

MECHANICAL
ME(H4SO 2.0)
Page
1. General Description ....................................................................................2
2. Compression.............................................................................................22
3. Idle Speed.................................................................................................23
4. Ignition Timing...........................................................................................24
5. Intake Manifold Vacuum............................................................................25
6. Engine Oil Pressure ..................................................................................26
7. Fuel Pressure............................................................................................27
8. Valve Clearance........................................................................................28
9. Engine Assembly ......................................................................................30
10. Engine Mounting.......................................................................................36
11. Preparation for Overhaul...........................................................................37
12. V-belt.........................................................................................................38
13. Crank Pulley..............................................................................................40
14. Timing Belt Cover......................................................................................42
15. Timing Belt................................................................................................43
16. Cam Sprocket ...........................................................................................48
17. Crank Sprocket .........................................................................................50
18. Valve Rocker Assembly ............................................................................51
19. Camshaft...................................................................................................53
20. Cylinder Head ...........................................................................................57
21. Cylinder Block...........................................................................................63
22. Engine Trouble in General........................................................................83
23. Engine Noise.............................................................................................88

ME(H4SO 2.0)-43
MECHANICAL
Timing Belt
15.Timing Belt
A: REMOVAL
1. TIMING BELT
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO
2.0)-40, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov-
er.>
4) Remove the timing belt guide. (MT model)
5) If the alignment mark (a) or arrow mark (which
indicates rotation direction) on timing belt fade
away, put new marks before removing the timing
belt as shown in procedures below.
(1) To turn crankshaft, use the ST: Align the
mark (a) of sprocket to the cylinder block notch
(b), and then ensure the right side cam sprocket
mark (c), cam cap and cylinder head matching
surface (d) or left side cam sprocket mark (e),
timing belt cover notch (f) are properly adjusted.
ST 499987500 CRANKSHAFT SOCKET
(2) Using white paint, put alignment marks or
arrow marks on the timing belts in relation to the
crank sprocket and cam sprockets.
Specified data:
Z1: Length of 46.8 teeth
Z2: Length of 43.7 teeth
6) Remove the belt idler (No. 2).
ME-0006
5
ME-0023
1
ST
ME-0023
2
(a)
(b)
(d)
(c)
(f)
(e)
ME-0023
3
ME-00023
4
Z1Z2

ME(H4SO 2.0)-44
MECHANICAL Timing Belt
7) Remove the belt idler No. 2.
8) Remove the timing belt.
2. BELT IDLER AND AUTOMATIC BELT
TENSION ADJUSTER ASSEMBLY
1) Remove the belt idler (No. 1).
2) Remove the automatic belt tension adjuster as-
sembly.
B: INSTALLATION
1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER
1) Preparation for installation of automatic belt ten-
sion adjuster assembly.
CAUTION:
• Always use a vertical type pressing tool to
move the adjuster rod down.
• Do not use a lateral type vise.
• Push the adjuster rod vertically.
• Press-in the push adjuster rod gradually tak-
ing more than three minutes.
• Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
• Press the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into cylinder. Doing so may damage the cyl-
inder.
• Do not release the press pressure until stop-
per pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kgf, 66 lb) until the adjust-
er rod is aligned with the stopper pin hole in the
cylinder.
(3) With a 2 mm (0.08 in) dia. stopper pin or a 2
mm (0.08 in) (nominal) dia. hex wrench inserted
into the stopper pin hole in cylinder, secure the
adjuster rod.
ME-0023
5
ME-0023
6
ME-0023
7
ME-0023
8
ME-0023
9
ME-0035
0

ME(H4SO 2.0)-45
MECHANICAL
Timing Belt
2) Install the automatic belt tension adjuster as-
sembly.
Tightening torque:
39 N
⋅ m (4.0 kgf-m, 28.9 ft-lb)
3) Install the belt idler (No. 1).
Tightening torque:
39 N
⋅ m (4.0 kgf-m, 28.9 ft-lb)
2. TIMING BELT
1) Prepare for installation of automatic belt tension
adjuster assembly. <Ref.toME(H4SO 2.0)-44, AU-
TOMATIC BELT TENSION ADJUSTER ASSEM-
BLY AND BELT IDLER, INSTALLATION, Timing
Belt.>
2) Installation of timing belt:
(1) Turn the cam sprocket No. 2 using ST1, and
turn the cam sprocket No. 1 using ST2 so that
their alignment marks (A) come to top positions.
ST1 18231AA010 CAM SPROCKET WRENCH
NOTE:
CAM SPROCKET WRENCH (499207100) can
also be used.
ST2 499207400 CAM SPROCKET WRENCH
(2) While aligning the alignment mark (B) on
timing belt with the mark (A) on sprockets, posi-
tion the timing belt properly.
3) Install the belt idler No. 2.
Tightening torque:
39 N
⋅ m (4.0 kgf-m, 28.9 ft-lb)
4) Install the belt idler (No. 2).
Tightening torque:
39 N
⋅ m (4.0 kgf-m, 28.9 ft-lb)
ME-0024
1
ME-0024
2
ME-0024
3
(A)
ME-0024
4
ME-0023
5

ME(H4SO 2.0)-46
MECHANICAL Timing Belt
5) After ensuring the marks on timing belt and cam
sprockets are aligned, remove the stopper pin from
belt tension adjuster.
6) Install the timing belt guide. (MT model)
(1) Temporarily tighten the timing belt guide
mounting bolts.
(2) Check and adjust the clearance between
timing belt and timing belt guide by using thick-
ness gauge.
Clearance:
1.0
± 0.5 mm (0.039 ± 0.020 in)
(3) Tighten the timing belt guide mounting bolts.
Tightening torque:
10 N
⋅ m (1.0 kgf-m, 7.2 ft-lb)
7) Install the timing belt cover.
<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
ing Belt Cover.>
8) Install the crank pulley. <Ref. to ME(H4SO 2.0)-
40, INSTALLATION, Crank Pulley.>
9) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
INSTALLATION, V-belt.>
C: INSPECTION
1. TIMING BELT
1) Check the timing belt teeth for breaks, cracks
and wear. If any fault is found, replace the belt.
2) Check the condition of the backside of belt. If
cracks are found, replace the belt.
CAUTION:
• Be careful not to let oil, grease or coolant
contact the belt. Remove quickly and thorough-
ly if this happens.
• Do not bend the timing belt sharply.
In radial diameter h:
60 mm (2.36 in) or more
ME-0024
5
ME-0023
0
ME-0024
6
ME-0024
7
ME-0024
8
h

ME(H4SO 2.0)-47
MECHANICAL
Timing Belt
2. AUTOMATIC BELT TENSION ADJUST-
ER
1) Visually check the oil seals for leaks, and rod
ends for abnormal wear or scratches. If necessary,
replace the faulty parts.
2) Check that the adjuster rod does not move when
a pressure of 294 N (30 kgf, 66 lb) is applied to it.
This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kgf, 66 lb), check it using
the following procedures:
(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this opera-
tion two to three times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kgf, 66 lb) to it.
Check the adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension adjust-
er assembly with a new one.
CAUTION:
• Always use a vertical type pressing tool to
move the adjuster rod down.
• Do not use a lateral type vise.
• Push the adjuster rod vertically.
• Press the adjuster rod gradually taking more
than three minutes.
• Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lb).
• Press the adjuster rod as far as the end sur-
face of cylinder. Do not press the adjuster rod
into cylinder. Doing so may damage the cylin-
der.
4) Measure the amount of rod protrusion beyond
the body. If it is not within specifications, replace
with a new one.
Amount of rod protrusion H:
5.7
± 0.5 mm (0.224 ± 0.020 in)
3. BELT TENSION PULLEY
1) Check the mating surfaces of timing belt and
contact point of adjuster rod for abnormal wear or
scratches. Replace the automatic belt tension ad-
juster assembly if faulty.
2) Check the belt tension pulley for smooth rota-
tion. Replace if noise or excessive play occurs.
3) Check the belttension pulley for greaseleakage.
4. BELT IDLER
1) Check the belt idler for smooth rotation. Replace
if noise or excessive play occurs.
2) Check the outer contacting surfaces of idler pul-
ley for abnormal wear and scratches.
3) Check the belt idler for grease leakage.
ME-0024
9
H

ME(H4SO 2.0)-48
MECHANICAL Cam Sprocket
16.Cam Sprocket
A: REMOVAL
1) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,
REMOVAL, V-belt.>
2) Remove the crank pulley. <Ref. to ME(H4SO
2.0)-40, REMOVAL, Crank Pulley.>
3) Remove the timing belt cover. <Ref. to
ME(H4SO 2.0)-42, REMOVAL, Timing Belt Cov-
er.>
4) Remove the timing belt. <Ref. to ME(H4SO 2.0)-
43, REMOVAL, Timing Belt.>
5) Remove the camshaft position sensor. <Ref. to
FU(H4SO 2.0)-22, REMOVAL, Camshaft Position
Sensor.>
6) Remove the cam sprocket No. 2. To lock the
camshaft, use ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
CAM SPROCKET WRENCH (499207100) can
also be used.
7) Remove the cam sprocket No. 1. To lock the
camshaft, use ST.
ST 499207400 CAM SPROCKET WRENCH
B: INSTALLATION
1) Install the cam sprocket No. 1. To lock the cam-
shaft, use ST.
ST 499207400 CAM SPROCKET WRENCH
Tightening torque:
78 N
⋅ m (8.0 kgf-m, 57.9 ft-lb)
NOTE:
Do not confuse left and right side cam sprockets
during installation. Cam sprocket No. 2 is identified
by a protrusion used to monitor the camshaft posi-
tion sensor.
2) Install the cam sprocket No. 2. To lock the cam-
shaft, use ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
CAM SPROCKET WRENCH (499207100) can
also be used.
Tightening torque:
78 N
⋅ m (8.0 kgf-m, 57.9 ft-lb)
3) Install the camshaft position sensor. <Ref. to
FU(H4SO 2.0)-22, INSTALLATION, Camshaft Po-
sition Sensor.>
4) Install the timing belt. <Ref. to ME(H4SO 2.0)-
44, INSTALLATION, Timing Belt.>
5) Install the timing belt cover.
<Ref. to ME(H4SO 2.0)-42, INSTALLATION, Tim-
ing Belt Cover.>
6) Install the crank pulley. <Ref. to ME(H4SO 2.0)-
40, INSTALLATION, Crank Pulley.>
7) Install the V-belts. <Ref. to ME(H4SO 2.0)-38,
INSTALLATION, V-belt.>
C: INSPECTION
1) Check the cam sprocket teeth for abnormal wear
and scratches.
2) Make sure there is no free play between cam
sprocket and key.
ME-0025
0
ST
ME-0025
1
ST
ME-0025
1
ST
ME-0025
0
ST

ME(H4SO 2.0)-49
MECHANICAL
Cam Sprocket
3) Check the cam sprocketprotrusion used for sen-
sor for damage and contamination of foreign mat-
ter.