Subaru 2003 Legacy Manuel utilisateur

FUJI HEAVY INDUSTRIES LTD. G2300GE4

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE SECTION 3

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(H4DOSTC)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICES) EC(H4DOSTC)

INTAKE (INDUCTION) IN(H4DOSTC)

MECHANICAL ME(H4DOSTC)

EXHAUST EX(H4DOSTC)

COOLING CO(H4DOSTC)

LUBRICATION LU(H4DOSTC)

SPEED CONTROL SYSTEMS SP(H4DOSTC)

IGNITION IG(H4DOSTC)

STARTING/CHARGING SYSTEMS SC(H4DOSTC)

ENGINE (DIAGNOSTICS) EN(H4DOSTC)

MECHANICAL

ME(H4DOSTC)

Page

1. General Description ....................................................................................2

2. Compression.............................................................................................21

3. Idle Speed.................................................................................................22

4. Ignition Timing...........................................................................................23

5. Intake Manifold Vacuum............................................................................24

6. Engine Oil Pressure..................................................................................25

7. Fuel Pressure............................................................................................26

8. Valve Clearance........................................................................................27

9. Engine Assembly ......................................................................................31

10. Engine Mounting.......................................................................................40

11. Preparation for Overhaul...........................................................................41

12. V-belt.........................................................................................................42

13. Crankshaft Pulley......................................................................................44

14. Belt Cover .................................................................................................46

15. Timing Belt Assembly................................................................................47

16. Camshaft Sprocket....................................................................................55

17. Crankshaft Sprocket..................................................................................56

18. Camshaft...................................................................................................57

19. Cylinder Head Assembly...........................................................................62

20. Cylinder Block...........................................................................................70

21. Engine Trouble in General........................................................................90

22. Engine Noise.............................................................................................95

ME(H4DOSTC)-55

MECHANICAL

CAMSHAFT SPROCKET

16.Camshaft Sprocket

A: REMOVAL

1) Remove the V-belt.

<Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.>

2) Remove the crankshaft pulley.

<Ref. to ME(H4DOSTC)-44, REMOVAL, Crank-

shaft Pulley.>

3) Remove the belt cover.

<Ref. to ME(H4DOSTC)-46, REMOVAL, Belt Cov-

er.>

4) Remove the timing belt assembly.

<Ref. to ME(H4DOSTC)-47, REMOVAL, Timing

Belt Assembly.>

5) Remove the camshaft position sensor.

<Ref. to FU(H4DOSTC)-30, REMOVAL, Camshaft

Position Sensor.>

6) Remove the camshaft sprockets. To lock the

camshaft, use ST.

ST 18231AA010 CAMSHAFT SPROCKET

WRENCH (INTAKE LH)

ST 499207400 CAMSHAFT SPROCKET

WRENCH (Except INTAKE

LH)

B: INSTALLATION

1) Install the camshaft sprocket. To lock the cam-

shaft, use ST.

ST 18231AA010 CAMSHAFT SPROCKET

WRENCH (INTAKE LH)

ST 499207400 CAMSHAFT SPROCKET

WRENCH (Except INTAKE

LH)

Tightening torque:

98 N·m (10 kgf-m, 72.4 ft-lb)

NOTE:

Do not confuse the right and left side camshaft

sprockets intake side during installation. The cam-

shaft sprocket LH is identified by a projection used

to monitor camshaft position sensor.

2) Install the camshaft position sensor.

<Ref. to FU(H4DOSTC)-30, INSTALLATION,

Camshaft Position Sensor.>

3) Install the timing belt assembly.

<Ref. to ME(H4DOSTC)-49, INSTALLATION, Tim-

ing Belt Assembly.>

4) Install the belt cover.

<Ref. to ME(H4DOSTC)-46, INSTALLATION, Belt

Cover.>

5) Install the crankshaft pulley.

<Ref. to ME(H4DOSTC)-44, INSTALLATION,

Crankshaft Pulley.>

6) Install the V-belt.

<Ref. to ME(H4DOSTC)-42, INSTALLATION, V-

belt.>

C: INSPECTION

1) Check the sprocket teeth for abnormal wear and

scratches.

2) Make sure there is no free play between sprock-

et and key.

3) Check the crankshaft sprocket notch used for

sensor for damage and contamination of foreign

matter.

ME-00368

ME(H4DOSTC)-56

MECHANICAL CRANKSHAFT SPROCKET

17.Crankshaft Sprocket

A: REMOVAL

1) Remove the V-belt.

<Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.>

2) Remove the crankshaft pulley.

<Ref. to ME(H4DOSTC)-44, REMOVAL, Crank-

shaft Pulley.>

3) Remove the belt cover.

<Ref. to ME(H4DOSTC)-46, REMOVAL, Belt Cov-

er.>

4) Remove the timing belt assembly.

<Ref. to ME(H4DOSTC)-47, REMOVAL, Timing

Belt Assembly.>

5) Remove the camshaft sprocket.

<Ref. to ME(H4DOSTC)-55, REMOVAL, Camshaft

Sprocket.>

6) Remove the crankshaft sprocket.

B: INSTALLATION

1) Install the crankshaft sprocket.

2) Install the camshaft sprocket.

<Ref. to ME(H4DOSTC)-55, INSTALLATION,

Camshaft Sprocket.>

3) Install the timing belt assembly.

<Ref. to ME(H4DOSTC)-49, INSTALLATION, Tim-

ing Belt Assembly.>

4) Install the belt cover.

<Ref. to ME(H4DOSTC)-46, INSTALLATION, Belt

Cover.>

5) Install the crankshaft pulley.

<Ref. to ME(H4DOSTC)-44, INSTALLATION,

Crankshaft Pulley.>

6) Install the V-belt.

<Ref. to ME(H4DOSTC)-42, INSTALLATION, V-

belt.>

C: INSPECTION

1) Check the sprocket teeth for abnormal wear and

scratches.

2) Make sure there is no free play between sprock-

et and key.

3) Check the crankshaft sprocket notch used for

sensor for damage and contamination of foreign

matter.

ME-00103

ME(H4DOSTC)-57

MECHANICAL

CAMSHAFT

18.Camshaft

A: REMOVAL

1) Remove the V-belt.

<Ref. to ME(H4DOSTC)-42, REMOVAL, V-belt.>

2) Remove the crankshaft pulley.

<Ref. to ME(H4DOSTC)-44, REMOVAL, Crank-

shaft Pulley.>

3) Remove the belt cover.

<Ref. to ME(H4DOSTC)-46, REMOVAL, Belt Cov-

er.>

4) Remove the timing belt assembly.

<Ref. to ME(H4DOSTC)-47, REMOVAL, Timing

Belt Assembly.>

5) Remove the camshaft sprocket.

<Ref. to ME(H4DOSTC)-55, REMOVAL, Camshaft

Sprocket.>

6) Remove the crankshaft sprocket.

<Ref. to ME(H4DOSTC)-56, REMOVAL, Crank-

shaft Sprocket.>

7) Remove the tensioner bracket.

8) Remove the belt cover No. 2 (LH).

9) Remove the belt cover No. 2 (RH).

10) Disconnect the ignition coil connector.

11) Remove the ignition coil.

12) Remove the rocker cover and gasket.

13) Loosentheintakecamshaftcapbolts equally,a

little at a time in alphabetical sequence shown in

the figure.

14) Remove the camshaft cap and intake cam-

shaft.

15) Loosen the exhaust camshaft cap bolts equal-

ly, a little at a time in alphabetical sequence shown

in the figure.

16) Remove the camshaft caps and exhaust cam-

shaft.

NOTE:

Arrange the camshaft caps in order so that they

can be installed in their original positions.

17) Similarly, remove the camshafts (RH) and re-

lated parts.

ME-00105

ME-00106

ME-00107

( A )

( B )

( C )

( D )

( E )

( F )

ME-00369

( A )

( B )

( C )

( D )

( E )

( F ) ME-00370

ME(H4DOSTC)-58

MECHANICAL CAMSHAFT

B: INSTALLATION

1) Camshaft installation:

Apply engine oil to the cylinder head at camshaft

bearing location before installing the camshaft. In-

stall the camshaft so that each valves is close to or

in contact with “base circle”of cam lobe.

NOTE:

•When the camshafts are positioned as shown in

the figure, camshafts need to be rotated at a mini-

mum to align with the timing belt during installation.

•Camshaft (RH) need not be rotated when set at

the position shown in the figure.

Intake camshaft (LH): Rotate 80°clockwise.

Exhaust camshaft (LH): Rotate 45°counterclock-

wise.

2) Camshaft cap installation:

(1) Apply fluid packing sparingly to the cap mat-

ing surface.

NOTE:

Do not apply fluid packing excessively. Failure to

do so may cause excess packing to come out and

flow toward oil seal, resulting in oil leaks.

Fluid packing:

Part No. 004403007

THREE BOND 1215 or equivalent

(2) Apply engine oil to cap bearing surface and

install the cap on camshaft as shown by identifi-

cation mark (A).

(3) Gradually tighten the camshaft cap in at

least two stages in alphabetical sequence

shown in the figure, and then tighten to specified

torque.

Tightening torque:

T1: 10 N·m (1.0 kgf-m, 7.2 ft-lb)

T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)

(4) Similarly, tighten the cap on exhaust side.

After tightening the cap, ensure the camshaft ro-

tates only slightly while holding it at“base”circle.

Tightening torque:

T1: 10 N·m (1.0 kgf-m, 7.2 ft-lb)

T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)

A Left side cylinder head

B Right side cylinder head

(a) Intake camshaft

(b) Exhaust camshaft

ME-00111

77.5

(a)

(b) (a)

(b)

L E

L I

ME-00112

( A )

ME-00371

(F) (D)

(C)

(A) (E)

(B)

ME-00115

(B)

(A) (E)

(F) (D)

(C)

ME(H4DOSTC)-59

MECHANICAL

CAMSHAFT

3) Camshaft oil seal installation:

Apply grease to the new oil seal lips andpress onto

the front end of camshaft by using ST1 and ST2.

NOTE:

Use a new oil seal.

ST1 499587600 OIL SEAL INSTALLER

ST2 499597200 OIL SEAL GUIDE

4) Rocker cover installation:

(1) Install the gasket on rocker cover.

Install the peripheral gasket and ignition coil

gasket.

(2) Apply fluid packing to the indicated portion

on rocker cover.

Fluid packing:

Part No. 004403007

THREE BOND 1215 or equivalent

(3) Install the rocker cover on cylinder head.

Ensure the gasket is properly positioned during

installation.

5) Install the ignition coil.

6) Connect the ignition coil connector.

7) Similarly, install the parts on right-hand side.

8) Install the belt cover No. 2 (RH).

Tightening torque:

5 N·m (0.5 kgf-m, 3.6 ft-lb)

9) Install the tensioner bracket.

Tightening torque:

25 N·m (2.5 kgf-m, 18.1 ft-lb)

10) Install the belt cover No. 2 (LH).

Tightening torque:

5 N·m (0.5 kgf-m, 3.6 ft-lb)

11) Install the crankshaft sprockets.

<Ref. to ME(H4DOSTC)-56, INSTALLATION,

Crankshaft Sprocket.>

12) Install the camshaft sprocket.

<Ref. to ME(H4DOSTC)-55, INSTALLATION,

Camshaft Sprocket.>

13) Install the timing belt assembly.

<Ref. to ME(H4DOSTC)-49, INSTALLATION, Tim-

ing Belt Assembly.>

14) Install the belt cover.

ST1 ST2 ME-00116

ME-00604

ME-00107

ME-00105

ME-00106

ME(H4DOSTC)-60

MECHANICAL CAMSHAFT

<Ref. to ME(H4DOSTC)-46, INSTALLATION, Belt

Cover.>

15) Install the crankshaft pulley.

<Ref. to ME(H4DOSTC)-44, INSTALLATION,

Crankshaft Pulley.>

16) Install the V-belt.

<Ref. to ME(H4DOSTC)-42, INSTALLATION, V-

belt.>

C: INSPECTION

1) Measure the bend, and repair or replace if nec-

essary.

Limit:

0.020 mm (0.0008 in)

2) Check the journal for damage and wear. Re-

place if faulty.

3) Measure the outside diameter of camshaft jour-

nal. If the jounal diameter is not as specified, check

the oil clearance.

4) Measurement of the camshaft journal oil clear-

ance:

(1) Clean the bearing caps and camshaft jour-

nals.

(2) Place the camshafts on cylinder head.

(Without installing the valve rocker.)

(3) Place a plastigauge across each of the cam-

shaft journals.

(4) Gradually tighten the cap in at least two

stages in alphabetical sequence shown in the

figure, and then tighten to specified torque.

Do not turn the camshaft.

Tightening torque:

T1: 10 N·m (1.0 kgf-m, 7.2 ft-lb)

T2: 20 N·m (2.0 kgf-m, 14.5 ft-lb)

(5) Remove the bearing caps.

(6) Measure the widest point of plastigauge on

each journal.

If the oil clearance exceeds the limit, replace the

camshaft. If necessary, replace the camshaft

caps and cylinder head as a set.

Standard:

0.037 — 0.072 mm (0.0015 — 0.0028 in)

Limit:

0.10 mm (0.0039 in)

(7) Completely remove the plastigauge.

5) Check the cam face condition; remove the minor

faults by grinding with oil stone. Measure the cam

height H; replace if the limit has been exceeded.

Cam height: H

Standard:

Intake:

46.25 — 46.35 mm (1.821 — 1.825 in)

Exhaust:

46.15 — 46.25 mm (1.817 — 1.821 in)

Limit:

Intake:

46.15 mm (1.817 in)

Exhaust:

46.65 mm (1.813 in)

Camshaft journal

Front Center, rear

Standard 37.946 —37.963 mm

(1.4939 —1.4946 in) 29.946 —29.963 mm

(1.1790 —1.1796 in)

ME-00118

ME-00371

(F) (D)

(C)

(A) (E)

(B)

ME-00119

ME(H4DOSTC)-61

MECHANICAL

CAMSHAFT

Cam base circle diameter A:

37.0 mm (1.457 in)

6) Measure the thrust clearance of camshaft with

dial gauge. If the clearance exceeds the limit, re-

place the caps and cylinder head as a set. If neces-

sary replace the camshaft.

Standard:

0.015 — 0.070 mm (0.0006 — 0.0028 in)

Limit:

0.1 mm (0.004 in)

ME-00120

ME-00121

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