Subaru 2003 Legacy Manuel utilisateur

FUJI HEAVY INDUSTRIES LTD. G2300GE2

2003 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)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICES) EC(H4SO)

INTAKE (INDUCTION) IN(H4SO)

MECHANICAL ME(H4SO)

EXHAUST EX(H4SO)

COOLING CO(H4SO)

LUBRICATION LU(H4SO)

SPEED CONTROL SYSTEMS SP(H4SO)

IGNITION IG(H4SO)

STARTING/CHARGING SYSTEMS SC(H4SO)

ENGINE (DIAGNOSTICS) EN(H4SO)

FUEL INJECTION (FUEL SYSTEMS) FU(H4SOw/oOBD)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICES) EC(H4SOw/oOBD)

INTAKE (INDUCTION) IN(H4SOw/oOBD)

MECHANICAL ME(H4SOw/oOBD)

EXHAUST EX(H4SOw/oOBD)

COOLING CO(H4SOw/oOBD)

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE SECTION 1

G2300GE2

LUBRICATION LU(H4SOw/oOBD)

SPEED CONTROL SYSTEMS SP(H4SOw/oOBD)

IGNITION IG(H4SOw/oOBD)

STARTING/CHARGING SYSTEMS SC(H4SOw/oOBD)

ENGINE (DIAGNOSTICS) EN(H4SOw/oOBD)

COOLING CO(H4SO)

Page

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

2. Radiator Main Fan System..........................................................................6

3. Radiator Sub Fan System.........................................................................10

4. Engine Coolant..........................................................................................14

5. Water Pump..............................................................................................16

6. Thermostat................................................................................................21

7. Radiator.....................................................................................................23

8. Radiator Cap.............................................................................................27

9. Radiator Main Fan and Fan Motor............................................................28

10. Radiator Sub Fan and Fan Motor..............................................................30

11. Reservoir Tank..........................................................................................32

12. Engine Cooling System Trouble in General..............................................33

CO(H4SO)-2

COOLING GENERAL DESCRIPTION

1. General Description

A: SPECIFICATIONS

Cooling system Electric fan + Forced engine coolant circula-

tion system

Total engine coolant capacity 2(US qt, Imp qt)

2.0 L MT: Approx. 7.0 (7.4, 6.2)

2.0 L AT: Approx. 6.9 (7.3, 6.1)

2.5 L MT: Approx. 6.8 (7.2, 6.0)

2.5 L AT: Approx. 6.7 (7.1, 5.9)

Water pump

Type Centrifugal impeller type

Discharge performance I Discharge 20 2(5.3 US gal, 4.4 Imp gal)/min.

Pump speed—pressure leak 760 rpm —0.3 mAq (1.0 ftAq)

Engine coolant temperature 85°C (185°F)

Discharge performance II Discharge 100 2(26.4 US gal, 22.0 Imp gal)/min.

Pump speed—pressure leak 3,000 rpm —5.0 mAq (16.4 ftAq)

Engine coolant temperature 85°C (185°F)

Discharge performance III Discharge 200 2(52.8 US gal, 44.0 Imp gal)/min.

Pump speed—pressure leak 6,000 rpm —23.0 mAq (75.5 ftAq)

Engine coolant temperature 85°C (185°F)

Impeller diameter 76 mm (2.99 in)

Number of impeller vanes 8

Pump pulley diameter 60 mm (2.36 in)

Clearance between impel-

ler and case Standard 0.5 —0.7 mm (0.020 —0.028 in)

Limit 1.0 mm (0.039 in)

“Thrust”runout of impeller end 0.5 mm (0.020 in)

Thermostat

Type Wax pellet type

Starts to open With OBD 80 —84°C (176 —183°F)

Without OBD 76 —80°C (169 —176°F)

Fully opened With OBD 95°C (203°F)

Without OBD 91°C (196°F)

Valve lift 9.0 mm (0.354 in) or more

Valve bore 35 mm (1.38 in)

Radiator fan Motor 75 W (main fan)

75 W (sub fan)

Fan diameter ×Blade 300 mm (11.81 in) ×5 (main fan)

300 mm (11.81 in) ×4 (sub fan)

Radiator

Type Down flow, pressure type

Core dimensions 691.5 ×340 ×16 mm

(27.22 ×13.39 ×0.63 in)

Pressure range in which cap valve is open or closed

Above: 108±15 kPa

(1.1±0.15 kg/cm2, 16±2 psi)

Below: −1.0 to −4.9 kPa

(−0.01 to −0.05 kg/cm2, −0.1 to −0.7 psi)

Fins Corrugated fin type

Reservoir tank Capacity 0.5 2(0.5 US qt, 0.4 Imp qt)

CO(H4SO)-3

COOLING

GENERAL DESCRIPTION

B: COMPONENT

1. WATER PUMP

(1) Water pump ASSY (5) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Gasket (6) Thermostat cover T1: First 12 (1.2, 8.7)

Second 12 (1.2, 8.7)

(3) Heater by-pass hose

(4) Thermostat T2: 6.5 (0.66, 4.8)

CO-00001

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

CO(H4SO)-4

COOLING GENERAL DESCRIPTION

2. RADIATOR AND RADIATOR FAN

(1) Radiator lower cushion (12) Main fan shroud (19) ATF inlet hose B (AT vehicles

only)

(2) Radiator (13) Radiator main fan and main fan

motor ASSY

(3) Radiator upper cushion (20) Radiator outlet hose

(4) Radiator upper bracket (14) ATF hose clamp (AT vehicles

only) (21) Radiator drain plug

(5) Clamp (22) O-ring

(6) Radiator inlet hose (15) ATF inlet hose A (AT vehicles

only) (23) Radiator lower bracket

(7) Engine coolant reservoir tank cap

(8) Overflow hose (16) ATF outlet hose A (AT vehicles

only) Tightening torque: N·m (kgf-m, ft-lb)

(9) Engine coolant reservoir tank T1: 4.4 (0.45, 3.3)

(10) Sub fan shroud (17) ATF pipe (AT vehicles only) T2: 12 (1.2, 8.7)

(11) Radiator sub fan and sub fan

motor ASSY (18) ATF outlet hose B (AT vehicles

only) T3: 18 (1.8, 13.0)

T4: 3.4 (0.35, 2.5)

T5: 4.9 (0.50, 3.6)

(19)

(15)

(14)

( 7 )

( 8 )

CO-00081

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 )

( 9 )

(10)

(11)

(12)

(13)

(16)

(17)

(18)

(20)

(21)

(22)

(23)

CO(H4SO)-5

COOLING

GENERAL DESCRIPTION

C: CAUTION

•Wear working clothing, including a cap, protec-

tive goggles, and protective shoes during opera-

tion.

•Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

•Keep the disassembled parts in order and pro-

tect them from dust or 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 your hands, because each

part in the vehicle is hot after running.

•Be sure to tighten fasteners including bolts and

nuts to the specified torque.

•Place shopjacks or safety stands atthe specified

points.

•Before disconnecting electrical connectors of

sensors or units, be sure to disconnect ground ca-

ble from battery.

D: PREPARATION TOOL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499977100 CRANKSHAFT PUL-

LEY WRENCH Used for fixing crankshaft pulley when loos-

ening and tightening crankshaft pulley bolts.

(2500 cc model)

499977400 CRANKSJAFT PUL-

LEY WRENCH Used for fixing crankshaft pulley when loos-

ening and tightening crankshaft pulley bolts.

(2000 cc model)

18231AA010 CAMSHAFT

SPROCKET

WRENCH

•Used for removing and installing camshaft

sprocket.

•Camshaft sprocket wrench (499207100) is

also available.

ST-499977100

ST-499977400

ST18231AA010

CO(H4SO)-6

COOLING RADIATOR MAIN FAN SYSTEM

2. Radiator Main Fan System

A: SCHEMATIC

CO-00169

20A

SUB FAN

RELAY

AIR CONDITIONING RELAY HOLDER

SUB FAN

MOTOR

MAIN FAN

MOTOR

MAIN FAN

RELAY

F28

F16

F66 F27

F17

B100 F2

B72

NO. 18

NO. 17

SBF-4

SBF-1

IGNITION

SWITCH

B72

B134

1 2 3 4 5 6 7 8

10 11 12 13 14 15 16 17 18 19 20 21 22 23

24 25 26 27 28 29 30 31 32 33 34 35

BATTERY

B134

ECM

F16 F17

2 1

F27

1 2

3 4

5 6 7

12 14 21

22 24 31

32 34

1615 17

2625 27

F66 F28

: 14

: 3

: 13

: 12

WITH OBD

WITHOUT OBD

*WITH OBD

WITHOUT OBD

12 89

10 11

12 13 14 15 16 17 18 19 20 21 22 23 24

56 7

CO(H4SO)-7

COOLING

RADIATOR MAIN FAN SYSTEM

B: INSPECTION

DETECTING CONDITION:

Condition:

•Engine coolant temperature is above 95°C (203°F).

•Vehicle speed is below 19 km/h (12 MPH).

TROUBLE SYMPTOM:

•Radiator main fan does not rotate under the above conditions.

Step Value Yes No

1 CHECK POWER SUPPLY TO MAIN FAN MO-

TOR.

CAUTION:

Be careful not to overheat engine during re-

pair.

1) Turn ignition switch to OFF.

2) Disconnect connector from main fan motor.

3) Start the engine, and warm it up until

engine coolant temperature increases over

95°C (203°F).

4) Stop the engine and turn ignition switch to

ON.

5) Measure voltage between main fan motor

connector and chassis ground.

Connector & terminal

(F17) No. 2 (+) — Chassis ground (

−

−−

−

Does the measured value exceed the spec-

ified value?

10 V Go to step 2. Go to step 5.

2 CHECK GROUND CIRCUIT OF MAIN FAN

MOTOR.

1) Turn ignition switch to OFF.

2) Measure resistance between main fan

motor connector and chassis ground.

Connector & terminal

(F17) No. 1 — Chassis ground:

Is the measured value less than the speci-

fied valve?

5 ΩGo to step 3. Repairopencircuit

in harness

between main fan

motor connector

and chassis

ground.

3 CHECK POOR CONTACT.

Check poor contact in main fan motor connec-

tor.

Is there poor contact in main fan motor con-

nector?

There is poor contact. Repair poor con-

tact in main fan

motor connector.

Go to step 4.

4 CHECK MAIN FAN MOTOR.

Connect battery positive (+) terminal to termi-

nal No. 2, and negative (−) terminal to terminal

No. 1 of main fan motor connector.

Does the main fan rotate?

The main fan rotates. Repair poor con-

tact in main fan

motor connector.

Replace main fan

motor with a new

one.

5 CHECK POWER SUPPLY TO MAIN FAN RE-

LAY.

1) Turn ignition switch to OFF.

2) Remove main fan relay from A/C relay

holder.

3) Measure voltage between main fan relay

terminal and chassis ground.

Connector & terminal

(F66) No. 8 (+) — Chassis ground (

−

−−

−

Does the measured value exceed the spec-

ified value?

10 V Go to step 6. Go to step 7.

CO(H4SO)-8

COOLING RADIATOR MAIN FAN SYSTEM

6 CHECK POWER SUPPLY TO MAIN FAN RE-

LAY.

1) Turn ignition switch to ON.

2) Measure voltage between main fan relay

terminal and chassis ground.

Connector & terminal

(F66) No. 5 (+) — Chassis ground (

−

−−

−

Does the measured value exceed the spec-

ified value?

10 V Go to step 10. Go to step 9.

7 CHECK 20 A FUSE.

1) Remove 20 A fuse from A/C relay holder.

2) Check condition of fuse.

Is the fuse blown-out?

Fuse is blown-out. Replace fuse. Go to step 8.

8 CHECK POWER SUPPLY TO A/C RELAY

HOLDER 20 A FUSE TERMINAL.

Measure voltage of harness between A/C relay

holder 20 A fuse terminal and chassis ground.

Connector & terminal

(F27) No. 1 (+) — Chassis ground (

−

−−

−

Does the measured valueexceed the specified

value?

10 V Repairopencircuit

in harness

between20 A fuse

and main fan relay

terminal.

Repairopencircuit

in harness

betweenmainfuse

box connector and

20 A fuse terminal.

9 CHECK FUSE.

1) Turn ignition switch to OFF.

2) Remove fuse No. 18 from joint box.

3) Check fuse.

Is the fuse blown-out?

Fuse is blown-out. Replace fuse. Repairopencircuit

in harness

between main fan

relay and ignition

switch.

10 CHECK MAIN FAN RELAY.

1) Turn ignition switch to OFF.

2) Measure resistance of main fan relay.

Terminal

No. 8 — No. 9:

Does the measured value exceed the spec-

ified value?

1 MΩGo to step 11. Replace main fan

relay.

11 CHECK MAIN FAN RELAY.

1) Connect battery to terminals No. 5 and No.

7 of main fan relay.

2) Measure resistance of main fan relay.

Terminal

No. 8 — No. 9:

Is the measured value less than the speci-

fied valve?

1 ΩGo to step 12. Replace main fan

relay.

12 CHECK HARNESS BETWEEN MAIN FAN

RELAY TERMINAL AND MAIN FAN MOTOR

CONNECTOR.

Measure resistance of harness between main

fan motor connector and main fan relay termi-

nal.

Connector & terminal

(F17) No. 2 — (F66) No. 9:

Is the measured value less than the specified

valve?

1 ΩGo to step 13. Repairopencircuit

in harness

between main fan

motor connector

and main fan relay

terminal.

Step Value Yes No

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