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)

COOLING CO(H4DOSTC)

Page

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

2. Radiator Main Fan System..........................................................................7

3. Radiator Sub Fan System.........................................................................11

4. Engine Coolant..........................................................................................15

5. Water Pump..............................................................................................17

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. Coolant Filler Tank....................................................................................33

13. Engine Cooling System Trouble in General..............................................34

CO(H4DOSTC)-2

COOLING GENERAL DESCRIPTION

1. General Description

A: SPECIFICATIONS

Cooling system Electric fan + Forced engine coolant circulation sys-

tem

Total engine coolant capacity 2(US qt, Imp qt) MT: Approx. 7.7 (8.1, 6.8)

AT: Approx. 7.6 (8.0, 6.7)

Water pump

Type Centrifugal impeller type

Discharge performance I

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

Pump speed—Discharge pres-

sure (pressure leak) 760 rpm —2.9 kPa [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—Discharge pres-

sure (pressure leak) 3,000 rpm —49.0 kPa [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—Discharge pres-

sure (pressure leak) 6,000 rpm —225.4 kPa [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 76 —80°C (169 —176°F)

Fully opened 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(H4DOSTC)-3

COOLING

GENERAL DESCRIPTION

B: COMPONENT

1. WATER PUMP

(1) Thermostat case (5) Gasket Tightening torque: N·m (kgf-m, ft-lb)

(2) Gasket (6) Heater by-pass hose T1: First 12 (1.2, 8.7)

Second 12 (1.2, 8.7)

(3) Thermostat (7) Coolant filler tank by-pass hose

(4) Water pump ASSY (8) Water by-pass hose T2: 6.5 (0.66, 4.8)

( 1 )

( 2 )

( 3 )

( 4 )

( 5 )

( 6 ) ( 7 )

( 8 )

CO-00201

CO(H4DOSTC)-4

COOLING GENERAL DESCRIPTION

2. RADIATOR AND RADIATOR FAN

(1) Radiator lower cushion (14) Radiator main fan and main fan

motor ASSY (25) ATF outlet hose B (AT vehicles

only)

(2) Radiator

(3) Radiator upper cushion (15) Radiator outlet hose (26) ATF inlet hose B (AT vehicles

only)

(4) Radiator upper bracket (16) Radiator drain plug

(5) Clamp (17) Engine coolant filler tank (27) ATF pipe (AT vehicles only)

(6) Radiator inlet hose (18) Engine coolant filler tank cap

(7) Engine coolant reservoir tank cap (19) Engine coolant hose Tightening torque: N·m (kgf-m, ft-lb)

(8) Overflow hose (20) Radiator lower bracket T1: 3.4 (0.35, 2.5)

(9) Engine coolant reservoir tank (21) O-ring T2: 4.4 (0.45, 3.3)

(10) Overflow pipe (22) ATF hose clamp (AT vehicles

only) T3: 4.9 (0.50, 3.6)

(11) Sub fan shroud T4: 18 (1.8, 13.0)

(12) Radiator sub fan and sub fan

motor ASSY (23) ATF outlet hose A (AT vehicles

only) T5: 12 (1.2, 8.7)

(13) Main fan shroud (24) ATF inlet hose A (AT vehicles

only)

CO-00145

T3 (7)

(18)

(17)

(5)

(5) (19)

(9)

(13)

(11)

(14)

(5)

(6)

(8)

(5)

(15)

(1)

(2)

(20)

(16)

(3)

(4)

(10 )

(21)

(12)

(24)

(25)

(22)

(26)

(27)

(23)

CO(H4DOSTC)-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.

•Placeshopjacksorsafetystandsatthespecified

points.

•Before disconnecting electrical connectors of

sensors or units, be sure to disconnect ground ca-

ble from battery.

CO(H4DOSTC)-6

COOLING GENERAL DESCRIPTION

D: PREPARATION TOOL

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

499977100 (MT

model) CRANK PULLEY

WRENCH Used for fixing crankshaft pulley when loos-

ening and tightening crankshaft pulley bolts.

499977400 (AT

model) CRANK PULLEY

WRENCH Used for fixing crankshaft pulley when loos-

ening and tightening crankshaft pulley bolts.

18231AA010 CAMSHAFT

SPROCKET

WRENCH

•Used for removing and installing camshaft

sprocket. (Intake side)

•Camshaft sprocket wrench (499207100) is

also available.

499207400 CAMSHAFT

SPROCKET

WRENCH

Used for removing and installing camshaft

sprocket. (Exhaust side)

ST-499977100

ST-499977400

ST18231AA010

ST-499207400

CO(H4DOSTC)-7

COOLING

RADIATOR MAIN FAN SYSTEM

2. Radiator Main Fan System

A: SCHEMATIC

CO-00146

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. 3

NO. 18

NO. 17

SBF-4

SBF-1

IGNITION

SWITCH

B72

B137

BATTERY

B137

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

12 3 4 5 6 7

10 11 12 13 14 15 16

8127895634

101112192021 293031 1314151617 2728

18 2223242526

CO(H4DOSTC)-8

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.

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