Subaru 2003 Legacy Manuel utilisateur

FUJI HEAVY INDUSTRIES LTD. G2300GE3

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

ENGINE SECTION 2

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(H6DO)

EMISSION CONTROL

(AUX. EMISSION CONTROL DEVICES) EC(H6DO)

INTAKE (INDUCTION) IN(H6DO)

MECHANICAL ME(H6DO)

EXHAUST EX(H6DO)

COOLING CO(H6DO)

LUBRICATION LU(H6DO)

SPEED CONTROL SYSTEMS SP(H6DO)

IGNITION IG(H6DO)

STARTING/CHARGING SYSTEMS SC(H6DO)

ENGINE (DIAGNOSTICS) EN(H6DO)

EMISSION CONTROL (AUX. EMISSION

CONTROL DEVICES)EC(H6DO)

Page

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

2. Front Catalytic Converter ............................................................................3

3. Rear Catalytic Converter.............................................................................6

4. Canister.......................................................................................................7

5. Purge Control Solenoid Valve.....................................................................8

6. EGR Valve ................................................................................................10

7. Two-way valve ..........................................................................................12

EC(H6DO)-2

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

GENERAL DESCRIPTION

1. General Description

A: 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 on the vehicle is hot after running.

•Be sure to tighten fasteners including bolts and

nuts to the specified torque.

•Placeshopjacks orsafetystands at thespecified

points.

•Before disconnecting electrical connectors of

sensors or units, be sure to disconnect ground ca-

ble from battery.

EC(H6DO)-3

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

FRONT CATALYTIC CONVERTER

2. Front Catalytic Converter

A: REMOVAL

1) Set the vehicle on the lift.

2) Remove battery.

3) Remove air cleaner case and air intake duct.

<Ref. to IN(H6DO)-5, REMOVAL, Air Cleaner.>

and <Ref. to IN(H6DO)-7, REMOVAL, Air Intake

Duct.>

4) Disconnect front oxygen (A/F) sensor connec-

tors.

5) Lift-up the vehicle.

6) Remove under cover.

7) Remove front oxygen (A/F) sensor harness from

the clips attached to both right and left cylinder

head covers.

8) Disconnect connector from rear oxygen sensor

connector.

9) Separate front exhaust pipe from rear exhaust

pipe.

CAUTION:

Be careful, exhaust pipe is hot.

10) Remove nuts which hold front exhaust pipe

onto cylinder heads.

11) Remove front exhaust pipe from hanger brack-

et.

CAUTION:

Be careful not to pull down front exhaust pipe.

EX-00056

LH side

RH side

EX-00058

EX-00059

EX-00060

RH side LH side

EX-00061

EC(H6DO)-4

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

FRONT CATALYTIC CONVERTER

12) Separate front catalytic converter (RH) from

front exhaust pipe.

B: INSTALLATION

NOTE:

Replace gaskets with new ones.

1) Install front catalytic converter (RH) to front ex-

haust pipe.

Tightening torque:

30 N·m (3.1 kgf-m, 22.4 ft-lb)

2) Install front exhaust pipe assembly to the vehi-

cle. And temporarily tighten bolt which installs front

exhaust pipe to hanger bracket.

3) Tighten nuts which hold front exhaust pipe onto

cylinder heads.

Tightening torque:

30 N·m (3.1 kgf-m, 22.4 ft-lb)

4) Tighten bolts which secure front exhaust pipe

assembly to rear exhaust pipe.

Tightening torque:

18 N·m (1.8 kgf-m, 13.0 ft-lb)

5) Tighten bolt which holds front exhaust pipes to

hanger bracket.

Tightening torque:

35 N·m (3.6 kgf-m, 26.0 ft-lb)

EX-00062

EX-00061

EX-00060

RH side LH side

EX-00059

EX-00061

EC(H6DO)-5

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

FRONT CATALYTIC CONVERTER

6) Connect connector to rear oxygen sensor con-

nector.

7) Install front oxygen (A/F) sensor harness to the

clips attached to the cylinder head covers.

8) Install under cover.

9) Lower the vehicle.

10) Connect front oxygen (A/F) sensor connector.

11) Install air cleaner case and air intake duct.

<Ref. to IN(H6DO)-5, INSTALLATION, Air Clean-

er.> and <Ref. to IN(H6DO)-7, INSTALLATION, Air

Intake Duct.>

12) Install battery.

C: INSPECTION

1) Make sure there are no exhaust leaks from con-

nections and welds.

2) Make sure there are no holes or rusting.

EX-00058

EX-00056

LH side

RH side

EC(H6DO)-6

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

REAR CATALYTIC CONVERTER

3. Rear Catalytic Converter

A: REMOVAL

The frontand rearcatalytic converter are integrated

into one unit. Therefore, the removal and installa-

tion procedures are the same as the those for the

frontcatalyticconverter.<Ref.to EC(H6DO)-3, RE-

MOVAL, Front Catalytic Converter.>

B: INSTALLATION

The frontand rearcatalytic converter are integrated

into one unit. Therefore, the removal and installa-

tion procedures are the same as the ones de-

scribed under front catalytic converter. <Ref. to

EC(H6DO)-4, INSTALLATION, Front Catalytic

Converter.>

C: INSPECTION

1) Make sure there are no exhaust leaks from con-

nections and welds.

2) Make sure there are no holes or rusting.

(A) Front catalytic converter RH

(B) Front catalytic converter LH

(A) Front catalytic converter RH

(B) Front catalytic converter LH

EC-00108

( A )

( B )

( C )

EC-00108

( A )

( B )

( C )

EC(H6DO)-7

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

CANISTER

4. Canister

A: REMOVAL

1) Lift-up the vehicle.

2) Loosen two clamps which hold two canister hos-

es, and disconnect evaporation hoses from canis-

ter.

3) Remove canister from body.

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

23 N·m (2.3 kgf-m, 17 ft-lb)

C: INSPECTION

Make sure the canister and canister hoses are not

cracked or loose.

EC-00127

EC-00128

EC(H6DO)-8

EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)

PURGE CONTROL SOLENOID VALVE

5. Purge Control Solenoid Valve

A: REMOVAL

1) Disconnect battery ground cable.

2) Remove power steering pump from bracket.

(1) Remove air intake duct and air cleaner

case. <Ref. to IN(H6DO)-5, REMOVAL, Air

Cleaner.> and <Ref. to IN(H6DO)-7, REMOV-

AL, Air Intake Duct.>

(2) Remove V-belt. <Ref. to ME(H6DO)-28,

REMOVAL, V-belt.>

(3) Remove power steering oil pipe with brack-

et.

(4) Remove bolts which install power steering

pump bracket.

CAUTION:

Do not separate hose and pipe from the pump

main unit.

(5) Remove power steering tank from the

bracket by pulling it upward.

(6) Place power steering pump on the right side

wheel apron.

3) Disconnect connector and hoses from purge

control solenoid valve.

4) Remove bolt which installs purge control sole-

noid valve onto intake manifold.

(A) Power steering pump

(B) Generator

FU-00009

ME-00449

ME-00482

( A ) ( B ) ( C )

(A) Cloth

ME-00451

ME-00483

( A )

EC-00109

EC-00110

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