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)

EXHAUST EX(H4SO 2.0)

Page

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

2. Front Exhaust Pipe......................................................................................7

3. Center Exhaust Pipe.................................................................................10

4. Rear Exhaust Pipe....................................................................................11

5. Muffler.......................................................................................................13

EX(H4SO 2.0)-2

EXHAUST General Description

1. General Description

A: COMPONENT

• 2.0 L model

EX-02020

(19)

(20) (21)

(22)

(19)

(18)

(17)

(16)

(15)

(14) (8)

(8)

(13)

(1)

(2)

(7)

(5)

(10)

(23)

(24)

(4)

(11)

(6)

(3)

(9)

(12)

EX(H4SO 2.0)-3

EXHAUST

General Description

(1) Front catalytic converter upper

cover (11) Center exhaust pipe lower cover (23) Rear exhaust pipe upper cover

(12) Gasket (24) Rear exhaust pipe lower cover

(2) Front catalytic converter (13) Front catalytic converter lower

cover

(3) Center exhaust pipe Tightening torque: N

⋅

m (kgf-m, ft-lb)

(4) Center exhaust pipe upper cover (14) Front oxygen (A/F) sensor T1: 13 (1.3, 9.4)

(5) Rear catalytic converter upper

cover (15) Gasket T2: 18 (1.8, 13.0)

(16) Spring T3: 21 (2.1, 15.2)

(6) Rear catalytic converter (17) Chamber T4: 30 (3.1, 22.4)

(7) Rear oxygen sensor (18) Rear exhaust pipe T5: 35 (3.6, 26.0)

(8) Gasket (19) Cushion rubber T6: 40.8 (4.2, 30.1)

(9) Front exhaust pipe (20) Self-locking nut T7: 48 (4.9, 35.4)

(10) Rear catalytic converter lower

cover (21) Gasket

(22) Muffler

EX(H4SO 2.0)-4

EXHAUST General Description

• 2.5 L model

(14) (8)

(8)

(13)

(1)

(2)

(5)

(10)

(4)

(11)

(6)

(3)

(9)

(12)

EX-02012

(19)

(20)

(21)

(23)

(19)

(18)

(17)

(16)

(15)

(19)

(22)

(20)

(7)

(24)

(25)

EX(H4SO 2.0)-5

EXHAUST

General Description

(1) Front catalytic converter upper

cover (11) Center exhaust pipe lower cover (23) Muffler (LH)

(12) Gasket (24) Rear exhaust pipe upper cover

(2) Front catalytic converter (13) Front catalytic converter lower

cover (25) Rear exhaust pipe lower cover

(3) Center exhaust pipe

(4) Center exhaust pipe upper cover (14) Front oxygen (A/F) sensor Tightening torque: N

⋅

m (kgf-m, ft-lb)

(5) Rear catalytic converter upper

cover (15) Gasket T1: 13 (1.3, 9.4)

(16) Spring T2: 18 (1.8, 13.0)

(6) Rear catalytic converter (17) Chamber T3: 21 (2.1, 15.2)

(7) Rear oxygen sensor (18) Rear exhaust pipe T4: 30 (3.1, 22.4)

(8) Gasket (19) Cushion rubber T5: 35 (3.6, 26.0)

(9) Front exhaust pipe (20) Self-locking nut T6: 40.8 (4.2, 30.1)

(10) Rear catalytic converter lower

cover (21) Gasket T7: 48 (4.9, 35.4)

(22) Muffler (RH)

EX(H4SO 2.0)-6

EXHAUST General Description

B: CAUTION

• Wear work clothing, including a cap, protective

goggles and protective shoes during operation.

• Remove contamination including dirt and corro-

sion before removal, installation or disassembly.

• Keep the disassembled parts in order and pro-

tect them from dust and 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 yourself, because each

part on the vehicle is hot after running.

• Be sure to tighten fasteners including bolts and

nuts to the specified torque.

• Place shop jacks or rigid racks at the specified

points.

• Before disconnecting electrical connectors of

sensors or units, be sure to disconnect the ground

cable from battery.

EX(H4SO 2.0)-7

EXHAUST

Front Exhaust Pipe

2. Front Exhaust Pipe

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Disconnect the front oxygen (A/F) sensor con-

nector.

3) Lift-up the vehicle.

4) Disconnect the rear oxygen sensor connector.

5) Separate the center exhaust pipe from rear ex-

haust pipe.

6) Remove the under cover.

7) Remove the nuts which hold front exhaust pipe

onto cylinder heads.

CAUTION:

Be careful not to pull down the front and center

exhaust pipe assembly.

8) Remove the bolt which holds center exhaust

pipe to hanger bracket.

9) Remove the front and center exhaust pipe as-

sembly from the vehicle.

CAUTION:

• Be careful not to let the front and center ex-

haust pipe assembly fall off when removing as

it is quite heavy.

• After removing the front and center exhaust

pipe assembly, do not apply excessive pulling

force on the rear exhaust pipe.

10) Separate the front exhaust pipe from center ex-

haust pipe.

IN-00203

ME-00859

FU-01116

EX-00214

EX-00215

EX-00216

EX-00217

EX(H4SO 2.0)-8

EXHAUST Front Exhaust Pipe

11) Remove the front oxygen (A/F)sensor and rear

oxygen sensor. <Ref. to FU(H4SO 2.0)-32, RE-

MOVAL, Front Oxygen (A/F) Sensor.> <Ref. to

FU(H4SO 2.0)-33, REMOVAL, Rear Oxygen Sen-

sor.> or <Ref. to FU(H4SO 2.5)-34, REMOVAL,

Front Oxygen (A/F) Sensor.> <Ref. to FU(H4SO

2.5)-35, REMOVAL, Rear Oxygen Sensor.>

B: INSTALLATION

1) Install the front oxygen (A/F) sensor and rear ox-

ygen sensor. <Ref. to FU(H4SO 2.0)-32, INSTAL-

LATION, Front Oxygen (A/F) Sensor.> <Ref. to

FU(H4SO 2.0)-33, INSTALLATION, Rear Oxygen

Sensor.>or<Ref.toFU(H4SO2.5)-34,INSTALLA-

TION, Front Oxygen (A/F) Sensor.> <Ref. to

FU(H4SO 2.5)-35, INSTALLATION, Rear Oxygen

Sensor.>

2) Install the front exhaust pipe to center exhaust

pipe.

NOTE:

Use a new gasket.

Tightening torque:

40.8 N

⋅

m (4.2 kgf-m, 30.1 ft-lb)

3) Install the front and center exhaust pipe assem-

bly to the vehicle.

4) Temporarily tighten the bolt which holds the cen-

ter exhaust pipe to hanger bracket.

5) Install the nuts to cylinder head which hold front

exhaust pipe.

Tightening torque:

30 N

⋅

m (3.1 kgf-m, 22.4 ft-lb)

6) Install the under cover.

7) Tighten the bolts which install the center exhaust

pipe to rear exhaust pipe.

Tightening torque:

18 N

⋅

m (1.8 kgf-m, 13.0 ft-lb)

8) Tighten the bolt which holds the center exhaust

pipe to hanger bracket.

Tightening torque:

35 N

⋅

m (3.6 kgf-m, 26.0 ft-lb)

EX-00217

EX-00216

EX-00215

EX-00214

EX-00216

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