2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
Contents
1. Excessively large tightening torque of uni versal joint bolts may lead to heavy steering wheel operation Standard clearance between gearbox and DOJ 15 mm 0 59 in or more ASA a O Q l EX 00008 15 Install the under cover 16 Lower the vehicle EX H4DOTC 8 Center Exhaust Pipe EXHAUST 17 Install the intercooler bracket EX 00203 18 Install the intercooler lt Ref to IN H4DOTC 12 INSTALLATION Intercooler gt 19 Install the collector cover C INSPECTION 1 Check the connections and welds for exhaust leaks 2 Check the rear exhaust pipe for holes or rust EX H4DOTC 9 Joint Pipe EXHAUST 4 Joint Pipe C INSPECTION 1 Check the connections and welds for exhaust A REMOVAL o ee 1 Remove the collector cover 2 Check the rear exhaust pipe for holes or rust 2 Disconnect the ground cable from battery i g gt IN 00203 3 Lift up the vehicle 4 Remove the under cover 5 Remove the front exhaust pipe cover 6 Remove the nuts which hold front exhaust man ifold to turbocharger joint pipe EX 00201 7 Remove the center exhaust pipe lt Ref to EX H4DOTC 6 REMOVAL Center Ex haust Pipe gt 8 Remove the turbocharger lt Ref to IN H4DOTC 14 REMOVAL Turbocharger gt 9 Remove the joint pipe from the lower side of ve hicle B INSTALLATION Install in the reverse order of remov2. the vehicle 16 Disconnect the connector from rear oxygen sensor a EX 00206 EX H4DOTC 6 Center Exhaust Pipe 17 Separate the center exhaust pipe from rear ex haust pipe EX 00207 18 Remove the bolt which holds center exhaust pipe bracket to transmission EX 00208 19 Remove the intercooler bracket 20 Remove the bolt which holds center exhaust pipe to hanger bracket CAUTION Be careful not to pull down the center exhaust pipe Es VES Rs ON EZ EX 00209 21 Remove the center exhaust pipe B INSTALLATION NOTE Use a new gasket 1 Install the center exhaust pipe and temporarily tighten the bolt which holds center exhaust pipe to hanger bracket 2 Temporarily tighten the bolt which holds center exhaust pipe to transmission EXHAUST 3 Connect the center exhaust pipe to turbocharg er Tightening torque 35 N m 3 6 kgf m 26 0 ft lb EX 00204 4 Install the center exhaust pipe to rear exhaust pipe Tightening torque 35 N m 3 6 kgf m 26 0 ft lb i ae EX 00207 5 Connect the connector to rear oxygen sensor O EX 00206 EX H4DOTC 7 Center Exhaust Pipe EXHAUST 6 Tighten the bolt which holds center exhaust pipe bracket to transmission Tightening torque 30 N m 3 1 kgf m 22 1 ft Ib EX 00208 7 Tighten the b
3. 2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX ENGINE SECTION 2 FUEL INJECTION FUEL SYSTEMS FU H4DOTC EMISSION CONTROL EC H4DOTC AUX EMISSION CONTROL DEVICES INTAKE INDUCTION IN H4DOTC MECHANICAL ME H4DOTC 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 EXHAUST EX H4DOTC COOLING CO H4DOTC LUBRICATION LU H4DOTC SPEED CONTROL SYSTEMS SP H4DOTC IGNITION IG H4DOTC STARTING CHARGING SYSTEMS SC H4DOTC ENGINE DIAGNOSTICS EN H4DOTC diag All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD G2320GE3 SSS SSS S EXHAUST EX H4DOTC Oa Pons Page General Description acrid acca tie A A ae ts ti eo aaNet es 2 Front Exhaust At A O 5 Center Exhaust Pipes uu aiii ds 6 Joint Pra dpi 10 Re
4. al Tightening torque T 35 N m 3 6 kgf m 26 0 ft lb EX 02019 EX H4DOTC 10 Rear Exhaust Pipe 5 Rear Exhaust Pipe A REMOVAL 1 Lift up the vehicle 2 Separate the rear exhaust pipe from center ex haust pipe EX 00207 3 Separate the rear exhaust pipe from both muf flers CAUTION Be careful not to pull down the rear exhaust pipe EX 00210 4 Remove the rear exhaust pipe B INSTALLATION NOTE Use a new gasket 1 Install the rear exhaust pipe to both mufflers Tightening torque 48 N m 4 9 kgf m 35 4 ft Ib EX 00210 2 Install the rear exhaust pipe to center exhaust pipe EXHAUST Tightening torque 35 N m 3 6 kgf m 26 0 ft Ib Ile J EX 00207 3 Lower the vehicle C INSPECTION 1 Check the connections and welds for exhaust leaks 2 Check the rear exhaust pipe for holes or rust 3 Check the cushion rubber for wear or crack EX H4DOTC 11 Muffler EXHAUST 6 Muffler C INSPECTION 1 Check the connections and welds for exhaust A REMOVAL ae we 1 Separate the muffler RH from rear exhaust 2 Check the mufflers for holes or rust pipe 3 Check the cushion rubber for wear or crack EX 00210 2 Remove the cushion rubbers and detach the muffler CAUTION Be careful not to drop the muffler during remov al NOTE To facilitate remova
5. ar Exha st Pipe a rn tine lt 11 A O aaeede desea a a tats 12 General Description EXHAUST 1 General Description A COMPONENT 1 FRONT EXHAUST PIPE EX 00248 1 Front exhaust pipe ASSY 3 Turbocharger joint pipe Tightening torque N m kgf m ft lb 2 Gasket 4 Front exhaust pipe cover T1 35 3 6 26 0 T2 30 3 1 22 1 T3 7 5 0 76 5 5 EX H4DOTC 2 General Description EXHAUST 2 CENTER AND REAR EXHAUST PIPE AND MUFFLER EX 02005 1 Gasket 12 Gasket Tightening torque N m kgf m ft lb 2 Front catalytic converter 13 Rear exhaust pipe T1 13 1 3 9 6 3 Center exhaust pipe Front 14 Chamber T2 18 1 8 13 3 4 Front oxygen A F sensor 15 Cushion rubber T3 23 2 3 17 0 5 Bracket 16 Spring T4 30 3 1 22 1 6 Gasket 17 Bolt T5 35 3 6 26 0 7 Center pipe upper cover Rear 18 Gasket T6 48 4 9 35 4 8 Clamp 19 Muffler RH T7 lt Ref to FU H4DOTC 33 9 Rear catalytic converter lower 20 Self locking nut INSTALLATION Front Oxygen cover 21 Muffler LH A F Sensor gt Rear oxygen sensor 22 Center exhaust pipe Rear T8 lt Ref to FU H4DOTC 34 11 Rear catalytic converter INSTALLATION Rear Oxygen Sensor gt EX H4DOTC 3 General Description EXHAUST B CAUTION Wear wor
6. exhaust pipe assembly to turbo charger joint pipe Tightening torque 35 N m 3 6 kgf m 26 0 ft lb ae Gg X 3 Install the front exhaust pipe cover 4 Install the under cover 5 Lower the vehicle C INSPECTION 1 Check the connections and welds for exhaust leaks 2 Check the rear exhaust pipe for holes or rust EX 00201 EX H4DOTC 5 Center Exhaust Pipe EXHAUST 3 Center Exhaust Pipe A REMOVAL 1 Set the vehicle on a lift 2 Remove the collector cover 3 Disconnect the ground cable from battery 4 Remove the intercooler lt Ref to IN H4DOTC 12 REMOVAL Intercooler gt 5 Remove the intercooler bracket EX 00203 6 Lift up the vehicle 7 Remove the under cover 8 Remove the universal joint bolts and then re move the universal joint CAUTION Scribe alignment marks on the universal joint so that it can be reassembled at the original serration EX 00008 9 Lower the vehicle 10 Remove the linear motion mounting lt Ref to ME H4DOTC 37 REMOVAL Linear Motion Mounting gt 11 Remove the linear motion mounting bracket 12 Remove the turbocharger cover EX 00249 A Linear motion mounting bracket B Turbocharger cover 13 Separate the center exhaust pipe from turbo charger 14 Disconnect the connector from front oxygen A F sensor We Wag CR SG EX 00205 15 Lift up
7. k clothing including a cap protective goggles and protective shoes during operation e Remove contamination including dirt and corro sion before removal installation or disassembly e 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 e Be sure to tighten fasteners including bolts and nuts to the specified torque e Place shop jacks or rigid racks at the specified points e Before disconnecting electrical connectors of sensors or units be sure to disconnect the ground cable from battery EX H4DOTC 4 Front Exhaust Pipe 2 Front Exhaust Pipe A REMOVAL 1 Lift up the vehicle 2 Remove the under cover 3 Remove the front exhaust pipe cover 4 Remove the nuts which hold front exhaust pipe assembly onto turbocharger joint pipe EX 00201 5 While holding the front exhaust pipe assembly remove the nuts which hold front exhaust pipe as sembly to cylinder head exhaust port EX 00202 6 Remove the front exhaust pipe assembly B INSTALLATION NOTE Use a new gasket 1 Install the front exhaust pipe assembly Tightening torque 30 N m 3 1 kgf m 22 1 ft Ib EXHAUST 2 Install the front
8. l apply a coat of spray type lu bricant to the mating area of cushion rubbers in ad vance EX 00211 3 Perform the same procedure for muffler LH B INSTALLATION Install in the reverse order of removal NOTE Always use a new gasket and self locking nuts Tightening torque 48 N m 4 9 kgf m 35 4 ft lb EX 00210 EX H4DOTC 12
9. olt which holds center exhaust pipe to hanger bracket Tightening torque 35 N m 3 6 kgf m 26 0 ft Ib s SS NS US 8 Lower the vehicle 9 Install the turbocharger cover 10 Install the linear motion mounting bracket Tightening torque T1 7 4 N m 0 75 kgf m 5 4 ft lb T2 40 N m 4 1 kgf m 29 5 ft Ib EX 00250 A Linear motion mounting bracket B Turbocharger cover 11 Install the linear motion mounting lt Ref to ME H4DOTC 37 INSTALLATION Linear Motion Mounting gt 12 Connect the connector of front oxygen A F sensor BSS ia EX 00205 13 Lift up the vehicle 14 Install the universal joint 1 Align the bolt hole on the long yoke side of universal joint with the cutout at the serrated section of shaft end and then insert the univer sal joint 2 Align the bolt hole on the short yoke side of universal joint with the cutout at the serrated section of gearbox assembly Lower the univer sal joint completely 3 Temporarily tighten the bolt of short yoke side Raise the universal joint to make sure the bolt is properly passing through the cutout at the serrated section 4 Tighten the long yoke side bolt and also tighten the short yoke side bolt Tightening torque 24 N m 2 4 kgf m 17 4 ft lb CAUTION Make sure the universal joint bolts are tight ened through the shaft serration notches
Download Pdf Manuals
Related Search