Subaru Outback manuals

Subaru Outback: Exhaust

General Description

A: COMPONENT

Subaru Outback. Exhaust

Subaru Outback. Exhaust

  1. Gasket
  2. Spring
  3. Chamber
  4. Rear exhaust pipe
  5. Cushion rubber (without protrusion)
  6. Self-locking nut
  7. Gasket
  8. Muffler
  9. Bolt
  10. Center exhaust pipe front upper cover
  11. Rear catalytic converter upper cover
  12. Center exhaust pipe
  13. Rear catalytic converter
  14. Rear catalytic converter lower cover
  15. Center exhaust pipe front lower cover
  16. Front oxygen (A/F) sensor
  17. Front catalytic converter
  18. Rear oxygen sensor
  19. Gasket
  20. Gasket
  21. Front exhaust pipe
  22. Front exhaust pipe upper cover LH
  23. Front exhaust pipe upper cover RH
  24. Front catalytic converter upper cover
  25. Front catalytic converter lower cover
  26. Front exhaust pipe lower cover RH
  27. Front exhaust pipe lower cover LH
  28. Band
  29. Hanger bracket (CVT model)
  30. Muffler cutter (models with muffler cutter)
  31. Cushion rubber (with protrusion)
  32. Hanger bracket (MT model)

Tightening torque: N*m (kgf-m, ft-lb)
T1: 7.5 (0.8, 5.5)
T2: 13 (1.3, 9.6)
T3: 18 (1.8, 13.3)
T4: 23 (2.3, 17.0)
T5: 30 (3.1, 22.1)
T6: 35 (3.6, 25.8)
T7: 40 (4.1, 29.5)
T8: 48 (4.9, 35.4)
T9: <Ref. to FU(H4SO)-42, INSTALLATION, Front Oxygen (A/F) Sensor.>
T10: <Ref. to FU(H4SO)-44, INSTALLATION, Rear Oxygen Sensor.>

B: CAUTION

Front Exhaust Pipe

A: REMOVAL

CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.

1) Remove the air intake duct. <Ref. to IN(H4SO)- 9, REMOVAL, Air Intake Duct.>

2) Disconnect the ground cable from battery.

Subaru Outback. Exhaust

3) Disconnect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B) and remove the clip (C) fastening the harness.

Subaru Outback. Exhaust

4) Lift up the vehicle.

5) Remove the under cover. <Ref. to EI-35, REMOVAL, Front Under Cover.>

6) Remove the rear exhaust pipe from center exhaust pipe.

Subaru Outback. Exhaust

Subaru Outback. Exhaust

7) Remove the nuts which hold front exhaust pipe onto cylinder heads.

CAUTION: Be careful not to drop the front exhaust pipe and center exhaust pipe assembly.

Subaru Outback. Exhaust

8) Remove the bolt which holds center exhaust pipe to hanger bracket.

Subaru Outback. Exhaust

9) Remove the front exhaust pipe and center exhaust pipe from vehicle as a unit.

CAUTION:

10) Remove the center exhaust pipe from the front exhaust pipe.

Subaru Outback. Exhaust

11) Remove the front oxygen (A/F) sensor and rear oxygen sensor from front exhaust pipe. <Ref. to FU(H4SO)-42, REMOVAL, Front Oxygen (A/F) Sensor.> <Ref. to FU(H4SO)-44, REMOVAL, Rear Oxygen Sensor.>

B: INSTALLATION

1) Install the front oxygen (A/F) sensor and rear oxygen sensor to the front exhaust pipe. <Ref. to FU(H4SO)-42, INSTALLATION, Front Oxygen (A/ F) Sensor.> <Ref. to FU(H4SO)-44, INSTALLATION, Rear Oxygen Sensor.>

2) Install the center exhaust pipe to front exhaust pipe.

NOTE: Use a new gasket.

Tightening torque: 40 N*m (4.1 kgf-m, 29.5 ft-lb)

Subaru Outback. Exhaust

3) Install the front exhaust pipe and center exhaust pipe as a unit to the vehicle.

NOTE: Use a new gasket.

4) Temporarily tighten the nuts which hold front exhaust pipe to cylinder heads.

Subaru Outback. Exhaust

5) Install the rear exhaust pipe to center exhaust pipe.

NOTE: Use a new gasket.

Tightening torque: 18 N*m (1.8 kgf-m, 13.3 ft-lb)

Subaru Outback. Exhaust

Subaru Outback. Exhaust

6) Tighten the bolts which secure the center exhaust pipe to the hanger bracket.

Tightening torque: 35 N*m (3.6 kgf-m, 25.8 ft-lb)

Subaru Outback. Exhaust

7) Tighten the nuts which hold front exhaust pipe to cylinder heads.

Tightening torque: 30 N*m (3.1 kgf-m, 22.1 ft-lb)

Subaru Outback. Exhaust

8) Install the under cover. <Ref. to EI-35, INSTALLATION, Front Under Cover.>

9) Lower the vehicle.

10) Connect the front oxygen (A/F) sensor connector (A) and rear oxygen sensor connector (B), and fasten the harness with the clip (C).

Subaru Outback. Exhaust

11) Connect the battery ground terminal.

Subaru Outback. Exhaust

12) Install the air intake duct. <Ref. to IN(H4SO)-9, INSTALLATION, Air Intake Duct.>

C: INSPECTION

1) Check the connections and welds for exhaust leaks.

2) Make sure there are no holes or rusting.

Center Exhaust Pipe

A: REMOVAL

After removing the center exhaust pipe and front exhaust pipe as a unit, separate them. Refer to "Front Exhaust Pipe" for the removal procedure.

<Ref. to EX(H4SO)-5, REMOVAL, Front Exhaust Pipe.>

B: INSTALLATION

Install the center exhaust pipe and front exhaust pipe as a unit. Refer to "Front Exhaust Pipe" for the installation procedure. <Ref. to EX(H4SO)-6, INSTALLATION, Front Exhaust Pipe.>

C: INSPECTION

1) Check the connections and welds for exhaust leaks.

2) Make sure there are no holes or rusting.

Rear Exhaust Pipe

A: REMOVAL

CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.

1) Lift up the vehicle.

2) Remove the center exhaust pipe from rear exhaust pipe.

Subaru Outback. Exhaust

Subaru Outback. Exhaust

3) Remove the muffler from rear exhaust pipe.

CAUTION: Be careful not to drop the rear exhaust pipe.

Subaru Outback. Exhaust

4) Apply a coat of spray type lubricant to the mating area of cushion rubber.

5) Remove the rear exhaust pipe from the cushion rubber.

CAUTION: Be careful not to let the muffler contact the rear bumper.

Subaru Outback. Exhaust

B: INSTALLATION

1) Apply a coat of spray type lubricant to the mating area of cushion rubber.

2) Install the rear exhaust pipe to cushion rubber.

NOTE: After assembling, degrease the lubricant which was applied to the cushion rubber while removing/ installing.

Subaru Outback. Exhaust

3) Install the rear exhaust pipe to the muffler.

NOTE: Use a new gasket and self-locking nut.

Tightening torque: 48 N*m (4.9 kgf-m, 35.4 ft-lb)

Subaru Outback. Exhaust

4) Install the center exhaust pipe to rear exhaust pipe.

NOTE: Use a new gasket.

Tightening torque: 18 N*m (1.8 kgf-m, 13.3 ft-lb)

Subaru Outback. Exhaust

Subaru Outback. Exhaust

5) Lower the vehicle.

C: INSPECTION

1) Check the connections and welds for exhaust leaks.

2) Make sure there are no holes or rusting.

3) Check the cushion rubber for wear or crack.

Muffler

A: REMOVAL

CAUTION: Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.

1) Lift up the vehicle.

2) Remove the rear exhaust pipe from the muffler.

Subaru Outback. Exhaust

3) Apply a coat of spray type lubricant to the mating area of cushion rubber.

4) Remove the muffler from the cushion rubber.

CAUTION: Be careful not to drop the muffler during removal.

Subaru Outback. Exhaust

B: INSTALLATION

Install in the reverse order of removal.

NOTE:

Tightening torque: 48 N*m (4.9 kgf-m, 35.4 ft-lb)

C: INSPECTION

1) Check the connections and welds for exhaust leaks.

2) Make sure there are no holes or rusting.

3) Check the cushion rubber for wear or crack.

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