Subaru Outback manuals

Subaru Outback: General Description

A: SPECIFICATION

Subaru Outback. Mechanical

NOTE:

US: Undersize OS: Oversize

Subaru Outback. Mechanical

Subaru Outback. Mechanical

B: COMPONENT

1. V-BELT

Subaru Outback. Mechanical

  1. V-belt
  2. V-belt cover bracket
  3. V-belt tensioner ASSY
  4. Power steering pump bracket
  5. Generator
  6. Generator plate
  7. A/C compressor bracket A
  8. Idler pulley ASSY
  9. Stopper rod RH
  10. Stopper rod LH
  11. A/C compressor
  12. A/C compressor bracket B
  13. Front cushion rubber

Tightening torque: N*m (kgf-m, ft-lb)
T1: 6.4 (0.7, 4.7)
T2: 20 (2.0, 14.8)
T4: 25 (2.5, 18.4)
T5: 26.5 (2.7, 19.5)
T6: 33 (3.4, 24.3)
T7: 36 (3.7, 26.6)

2. TIMING BELT

Subaru Outback. Mechanical

  1. Timing belt cover No. 2 RH
  2. Timing belt guide (MT model)
  3. Crank sprocket
  4. Timing belt cover No. 2 LH
  5. Cam sprocket No. 1
  6. Belt idler (A)
  7. Tensioner bracket
  8. Belt idler (B)
  9. Automatic belt tension adjuster ASSY
  10. Belt idler No. 2
  11. Cam sprocket No. 2
  12. Timing belt
  13. Front timing belt cover
  14. Timing belt cover LH
  15. Crank pulley (MT model)
  16. Crank pulley (CVT model)

Tightening torque: N*m (kgf-m, ft-lb)
T1: 5 (0.5, 3.7)
T2: 9.75 (1.0, 7.2)
T3: 24.5 (2.5, 18.1)
T4: 39 (4.0, 28.8)
T5: 78 (8.0, 57.5)
T6: <Ref. to ME(H4SO)-45, INSTALLATION, Crank Pulley.>

3. CYLINDER HEAD AND CAMSHAFT

Subaru Outback. Mechanical

  1. Rocker cover RH
  2. Intake valve rocker ASSY
  3. Exhaust valve rocker ASSY
  4. Camshaft cap RH
  5. Oil seal
  6. Camshaft RH
  7. Plug
  8. Spark plug pipe gasket
  9. Cylinder head RH
  10. Cylinder head gasket
  11. Cylinder head LH
  12. Camshaft LH
  13. Camshaft cap LH
  14. Oil filler cap
  15. Gasket
  16. Oil filler duct
  17. O-ring
  18. Rocker cover LH
  19. Stud bolt
  20. Rocker cover gasket RH
  21. Rocker cover gasket LH
  22. Oil switching solenoid valve RH
  23. Oil switching solenoid valve holder RH
  24. Gasket
  25. Oil temperature sensor
  26. Variable valve lift diagnosis oil pressure switch RH
  27. Oil switching solenoid valve LH
  28. Oil switching solenoid valve holder LH
  29. Gasket
  30. Variable valve lift diagnosis oil pressure switch LH
  31. Seal washer
  32. Washer

Tightening torque: N*m (kgf-m, ft-lb)
T1: 6 (0.6, 4.4)
T2: 6.4 (0.7, 4.7)
T3: 9.75 (1.0, 7.2)
T4: 10 (1.0, 7.4)
T5: 17 (1.7, 12.5)
T6: 18 (1.8, 13.3)
T7: 25 (2.5, 18.4)
T8: <Ref. to ME(H4SO)-63, INSTALLATION, Cylinder Head.>
T9: <Ref. to ME(H4SO)-55, INSTALLATION, Valve Rocker Assembly.>

4. VALVE ROCKER ASSY

Subaru Outback. Mechanical

  1. Intake valve rocker ASSY
  2. Valve rocker nut
  3. Valve rocker adjusting screw
  4. Exhaust rocker shaft
  5. Exhaust valve rocker arm

Tightening torque: N*m (kgf-m, ft-lb)
T1: 6 (0.6, 4.4)
T2: 9.75 (1.0, 7.2)
T3: 25 (2.5, 18.4)

5. CYLINDER HEAD AND VALVE ASSEMBLY

Subaru Outback. Mechanical

  1. Exhaust valve
  2. Intake valve
  3. Valve guide
  4. Valve spring seat
  5. Intake valve oil seal
  6. Valve spring
  7. Valve spring retainer
  8. Valve spring retainer key
  9. Exhaust valve oil seal

6. CYLINDER BLOCK

Subaru Outback. Mechanical

  1. Oil pressure switch
  2. Cylinder block RH
  3. Service hole plug
  4. Gasket
  5. Oil separator cover
  6. Water by-pass pipe
  7. Oil pump
  8. Front oil seal
  9. Rear oil seal
  10. O-ring
  11. Service hole cover
  12. Cylinder block LH
  13. Water pump
  14. Baffle plate
  15. Oil filter connector
  16. Oil strainer
  17. Cylinder block lower
  18. Oil pan
  19. Drain plug
  20. Drain plug gasket
  21. Oil level gauge guide
  22. Water pump sealing
  23. Oil filter
  24. Gasket
  25. Water pump hose
  26. Plug
  27. Seal
  28. Seal washer
  29. Washer
  30. O-ring
  31. Engine rear hanger
  32. Oil pump seal
  33. Oil level gauge
  34. O-ring
  35. O-ring
  36. Oil drain pipe
  37. O-ring
  38. Oil level switch

Tightening torque: N*m (kgf-m, ft-lb)
T1: 5 (0.5, 3.7)
T2: 6.4 (0.7, 4.7)
T3: 10 (1.0, 7.4)
T4: First 12 (1.2, 8.9)
Second 12 (1.2, 8.9)
T5: 16 (1.6, 11.8)
T6: 25 (2.5, 18.4)
T7: 41.7 (4.3, 30.8)
T8: 45 (4.6, 33.2)
T9: 70 (7.1, 51.6)
T10: <Ref. to ME(H4SO)-76, INSTALLATION, Cylinder Block.>

7. CRANKSHAFT AND PISTON

Subaru Outback. Mechanical

  1. Reinforcement (CVT model)
  2. Drive plate (CVT model)
  3. Flywheel (MT model)
  4. Ball bearing (MT model)
  5. Top ring
  6. Second ring
  7. Oil ring
  8. Piston
  9. Piston pin
  10. Snap ring
  11. Connecting rod nut
  12. Connecting rod
  13. Connecting rod bearing
  14. Connecting rod cap
  15. Crankshaft
  16. Woodruff key
  17. Crankshaft bearing #1, #3
  18. Crankshaft bearing #2, #4
  19. Crankshaft bearing #5

Tightening torque: N*m (kgf-m, ft-lb)
T1: 45 (4.6, 33.2)
T2: <Ref. to CVT-133, INSTALLATION, Drive Plate.>
T3: <Ref. to CL-14, INSTALLATION, Flywheel.>

8. ENGINE MOUNTING

Subaru Outback. Mechanical

  1. Front mounting bracket
  2. Front cushion rubber
  3. Engine mounting bracket

Tightening torque: N*m (kgf-m, ft-lb)
T1: 25 (2.5, 18.4)
T2: 45 (4.6, 33.2)
T3: 58 (5.9, 42.8)
T4: 60 (6.1, 44.3)

C: CAUTION

D: PREPARATION TOOL

1. SPECIAL TOOL

Subaru Outback. Mechanical

Subaru Outback. Mechanical

Subaru Outback. Mechanical

Subaru Outback. Mechanical

Subaru Outback. Mechanical

Subaru Outback. Mechanical

Subaru Outback. Mechanical

Subaru Outback. Mechanical

2. GENERAL TOOL

Subaru Outback. Mechanical

Compression

A: INSPECTION

CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself during measurement.

1) After warming-up the engine, turn the ignition switch to OFF.

2) Make sure that the battery is fully charged.

3) Remove the fuse of fuel pump from main fuse box.

Subaru Outback. Mechanical

4) Start the engine and run it until it stalls.

5) After the engine stalls, crank it for five more seconds.

6) Turn the ignition switch to OFF.

7) Remove all spark plugs. <Ref. to IG(H4SO)-3, REMOVAL, Spark Plug.>

8) Fully open the throttle valve.

9) Check the starter motor for satisfactory performance and operation.

10) Install the compression gauge to the spark plug hole.

NOTE: When using a screw-in type compression gauge, the screw should be less than 18 mm (0.71 in) long.

Subaru Outback. Mechanical

11) Crank the engine by starter motor and read the value when the needle of the compression gauge becomes stable.

NOTE:

Compression (fully open throttle):
Standard
1,020 - 1,275 kPa (10.4 - 13.0 kgf/cm2, 148 - 185 psi)
Difference between cylinders
49 kPa (0.5 kgf/cm2, 7 psi) or less

12) After inspection, install the related parts in the reverse order of removal.

Idle Speed

A: INSPECTION

1) Before checking the idle speed, check the following item:

  1. Check the air cleaner element is free from clogging, ignition timing is correct, spark plugs are in good condition, and hoses are connected properly.
  2. Check the malfunction indicator light does not illuminate.

2) Warm up the engine.

3) Read the engine idle speed using Subaru Select Monitor. <Ref. to EN(H4SO)(diag)-33, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.>

NOTE:

  1. Check the idle speed when no-loaded.

    (Headlight, heater fan, rear defroster, radiator fan, A/C and etc. are OFF)

Idle speed (No load, and for CVT model, select lever in "P" or "N" range, for MT model, gear shift lever in neutral position.):
Standard
675+-100 rpm (CVT model)
650+-100 rpm (MT model)

  1. Check the idle speed when loaded. (Turn the A/C switch to "ON" and operate the compressor for at least one minute before measurement.)

Idle speed (A/C on, and for CVT model, select lever in "P" or "N" range, for MT model, gear shift lever in neutral position.):
Standard
700 - 850+-100 rpm

Ignition Timing

A: INSPECTION

CAUTION: After warming-up, engine becomes very hot. Be careful not to burn yourself at measurement.

1) Before checking the ignition timing, check the following item:

  1. Check the air cleaner element is free from clogging, spark plugs are in good condition, and hoses are connected properly.
  2. Check the malfunction indicator light does not illuminate.

2) Warm up the engine.

3) Read the ignition timing using Subaru Select Monitor. <Ref. to EN(H4SO)(diag)-33, READ CURRENT DATA FOR ENGINE (NORMAL MODE), OPERATION, Subaru Select Monitor.>

NOTE: If ignition timing is out of standard, check the ignition control system. Refer to "Engine Control System".

<Ref. to EN(H4SO)(diag)-2, Basic Diagnostic Procedure.>

Ignition timing [BTDC/rpm]:
Standard
15º+-10º/675 (CVT model)
10º+-10º/650 (MT model)

Intake Manifold Vacuum

A: INSPECTION

1) Warm up the engine.

2) Disconnect the brake booster vacuum hose from the intake manifold, and attach the vacuum gauge.

Subaru Outback. Mechanical

3) Keep the engine at idle speed and read the vacuum gauge indication.

NOTE: Condition of engine inside can be diagnosed by observing the behavior of the vacuum gauge needle as described in table below.

Intake manifold vacuum (at idling, A/C OFF):
Standard
-60.0 kPa (-450 mmHg, -17.72 inHg) or more

4) After inspection, install the related parts in the reverse order of removal.

Subaru Outback. Mechanical

Engine Oil Pressure

A: INSPECTION

1) Disconnect the ground cable from battery.

Subaru Outback. Mechanical

2) Remove the oil pressure switch. <Ref. to LU(H4SO)-25, REMOVAL, Oil Pressure Switch.>

3) Install the oil pressure gauge to cylinder block.

Subaru Outback. Mechanical

4) Connect the battery ground terminal.

Subaru Outback. Mechanical

5) Start the engine, and check the oil pressure.

NOTE:

Engine oil pressure:
Standard
98 kPa (1.0 kgf/cm2, 14 psi) or more (at 600 rpm)
294 kPa (3.0 kgf/cm2, 43 psi) or more (at 5,000 rpm)

6) After inspection, install the related parts in the reverse order of removal.

Fuel Pressure

A: INSPECTION

CAUTION:

1) Release the fuel pressure. <Ref. to FU(H4SO)- 53, RELEASING OF FUEL PRESSURE, PROCEDURE, Fuel.>

2) Open the fuel filler lid and remove the fuel filler cap.

3) Disconnect the fuel delivery hose from the fuel delivery pipe, and connect the fuel pressure gauge.

CAUTION:

  1. Attach ST to the fuel delivery pipe and push ST1 in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose.

ST 42099AE000 QUICK CONNECTOR RELEASE

Subaru Outback. Mechanical

  1. Connect the fuel pressure gauge with ST2 and ST3.

NOTE:
ST2 is a SUBARU genuine part.
ST2 42075AG690 FUEL HOSE
ST3 18471AA000 FUEL PIPE ADAPTER

Subaru Outback. Mechanical

4) Start the engine.

5) Check the fuel pressure after warming up the engine.

NOTE:

Fuel pressure:
Standard
340 - 400 kPa (3.5 - 4.1 kgf/cm2, 49 - 58 psi)

6) After inspection, install the related parts in the reverse order of removal.

Valve Clearance

A: INSPECTION

CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire.

NOTE: Inspection of valve clearance should be performed while engine is cold.

1) Lift up the vehicle.

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

3) Lower the vehicle.

4) Disconnect the ground cable from battery.

Subaru Outback. Mechanical

5) Remove the timing belt cover LH.

Subaru Outback. Mechanical

6) Remove the fuel injector. <Ref. to FU(H4SO)- 37, REMOVAL, Fuel Injector.>

7) When inspecting #1 and #3 cylinders

  1. Disconnect the ignition coil from spark plug on RH side. <Ref. to IG(H4SO)-3, RH SIDE, REMOVAL, Spark Plug.>
  2. Place a suitable container under the vehicle.
  3. Disconnect the PCV hose from the rocker cover RH.
  4. Remove the bolts, then remove the rocker cover RH.

8) When inspecting #2 and #4 cylinders

  1. Disconnect the ignition coil from spark plug on LH side. <Ref. to IG(H4SO)-3, LH SIDE, REMOVAL, Spark Plug.>
  2. Place a suitable container under the vehicle.
  3. Disconnect the PCV hose from the rocker cover LH.
  4. Remove the bolts, then remove the rocker cover LH.

9) Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench.

NOTE: When the arrow mark (A) on cam sprocket LH is at the top position, the #1 cylinder piston is at top dead center of the compression stroke.

Subaru Outback. Mechanical

10) Measure #1 cylinder valve clearance by using thickness gauge (A).

NOTE:

Valve clearance (inspection value):
Intake
0.20+-0.04 mm (0.0079+-0.0016 in)
Exhaust
0.25+-0.04 mm (0.0098+-0.0016 in)

Subaru Outback. Mechanical

11) Measure the valve clearance in #3, #2 and #4 cylinder in the same measurement procedure as #1 cylinder in this order.

NOTE:

12) If necessary, adjust the valve clearance. <Ref. to ME(H4SO)-30, ADJUSTMENT, Valve Clearance.>

13) After inspection, install the related parts in the reverse order of removal.

NOTE: Refer to "Camshaft" when installing the rocker cover. <Ref. to ME(H4SO)-59, INSTALLATION, Camshaft.>

B: ADJUSTMENT

CAUTION: If engine oil is spilt onto the exhaust pipe, wipe it off with cloth to avoid emission of smoke or causing a fire.

NOTE: Adjustment of valve clearance should be performed while engine is cold.

1) Set #1 cylinder piston to top dead center of compression stroke by rotating the crank pulley clockwise using the socket wrench.

NOTE: When the arrow mark (A) on cam sprocket LH is at the top position, the #1 cylinder piston is at top dead center of the compression stroke.

Subaru Outback. Mechanical

2) Adjust the #1 cylinder valve clearance.

  1. Loosen the valve rocker nut and screw.
  2. Set a suitable thickness gauge.
  3. While noting the valve clearance, tighten the valve rocker adjusting screw.
  4. When the specified valve clearance is obtained, tighten the valve rocker nut.

NOTE:

Valve clearance (adjustment value):
Intake
0.20+-0.04 mm (0.0079+-0.0016 in)
Exhaust
0.25+-0.04 mm (0.0098+-0.0016 in)

Tightening torque:
9.75 N*m (1.0 kgf-m, 7.2 ft-lb)

Subaru Outback. Mechanical

3) Adjust the valve clearance in #3, #2 and #4 cylinder in the same adjustment procedure as #1 cylinder in this order.

NOTE:

4) Ensure the valve clearances of each cylinder are within specifications. If necessary, readjust the valve clearances.

5) After adjustment, install the related parts in the reverse order of removal.

NOTE: Refer to "Camshaft" when installing the rocker cover.

<Ref. to ME(H4SO)-59, INSTALLATION, Camshaft.>

READ NEXT:

 Engine Assembly

A: REMOVAL 1) Change the front hood damper mounting position from (A) to (B), and completely open the front hood. Tightening torque: 20 N*m (2.0 kgf-m, 14.8 ft-lb) 2) Remove the V-belt covers. 3) C

 Engine Mounting

A: REMOVAL 1) Change the front hood damper mounting position from (A) to (B), and completely open the front hood. Tightening torque: 20 N*m (2.0 kgf-m, 14.8 ft-lb) 2) Disconnect the ground cable from

 Timing Belt Cover

A: REMOVAL NOTE: When replacing a single part, perform the work with the engine assembly installed to body. 1) Remove the crank pulley. <Ref. to ME(H4SO)- 45, REMOVAL, Crank Pulley.> 2) Remove

SEE MORE:

 Parking Brake

General Description A: SPECIFICATION B: COMPONENT 1. PARKING BRAKE (REAR DISC BRAKE) Back plate Retainer Lever Parking brake shoe (Primary) Parking brake shoe (Secondary) Strut spring Strut Shoe guide plate Primary return spring Secondary return spring Adjusting screw Adjusting spring

 Rear window wiper blade rubber (Outback)

1. Pull out the end of the blade rubber assembly to unlock it from the plastic support. 2. Pull the blade rubber assembly out of the plastic support. 1) Metal spines 3. If the new blade rubber is not provided with two metal spines, remove the metal spines from the old blade rubber and i

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