Subaru Outback manuals

Subaru Outback: Oil Pump

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the V-belts. <Ref. to ME(H4SO)-43, REMOVAL, V-belt.>

3) Remove the power steering oil pump assembly.

  1. Disconnect the connector from power steering pump switch.
  2. Disconnect the pressure hose (b) and suction hose (a) from power steering oil pump.

CAUTION:

Subaru Outback. Power Assisted System (Power Steering)

  1. Remove the bolts, and remove the power steering oil pump assembly.

Subaru Outback. Power Assisted System (Power Steering)

4) Secure the oil pump bracket in a vise, and remove the bolts from both front and rear sides of the oil pump.

CAUTION: When securing the oil pump bracket in a vice, hold the oil pump bracket with the least possible force between two pieces of wood.

Subaru Outback. Power Assisted System (Power Steering)

5) Remove the power steering oil pump assembly from the bracket.

B: INSTALLATION

1) Install the bracket to the power steering oil pump.

Subaru Outback. Power Assisted System (Power Steering)

Tightening torque:
T1: 16 N*m (1.63 kgf-m, 11.8 ft-lb)
T2: 36 N*m (3.67 kgf-m, 26.6 ft-lb)

2) Install the power steering pump bracket.

Tightening torque:
H4 model: 22 N*m (2.24 kgf-m, 16.2 ft-lb)
H6 model: 33 N*m (3.36 kgf-m, 24.3 ft-lb)

3) Connect the pressure hose (b) and suction hose (a).

CAUTION: Be careful when installing; If the hose is twisted it may come into contact with other parts.

Subaru Outback. Power Assisted System (Power Steering)

Tightening torque: Eye bolt: 40 N*m (4.08 kgf-m, 29.5 ft-lb)

4) Connect the power steering pump switch to the connector.

5) After installing the oil pump, fill the oil pump with as much fluid as possible by rotating the pulley by hand.

CAUTION: Always fill the oil pump with the fluid to prevent abnormal noise and seizure of the oil pump.

6) Install the V-belts. <Ref. to ME(H4SO)-43, INSTALLATION, V-belt.>

7) Connect the battery ground terminal.

8) Fill with recommended power steering fluid and perform air bleeding. <Ref. to PS-77, Power Steering Fluid.>

CAUTION: Never start the engine before filling with fluid; otherwise the vane pump may become seized.

C: INSPECTION

1. BASIC INSPECTION

Perform the following inspection procedures and replace any faulty parts.

Subaru Outback. Power Assisted System (Power Steering)

2. SERVICE LIMIT

Make a measurements as follows. If it exceeds the service limit, replace with a new part.

CAUTION:

1) Play of the pulley shaft

Condition:
P: When applying a force of 9.8 N (1.0 kgf, 2.2 lbf)

Service limit:
Play in the radial direction (Direction
Subaru Outback. Power Assisted System (Power Steering)):0.2 mm (0.008 in) or less
Axial play (Direction
Subaru Outback. Power Assisted System (Power Steering)):0.9 mm (0.035 in) or less

Subaru Outback. Power Assisted System (Power Steering)

2) Deflection of the pulley groove

Service limit: 1.0 mm (0.039 in) or less

NOTE: Read the value on one surface of V groove, set the dial gauge on the other surface, and read the value of the dial gauge.

Subaru Outback. Power Assisted System (Power Steering)

  1. Dial gauge

3) Rotating resistance of pulley

Service limit: Maximum load: 9.22 N (0.94 kgf, 2.07 lbf) or less

NOTE:

Subaru Outback. Power Assisted System (Power Steering)

  1. Spring scale

3. HYDRAULIC PRESSURE

CAUTION:

Regular pressure measurement

1) Connect the ST1, ST2 and ST3.

PREPARATION TOOL:
ST1: PRESSURE GAUGE (925711000)
ST2: ADAPTER HOSE B (34099AC020)
ST3: ADAPTER HOSE A (34099AC010)

Subaru Outback. Power Assisted System (Power Steering)

2) Remove the air intake duct.

3) Disconnect the pressure hose (a) from the pump.

4) Using the gasket (Part No. 34621AC021) and bolt (Part No. 34620AC010), install the ST2 to pump instead of pressure hose (a).

Subaru Outback. Power Assisted System (Power Steering)

5) Attach the ST3 to the end of pressure hose which is removed from pump.

6) Replenish power steering fluid up to the specified level.

7) Open the valve, and start the engine.

Subaru Outback. Power Assisted System (Power Steering)

8) Measure the regular pressure.

Service limit: 981 kPa (10 kgf/cm2, 142 psi) or less

9) If it is not within the specification, replace the faulty part for the following problems. (Pipe or hose clogged, leaks from fluid line, and mixture of foreign matter in fluid line)

Relief pressure measurement

1) Attach ST1, ST2 and ST3 to the vehicle body in the same way as for regular pressure measurement.

PREPARATION TOOL:
ST1: PRESSURE GAUGE (925711000)
ST2: ADAPTER HOSE B (34099AC020)
ST3: ADAPTER HOSE A (34099AC010)

Subaru Outback. Power Assisted System (Power Steering)

2) Close the valve.

3) Measure the relief pressure.

Service limit:
H4 non-turbo model: 8,300 - 9,000 kPa (85 - 92 kgf/cm2, 1,203 - 1,305 psi)
H6, H4 turbo model: 8,900 - 9,600 kPa (91 - 98 kgf/cm2, 1,290 - 1,392 psi)

4) If the torque is not within specified range, replace the oil pump.

Working pressure measurement

1) Attach ST1, ST2 and ST3 to the vehicle body in the same way as for regular pressure measurement.

PREPARATION TOOL:
ST1: PRESSURE GAUGE (925711000)
ST2: ADAPTER HOSE B (34099AC020)
ST3: ADAPTER HOSE A (34099AC010)

Subaru Outback. Power Assisted System (Power Steering)

2) Open the valve.

3) Measure the working pressure of control valve by turning steering wheel from stop to stop.

Service limit:
H4 non-turbo model: 8,300 - 9,000 kPa (85 - 92 kgf/cm2, 1,203 - 1,305 psi)
H6, H4 turbo model: 8,900 - 9,600 kPa (91 - 98 kgf/cm2, 1,290 - 1,392 psi)

4) If it is out of specification, measure the steering effort. <Ref. to PS-82, MEASUREMENT OF STEERING EFFORT, INSPECTION, General Diagnostic Table.>

If the steering wheel effort is not within specification, replace the control valve itself or control valve and pinion as a single unit, using new parts.

Reservoir Tank

A: REMOVAL

1) Drain fluid from the reservoir tank.

2) Disconnect the hose from reservoir tank.

CAUTION: Plug the ends of the hose and pipe to prevent foreign matter from entering.

3) Remove the reservoir tank from the body.

Subaru Outback. Power Assisted System (Power Steering)

  1. Reservoir tank
  2. Suction hose
  3. Return hose

B: INSTALLATION

1) Install the reservoir tank to the body.

Tightening torque: 13 N*m (1.33 kgf-m, 9.6 ft-lb)

2) Connect the hose to the reservoir tank.

Subaru Outback. Power Assisted System (Power Steering)

  1. Reservoir tank
  2. Suction hose
  3. Return hose

3) Replenish power steering fluid up to the specified level. <Ref. to PS-77, INSPECTION, Power Steering Fluid.>

C: INSPECTION

Check the reservoir tank for cracks, breakage or damage. If a failure is found, replace the reservoir tank.

Power Steering Fluid

A: SPECIFICATION

Recommended power steering fluid: SUBARU ATF or DEXRON III

B: INSPECTION

1) Check the power steering fluid for deterioration or contamination. If the fluid is highly deteriorated or contaminated, drain it and refill with new fluid.

2) Check the joints and units for oil leakage. If any oil leaks are found, repair or replace the applicable part.

3) Inspect the fluid level of reservoir tank with vehicle on level surface and engine stopped.

If the level is at "MIN." point or below, add fluid to keep the level in the specified range of the indicator. If at "MAX". point or above, drain fluid by using a syringe or the like.

  1. Check at power steering fluid temperature 20ºC (68ºF); read the fluid level on the "COLD" side.
  2. Check at power steering fluid temperature 80ºC (176ºF); read the fluid level on the "HOT" side.

Subaru Outback. Power Assisted System (Power Steering)

C: REPLACEMENT

1) Lift up the vehicle.

2) Drain the power steering fluid.

3) Add the specified fluid to reservoir tank at "MAX" level.

4) Continue to turn the steering wheel slowly from lock to lock until the bubbles stop appearing on oil surface while keeping the fluid at the level in the Step 3).

5) If the steering wheel is turned in a low fluid level condition, air will be sucked into the pipe. If air has entered, leave it for about half an hour and then repeat step 4) again.

6) Start the engine and let it idle.

7) Continue to turn the steering wheel slowly from lock to lock again until the bubbles stop appearing on oil surface, while keeping the fluid at the level in Step 3).

Normally bubbles will stop appearing after turning the steering wheel from lock to lock three times.

8) In case bubbles do not stop appearing in the tank, leave it for about half an hour and then repeat from step 3) again.

9) Lower the vehicle, and then idle the engine.

10) Continue to turn the steering wheel from lock to lock until the bubbles stop appearing and change of the fluid level is within 3 mm (0.12 in).

11) In case the following happens, leave it about half an hour and then perform step 7) to 10) again.

  1. The fluid level changes by 3 mm (0.12 in) or more.
  2. Bubbles remain on the upper surface of the fluid.
  3. Grinding noise is generated from oil pump.

12) Check the fluid leakage after turning steering wheel from lock to lock with engine running.

General Diagnostic Table

A: INSPECTION

Subaru Outback. Power Assisted System (Power Steering)

*1 If the tires or wheels are wider than standard, the load to power steering system is increased. Accordingly, in a condition, for example before fluid warms-up, relief valve may work before reaching maximum turning angle. In this case, steering effort may be heavy. When the measured hydraulic pressure is normal, there is no abnormal thing.
*2 In cold weather, steering effort may be heavy due to increased flow resistance of cold fluid. After warming-up engine, turn the steering wheel from stop to stop several times to warm up fluid. If steering effort reduces normally, function is normal.
*3 In cold weather or with insufficient warm up of the engine, steering effort may be heavy due to excessive drop of idling when turning the steering wheel. In this case, start the vehicle with increasing engine speed than usual. If steering effort reduces normally, function is normal.

1. NOISE AND VIBRATION

CAUTION: Do not keep the relief valve operated for five seconds or more at any time or inner parts of the oil pump may be damaged due to rapid increase of fluid temperature.

NOTE:

Subaru Outback. Power Assisted System (Power Steering)

Subaru Outback. Power Assisted System (Power Steering)

2. MEASUREMENT OF STEERING EFFORT

Subaru Outback. Power Assisted System (Power Steering)

Subaru Outback. Power Assisted System (Power Steering)

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