Subaru Outback (BR): Oil Pressure Switch

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the generator. <Ref. to SC(H4SO)-18, REMOVAL, Generator.>

3) Disconnect the terminal from oil pressure switch.

4) Remove the oil pressure switch.

B: INSTALLATION

1) Apply liquid gasket to the oil pressure switch threads.

Liquid gasket: THREE BOND 1324 (Part No. 004403042) or equivalent

2) Install the oil pressure switch to cylinder block.

Tightening torque: 25 N*m (2.5 kgf-m, 18.4 ft-lb)

3) Connect the terminal to the oil pressure switch.

4) Install the generator. <Ref. to SC(H4SO)-18, INSTALLATION, Generator.>

5) Connect the battery ground terminal.

C: INSPECTION

1) Check that the oil pressure switch does not have deformation, cracks or damage.

2) Check the oil pressure switch installation portion for oil leakage and oil seepage.

Engine Oil Cooler

A: REMOVAL

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: Turbo model is equipped with engine oil cooler.

1) Lift up the vehicle.

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

3) Drain engine coolant. <Ref. to CO(H4DOTC)- 14, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

4) Remove the front exhaust pipe. <Ref. to EX(H4DOTC)-5, REMOVAL, Front Exhaust Pipe.>

5) Remove the engine oil filter. <Ref. to LU(H4SO)- 36, REMOVAL, Engine Oil Filter.>

6) Remove the bolt (B) holding the oil cooler pipe (A) to the oil pump.

7) Remove the oil cooler pipe (A), oil cooler hose A (C) and oil cooler hose B (J).

8) Remove the oil cooler connector (D) and oil cooler (E).

1. Oil cooler pipe
2. Bolt
3. Oil cooler hose A
4. Oil cooler connector
5. Oil cooler
6. Gasket
7. Clip
8. Oil cooler pipe stay
9. O-ring
10. Oil cooler hose B

B: INSTALLATION

Install in the reverse order of removal.

NOTE:

• Use new gaskets and O-rings.
• After installing, check the engine oil level and replenish it if necessary. <Ref. to LU(H4SO)-13, INSPECTION, Engine Oil.>
• After temporarily installing the oil cooler pipe, tighten the bolts in alphabetical order as shown below.

Tightening torque:
T1: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)
T2: 54 N*m (5.5 kgf-m, 39.8 ft-lb)

1. Oil cooler pipe
2. Bolt
3. Oil cooler hose A
4. Oil cooler connector
5. Oil cooler
6. Gasket
7. Clip
8. Oil cooler pipe stay
9. O-ring
10. Oil cooler hose B

C: INSPECTION

1) Check that the engine oil cooler, oil cooler pipe and oil cooler connector do not have deformation, cracks or damage.

2) Make sure the oil cooler hoses are not cracked, damaged or loose.

3) Check the coolant paths for clogs while spraying compressed air.

4) Make sure the mating surfaces of the cylinder block do not have damage.

Oil Catch Tank

A: REMOVAL

For the removal procedures, refer to IN (H4DOTC) section. <Ref. to IN(H4DOTC)-23, REMOVAL, Oil Catch Tank.>

B: INSTALLATION

For the installation procedures, refer to IN (H4DOTC) section. <Ref. to IN(H4DOTC)-23, INSTALLATION, Oil Catch Tank.>

C: INSPECTION

For the inspection procedures, refer to IN (H4DOTC) section. <Ref. to IN(H4DOTC)-24, INSPECTION, Oil Catch Tank.>

Scavenge Pump

A: REMOVAL

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: The scavenge pump is installed on turbo models.

1) Lift up the vehicle.

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

3) Remove the union bolt (A) which fixes the oil pipe (C) to the scavenge pump (E).

4) Remove the bolt (D) which fixes the scavenge pump (E) to the cylinder head, and remove the scavenge pump using a flat tip screwdriver.

CAUTION: Be careful not to damage the mating surfaces of the cylinder head and scavenge pump.

1. Union bolt
2. Gasket
3. Oil pipe
4. Bolt
5. Scavenge pump

B: INSTALLATION

Install in the reverse order of removal.

CAUTION: Do not start applying liquid gasket from (A) as shown in the following figure.

NOTE:

• Use a new gasket.
• Install within 5 min. after applying liquid gasket.

Liquid gasket: THREE BOND 1217G (Part No. K0877Y0100) or equivalent

Tightening torque:
T1: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)
T2: 29 N*m (3.0 kgf-m, 21.4 ft-lb)

1. Union bolt
2. Gasket
3. Oil pipe
4. BOLT
5. Scavenge pump

C: INSPECTION

1) Check that the scavenge pump and oil pipe have no deformation, cracks and other damages.

2) Check that the scavenge pump has no cracks, damage or loose part.

Oil Pipe

A: REMOVAL

NOTE: Turbo model is equipped with oil pipe.

1) Remove the collector cover.

2) Disconnect the ground cable from battery.

3) Remove the intercooler. <Ref. to IN(H4DOTC)- 17, REMOVAL, Intercooler.>

4) Lift up the vehicle.

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

6) Remove the ground cable from the oil outlet pipe.

7) Disconnect the oil outlet hose from the oil outlet pipe.

8) Remove oil inlet pipe B (B) from oil inlet pipe A (A), and remove the bolt which holds oil outlet pipe C (C) and oil inlet pipe A (A).

CAUTION: In order to prevent damaging the oil inlet pipe, fix the section (a) shown in the figure when loosing the oil inlet pipe flare nut, and avoid the part from rotating together while loosening the nut.

9) Lower the vehicle.

10) Remove the union bolt (B) securing the oil outlet pipe (A) from the scavenge pump.

11) Remove the bolts (C) and (D) securing the oil outlet pipe (A) to the cylinder head, and remove the oil outlet pipe (A).

12) Remove the oil inlet pipe B (A) from the oil inlet pipe C (C).

CAUTION: In order to avoid damaging the oil inlet pipe C (C), fix the section (a) shown in the figure so that it will not rotate together when loosening the flare nut of the oil inlet pipe B (A).

13) Remove the bolt (B) securing the oil inlet pipe B (A) to the cylinder head and stay, and remove the oil inlet pipe B (A).

14) Remove the union bolt (D) securing the oil inlet pipe C (C) to the cylinder head, and remove the oil inlet pipe C (C).

15) Remove the intake manifold. <Ref. to FU(H4DOTC)-18, REMOVAL, Intake Manifold.>

16) Remove the radiator main fan and radiator sub fan. <Ref. to CO(H4DOTC)-25, REMOVAL, Radiator Main Fan and Fan Motor.> <Ref. to CO(H4DOTC)-27, REMOVAL, Radiator Sub Fan and Fan Motor.>

17) Remove the V-belts. <Ref. to ME(H4DOTC)- 42, REMOVAL, V-belt.>

18) Remove the crank pulley. <Ref. to ME(H4DOTC)-44, REMOVAL, Crank Pulley.>

19) Remove the timing belt cover. <Ref. to ME(H4DOTC)-46, REMOVAL, Timing Belt Cover.>

20) Remove the timing belt. <Ref. to ME(H4DOTC)-52, REMOVAL, Timing Belt.>

21) Remove the cam sprocket LH. <Ref. to ME(H4DOTC)-61, REMOVAL, Cam Sprocket.>

22) Remove the belt cover No. 2 LH.

23) Remove the oil pipe.

1. Union bolt with filter (with protrusion)
2. Union bolt without filter (without protrusion)
3. Oil pipe RH
4. Oil pipe LH
5. Gasket

B: INSTALLATION

1) Inspect the union bolt with filter. <Ref. to LU(H4SO)-35, INSPECTING UNION BOLT WITH FILTER, INSPECTION, Oil Pipe.>

2) Install the oil pipe.

NOTE:

• Be careful of the install location of the union bolt; the location will differ depending on the presence of filter.
• Use a new gasket.

Tightening torque:
T1: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)
T2: 29 N*m (3.0 kgf-m, 21.4 ft-lb)

1. Union bolt with filter (with protrusion)
2. Union bolt without filter (without protrusion)
3. Oil pipe RH
4. Oil pipe LH
5. Gasket

3) Install the belt cover No. 2 LH.

Tightening torque: 5 N*m (0.5 kgf-m, 3.7 ft-lb)

4) Install the cam sprocket LH. <Ref. to ME(H4DOTC)-61, INSTALLATION, Cam Sprocket.>

5) Install the timing belt. <Ref. to ME(H4DOTC)-55, TIMING BELT, INSTALLATION, Timing Belt.>

6) Install the timing belt cover. <Ref. to ME(H4DOTC)-49, INSTALLATION, Timing Belt Cover.>

7) Install the crank pulley. <Ref. to ME(H4DOTC)- 44, INSTALLATION, Crank Pulley.>

8) Install the V-belts. <Ref. to ME(H4DOTC)-42, INSTALLATION, V-belt.>

9) Install the radiator main fan and the radiator sub fan. <Ref. to CO(H4DOTC)-25, INSTALLATION, Radiator Main Fan and Fan Motor.> <Ref. to CO(H4DOTC)-27, INSTALLATION, Radiator Sub Fan and Fan Motor.>

10) Install the intake manifold. <Ref. to FU(H4DOTC)-22, INSTALLATION, Intake Manifold.>

11) Install the oil inlet pipe C (C) to the cylinder head with the union bolt (D).

NOTE: Use a new gasket.

Tightening torque: 29 N*m (3.0 kgf-m, 21.4 ft-lb)

12) Temporarily install the oil inlet pipe B (A) to the oil inlet pipe C (C).

13) Install the oil inlet pipe B (A) to the cylinder head with the bolt (B).

Tightening torque: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)

14) Tighten the flare nut of the oil inlet pipe B (A).

CAUTION: In order to avoid damaging the oil inlet pipe C (C), fix the section (a) shown in the figure so that it will not rotate together when tightening the flare nut of the oil inlet pipe B (A).

Tightening torque: 20 N*m (2.0 kgf-m, 14.8 ft-lb)

15) Temporarily install the oil outlet pipe (A) to the scavenge pump using the union bolt (B).

16) Secure the oil outlet pipe (A) to the cylinder head and stay with bolts (C) and (D).

Tightening torque: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)

17) Tighten the union bolt (B) of the oil outlet pipe (A).

Tightening torque: 29 N*m (3.0 kgf-m, 21.4 ft-lb)

18) Lift up the vehicle.

19) Install the bolt which holds oil outlet pipe (C) and oil inlet pipe A (A), and install oil inlet pipe B (B) to oil inlet pipe A (A).

CAUTION: In order to prevent damaging the oil inlet pipe, fix the section (a) shown in the figure when tightening the oil inlet pipe flare nut, and avoid the part from rotating together while tightening the nut.

Tightening torque:
T1: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)
T2: 20 N*m (2.0 kgf-m, 14.8 ft-lb)

20) Attach the ground cable to the oil outlet pipe.

Tightening torque: 7 N*m (0.7 kgf-m, 5.2 ft-lb)

21) Connect the oil outlet hose to the oil outlet pipe.

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

23) Lower the vehicle.

24) Install the intercooler. <Ref. to IN(H4DOTC)- 18, INSTALLATION, Intercooler.>

25) Connect the battery ground terminal.

26) Install the collector cover.

C: INSPECTION

1. INSPECTING UNION BOLT WITH FILTER

Check the filter part of union bolt for clogging or damage, and if defective, replace the union bolt with filter with the new part.

1. Union bolt with filter (with protrusion)
2. Union bolt without filter (without protrusion)
3. Oil pipe RH
4. Oil pipe LH
5. Gasket

2. OTHER INSPECTIONS

1) Check that the oil pipe and union bolt have no deformation, cracks and other damages.

2) Check that there are no oil leaks or oil oozing from the oil pipe attachment section.

Engine Oil Filter

A: REMOVAL

CAUTION: If the engine oil is spilt over exhaust pipe or the under cover, wipe it off with cloth to avoid emitting smoke or causing a fire.

1) Lift up the vehicle.

2) Remove the service hole cover of under cover.

• Medium under cover model

• Models with large under cover

3) Remove the oil filter.

• Black oil filter

Remove it using the ST.

ST 18332AA000 OIL FILTER WRENCH (OUTER DIAMETER: 68 MM (2.68 IN) FOR OIL FILTER)

• Blue oil filter

Remove it using the general tool (65/67 mm 14 flutes).

B: INSTALLATION

CAUTION: Do not tighten excessively, or oil may leak.

1) Clean the oil filter installation surface on the cylinder block or engine oil cooler.

2) Obtain a new oil filter and apply a thin coat of engine oil to the seal rubber.

3) Install the oil filter turning it by hand, being careful not to damage the seal rubber of the oil filter.

• Tighten the oil filter (Black) with an outer diameter of 68 mm (2.68 in) (approx. 1 rotation) after the seal rubber of the oil filter comes in contact with cylinder block. When using a torque wrench, tighten to 14 N*m (1.4 kgf-m, 10.3 ft-lb).
• Tighten the oil filter (Blue) with an outer diameter of 67.4 mm (2.65 in) (approx. 7/8 rotation) after the seal rubber of the oil filter comes in contact with cylinder block. When using a torque wrench, tighten to 12 N*m (1.2 kgf-m, 8.9 ft-lb).

4) Return the service hole cover to its original position.

5) Lower the vehicle.

6) After installing, check the engine oil level and replenish it if necessary. <Ref. to LU(H4SO)-13, INSPECTION, Engine Oil.>

C: INSPECTION

1) After installing the oil filter, run the engine and make sure that no oil is leaking around seal rubber.

NOTE: The filter element and filter case are permanently jointed; therefore, interior cleaning is not necessary.

2) Check the engine oil level. <Ref. to LU(H4SO)- 13, INSPECTION, Engine Oil.>

Oil Level Switch

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Lift up the vehicle.

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

4) Drain the engine oil. <Ref. to LU(H4SO)-13, REPLACEMENT, Engine Oil.>

5) Disconnect the connector of the oil level switch from the engine harness.

6) Remove the clip holding the oil level switch harness.

• Turbo model

• Non-turbo model

7) Remove the oil level switch from the cylinder block lower.

B: INSTALLATION

1) Install the oil level switch to the cylinder block lower.

NOTE:

• Use new O-rings.
• Apply a coat of engine oil to the O-rings.

Tightening torque: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)

2) Hold the oil level switch harness with the clip.

• Turbo model

• Non-turbo model

3) Connect the connector of the oil level switch to the engine harness.

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

5) Lower the vehicle.

6) Refill the engine oil. <Ref. to LU(H4SO)-13, REPLACEMENT, Engine Oil.>

7) Check the engine oil level. <Ref. to LU(H4SO)- 13, INSPECTION, Engine Oil.>

8) Connect the battery ground terminal.

C: WIRING DIAGRAM

D: INSPECTION

1. INSPECTION WHEN LOW ENGINE OIL WARNING LIGHT IS ILLUMINATED

2. OTHER INSPECTIONS

1) Check that the oil level switch does not have deformation, cracks, or damage.

2) Check the oil level switch installation part for oil leakage and oil seepage.

Engine Lubrication System Trouble in General

A: INSPECTION

Before performing diagnostics, make sure that the engine oil level is correct and no oil leakage exists.

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