Subaru Outback (BR): Oil Pressure System

A: WIRING DIAGRAM

B: INSPECTION

Engine Oil

A: INSPECTION

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) Park the vehicle on a level surface.

2) Remove the oil level gauge and wipe away the oil.

3) Reinsert the oil level gauge all the way. Be sure that the oil level gauge is correctly inserted and properly orientated.

4) Pull out the oil level gauge again, and check the oil level. If the engine oil level is below "L" line, check for oil leakage from engine and add oil to bring the level up to "F" line.

5) Start the engine to circulate the oil in engine room.

6) After turning off the engine, wait a few minutes for the oil to return to the oil pan before checking the level.

NOTE:

• Just after driving or while the engine is warm, engine oil level shows in the range between the "F" line and the notch mark. This is caused by thermal expansion of engine oil.
• To prevent overfilling of engine oil, do not add oil above "F" line when the engine is cold.
• As the oil level gauge is used for daily maintenance, "F" line and "L" line is set assuming that the engine is cold.

1. Oil level gauge
2. Oil filler cap
3. "F" line
4. "L" line
5. Approx. 1.0 (1.1 US qt, 0.9 Imp qt)
6. Notch mark

B: REPLACEMENT

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) Open the oil filler cap for quick draining of engine oil.

2) Lift up the vehicle.

3) Remove the service hole cover of the under cover.

(Large under cover model)

4) Drain engine oil by loosening the drain plug.

NOTE: Prepare the container for draining of engine oil.

• Models with small and medium size under covers

• Models with large under cover

5) After draining the engine oil, tighten the engine oil drain plug.

NOTE: Use a new drain plug gasket.

Tightening torque: 41.7 N*m (4.3 kgf-m, 30.8 ft-lb)

• Models with small and medium size under covers

• Models with large under cover

6) Install the service hole cover of the under cover.

(Large under cover model)

7) Lower the vehicle.

8) Select engine oil of adequate quality and viscosity and fill it through the oil filler duct to the "F" line on the oil level gauge. Make sure that the vehicle is parked on a level surface when checking oil level.

Recommended oil: Refer to "SPECIFICATION" for recommended oil. <Ref. to LU(H4SO)-2, SPECIFICATION, General Description.>

Engine oil capacity: Refer to "SPECIFICATION" for engine oil capacity.

<Ref. to LU(H4SO)-2, SPECIFICATION, General Description.>

9) Close the oil filler cap.

10) Start the engine to circulate the oil in engine room.

11) After stopping the engine, recheck the oil level.

If necessary, add engine oil up to the "F" line on oil level gauge.

1. Oil level gauge
2. Oil filler cap
3. "F" line
4. "L" line
5. Approx. 1.0 (1.1 US qt, 0.9 Imp qt)
6. Notch mark

Oil Pump

A: REMOVAL

1) Remove the collector cover. (turbo model)

2) Disconnect the ground cable from battery.

3) Remove the radiator. <Ref. to CO(H4SO)-20, REMOVAL, Radiator.> <Ref. to CO(H4DOTC)-21, REMOVAL, Radiator.>

4) Remove the crankshaft position sensor. <Ref. to FU(H4SO)-25, REMOVAL, Crankshaft Position Sensor.> <Ref. to FU(H4DOTC)-35, REMOVAL, Crankshaft Position Sensor.>

5) Remove the water pump. <Ref. to CO(H4SO)- 16, REMOVAL, Water Pump.> <Ref. to CO(H4DOTC)-16, REMOVAL, Water Pump.>

6) Remove the crank sprocket. <Ref. to ME(H4SO)-54, REMOVAL, Crank Sprocket.>

<Ref. to ME(H4DOTC)-62, REMOVAL, Crank Sprocket.>

7) Remove the bolts which install oil pump onto cylinder block.

NOTE: When disassembling and checking the oil pump, loosen the relief valve plug before removing the oil pump.

8) Remove the oil pump by using flat tip screwdriver.

CAUTION: Be careful not to scratch the mating surface of the cylinder block and oil pump.

9) Remove the front oil seal from the oil pump.

B: INSTALLATION

1) Using the ST, install the front oil seal.

ST 499587100 OIL SEAL INSTALLER

NOTE: Use a new front oil seal.

2) Apply liquid gasket to the mating surfaces of oil pump.

NOTE: Install within 5 min. after applying liquid gasket.

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

1. O-ring

3) Apply a coat of engine oil to the inside of front oil seal.

4) Install the oil pump to cylinder block.

CAUTION:

• Be careful not to damage the front oil seal during installation.
• Make sure the front oil seal lip is not folded.

NOTE:

• Align the flat surface of oil pump's inner rotor with that of crankshaft before installation.
• Use new O-rings.
• Do not forget to assemble O-rings.

5) Apply liquid gasket to the three bolts thread shown in figure. (when reusing bolts)

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

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

6) Install the crank sprocket. <Ref. to ME(H4SO)- 54, INSTALLATION, Crank Sprocket.> <Ref. to ME(H4DOTC)-62, INSTALLATION, Crank Sprocket.>

7) Install the water pump. <Ref. to CO(H4SO)-16, INSTALLATION, Water Pump.> <Ref. to CO(H4DOTC)-17, INSTALLATION, Water Pump.>

8) Install the crankshaft position sensor. <Ref. to FU(H4SO)-25, INSTALLATION, Crankshaft Position Sensor.> <Ref. to FU(H4DOTC)-35, INSTALLATION, Crankshaft Position Sensor.>

9) Install the radiator. <Ref. to CO(H4SO)-21, INSTALLATION, Radiator.> <Ref. to CO(H4DOTC)- 22, INSTALLATION, Radiator.>

10) Connect the battery ground terminal.

C: DISASSEMBLY

Remove the screw which secures oil pump cover and then disassemble oil pump. Inscribe alignment marks on the inner rotor and outer rotor so that they can be replaced in their original positions during reassembly.

NOTE: Before disassembling the oil pump, remove the relief valve.

1. Front oil seal
2. Oil pump case
3. Inner rotor
4. Outer rotor
5. Oil pump cover
6. Relief valve
7. Relief valve spring
8. Plug
9. Gasket

D: ASSEMBLY

1) Using the ST, install the front oil seal.

ST 499587100 OIL SEAL INSTALLER

NOTE: Use a new front oil seal.

2) Apply a coat of engine oil to the inner rotor and outer rotor.

3) Install the inner rotor and outer rotor.

4) Assemble the oil relief valve and install relief valve spring and plug.

NOTE: Use a new gasket.

5) Install the oil pump cover.

Tightening torque:
T1: 5.4 N*m (0.6 kgf-m, 4.0 ft-lb)
T2: 44 N*m (4.5 kgf-m, 32.5 ft-lb)

1. Front oil seal
2. Oil pump case
3. Inner rotor
4. Outer rotor
5. Oil pump cover
6. Relief valve
7. Relief valve spring
8. Plug
9. Gasket

E: INSPECTION

1. TIP CLEARANCE

Measure the tip clearance of rotors. If the clearance is out of standard, replace the rotors as a set.

Tip clearance between inner and outer rotors: Standard 0.04 - 0.14 mm (0.0016 - 0.0055 in)

2. CASE CLEARANCE

Measure the clearance between outer rotor and oil pump case. If clearance is out of standard, replace the oil pump case.

Case clearance between outer rotor and pump case: Standard 0.10 - 0.175 mm (0.0039 - 0.0069 in)

3. SIDE CLEARANCE Measure the gap between the inner rotor and the oil pump case to measure the clearance between the inner rotor and the oil pump cover as shown in the figure. If clearance is out of standard, replace the rotor or the oil pump case.

Side clearance between inner rotor and pump case: Standard 0.02 - 0.07 mm (0.0008 - 0.0028 in)

4. OIL RELIEF VALVE

Check the valve for assembly condition and damage, and the relief valve spring for damage and deterioration.

Replace the parts if defective.

Relief valve spring: Free length 73.7 mm (2.902 in)

Installed length 54.7 mm (2.154 in)

Load when installed 93.1 N (9.49 kgf, 20.93 lbf)

5. OIL PUMP CASE

Check for worn shaft hole, clogged oil passage, worn rotor chamber, cracks and other faults.

6. FRONT OIL SEAL

Check the front oil seal lips for deformation and hardening, wear.

Oil Pan and Strainer

A: REMOVAL

1. OIL PAN

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) Remove the front exhaust pipe. <Ref. to EX(H4SO)-5, REMOVAL, Front Exhaust Pipe.>

<Ref. to EX(H4DOTC)-5, REMOVAL, Front Exhaust Pipe.>

6) Remove the bolts which secure the oil pan to the cylinder block lower.

7) Insert an oil pan cutter blade into the gap between cylinder block lower and oil pan, and remove the oil pan.

CAUTION: Do not use a screwdriver or similar tool in place of oil pan cutter.

2. CYLINDER BLOCK LOWER

1) Remove the collector cover. (turbo model)

2) Disconnect the ground cable from battery.

3) Remove the cover (A) and clip (B) from air intake boot assembly. (non-turbo model)

4) Loosen the clamp (A) which connects the air intake boot assembly and air cleaner case. (non-turbo model)

5) Loosen the clamp (B) which connects the air intake boot assembly and throttle body. (non-turbo model)

6) Remove the air intake boot from the throttle body, and move it to the left side wheel apron. (non-turbo model)

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

8) Support the engine with a lifting device and wire ropes.

9) Lift up the vehicle.

CAUTION: When lifting up the vehicle, raise up wire ropes at the same time.

10) Remove the oil pan. <Ref. to LU(H4SO)-19, OIL PAN, REMOVAL, Oil Pan and Strainer.>

11) Remove the engine mounting. <Ref. to ME(H4SO)-39, REMOVAL, Engine Mounting.>

<Ref. to ME(H4DOTC)-38, REMOVAL, Engine Mounting.>

12) Remove the bolt which secures the cylinder block lower to the cylinder block.

13) Use a flat tip screwdriver through the gap between the cylinder block and cylinder block lower to remove the cylinder block lower.

CAUTION: Insert the flat tip screwdriver to the position shown in the figure, and be careful not to damage the mating surface of the cylinder block and cylinder block lower.

14) Remove the oil strainer from the cylinder block lower.

15) Remove the oil level switch from the cylinder block lower. <Ref. to LU(H4SO)-37, REMOVAL, Oil Level Switch.>

16) Remove the baffle plate.

1. Oil pan
2. Oil drain pipe
3. Cylinder block lower
4. O-ring
5. Oil strainer
6. Baffle plate
7. Cylinder block
8. O-ring
9. Seal
10. O-ring
11. Oil level switch

B: INSTALLATION

1. OIL PAN

NOTE: Before installing the oil pan, clean the mating surface of oil pan and cylinder block.

1) Apply liquid gasket to the mating surfaces of oil pan, and install the oil pan.

NOTE: Install within 5 min. after applying liquid gasket.

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

2) Tighten the bolts to install the oil pan to the cylinder block lower.

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

3) Install the front exhaust pipe. <Ref. to EX(H4SO)-6, INSTALLATION, Front Exhaust Pipe.> <Ref. to EX(H4DOTC)-7, INSTALLATION, Front Exhaust Pipe.>

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

5) Lower the vehicle.

6) Connect the battery ground terminal.

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

2. CYLINDER BLOCK LOWER

NOTE: Before installing the cylinder block lower, clean the mating surface of cylinder block lower and cylinder block.

1) Make sure that the seals (A) are installed securely on the baffle plate in a direction as shown in the figure below.

NOTE: Use a new seal.

2) Install the baffle plate.

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

3) Install the oil drain pipe to the cylinder block lower.

1. Draw a reference line (A) on the oil drain pipe using a marker as shown in the figure.

Oil drain pipe protrusion L: 90.0 mm (3.54 in)

2. Insert the oil drain pipe up to the reference line (A) using a plastic hammer.

NOTE: Be careful not to deform the oil drain pipe.

3. Measure the oil drain pipe protrusion "L" and check that the value is within the specified range.

Oil drain pipe protrusion L: Standard 89.0 - 91.0 mm (3.50 - 3.58 in)

4) Install the oil level switch to the cylinder block lower. <Ref. to LU(H4SO)-38, INSTALLATION, Oil Level Switch.>

5) Install the oil strainer to the cylinder block lower.

NOTE: Use new O-rings.

Tightening torque: 10 N*m (1.0 kgf-m, 7.4 ft-lb)

6) Install the O-ring to the cylinder block lower.

NOTE:

• Use new O-rings.
• Install the O-ring with the metal side facing upward.

7) Apply liquid gasket to the mating surfaces of the oil pan, and install the cylinder block lower.

CAUTION: Be careful not to apply any liquid gasket to the O-ring (A).

NOTE: Install within 5 min. after applying liquid gasket.

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

1. O-ring

8) Tighten the bolts to install the cylinder block lower to the cylinder block.

Tightening torque:
T1: 5 N*m (0.5 kgf-m, 3.7 ft-lb)
T2: 6.4 N*m (0.7 kgf-m, 4.7 ft-lb)
T3: 10 N*m (1.0 kgf-m, 7.4 ft-lb)
T4: 16 N*m (1.6 kgf-m, 11.8 ft-lb)

1. Oil pan
2. Oil drain pipe
3. Cylinder block lower
4. O-ring
5. Oil strainer
6. Baffle plate
7. Cylinder block
8. O-ring
9. Seal
10. O-ring
11. Oil level switch

9) Install the engine mount. <Ref. to ME(H4SO)- 40, INSTALLATION, Engine Mounting.> <Ref. to ME(H4DOTC)-39, INSTALLATION, Engine Mounting.>

10) Install the oil pan. <Ref. to LU(H4SO)-21, OIL PAN, INSTALLATION, Oil Pan and Strainer.>

11) Lower the vehicle.

CAUTION: When lowering the vehicle, lower the lift up device and wire ropes at the same time.

12) Remove the lifting device and wire ropes.

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

14) Install the air intake boot assembly. (non-turbo model)

NOTE: Align the clamp hole with the protrusion of the air intake boot assembly.

Tightening torque: Clamp (A), (B) 3 N*m (0.3 kgf-m, 2.2 ft-lb)

15) Connect the battery ground terminal.

16) Install the collector cover. (turbo model) 17) Refill the engine oil. <Ref. to LU(H4SO)-13, REPLACEMENT, Engine Oil.>

C: INSPECTION

Check that the oil pan, oil strainer and baffle plate do not have deformation, cracks or damage.

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