2005 Subaru Outback 3 Service Repair Manual

G2360GE.book

1 ページ

２００７年１１月２９日 木曜日 午後１時２８分

2005-2009 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No. G2360GE1) ENGINE SECTION 1 (Pub.No. G2360GE2) ENGINE SECTION 2 (Pub.No. G2360GE3) ENGINE SECTION 3 (Pub.No. G2360GE4) TRANSMISSION SECTION (Pub.No. G2360GE5) CHASSIS SECTION (Pub.No. G2360GE6) BODY SECTION (Pub.No. G2360GE7) WIRING SYSTEM SECTION (Pub.No. G2360GE8)

Foreword FOREWORD

1. Foreword A: FOREWORD These manuals are used when performing maintenance, repair or diagnosis of Subaru LEGACY. Applicable model: 2009MY BL*****, BP***** The manuals contain the latest information at the time of publication. Changes in the specifications, methods, etc. may be made without notice.

FW-2

How to Use This Manuals HOW TO USE THIS MANUALS

1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each component. The specification, maintenance and other information for the components are included, and the diagnostic information has also been added where necessary.

2. CONTENTS The first page has an index with tabs.

HU-2

How to Use This Manuals HOW TO USE THIS MANUALS

3. COMPONENT Illustrations are provided for each component. The information necessary for repair work (tightening torque, grease up points, etc.) is described on these illustrations. Information is described using symbol.

To order parts, refer to parts catalogue.

Example:

(7)

(5)

(21)

T2

(5)

T6

(8) (20)

(1)

T1

T3

(4)

(2) T8

T2

(3) (6)

T3

T10 (1)

T5

T3

T2 T3

(2)

T4 (4)

(4)

(3)

(12) (22) (23) (16) (14)

(9)

(6)

(10) (11)

(11)

(18) T1

(13)

(10)

(9)

T3

(15)

T2

(17) (19)

T6 (4)

(3) (7)

T4

(10) (4)

(15)

T2 T11

T5

(22)

T6

(3)

(12)

(35)

T4

(8) (10)

T3

(26) (23)

(14)

T2

T5

(27)

T2

(34)

(24) (25)

T7 (24)

(36)

(25)

(13)

(31) (30)

T2

T5 (29)

(10) (17)

(16)

(37) (32)

(28)

(18) T3

(33)

T4 T1

: Selective part : Replacement part

T1 (21)

: Sealing point : Should be lubricated with oil.

(20) T9

: Should be lubricated with grease.

(19) T1

,

T2

....

: Tightening torque

HU-00017

HU-3

How to Use This Manuals HOW TO USE THIS MANUALS

4. SPECIFICATION If necessary, specifications are also included.

5. INSPECTION Inspections to be carried out before and after maintenance are included.

6. MAINTENANCE • Maintenance instructions for serviceable parts describe work area and detailed step with illustration. It also describes the use of special tool, tightening torque, caution for each procedure.

• If many serviceable parts are included in one service procedure, appropriate reference is provided for each parts.

Example:

15.Main Shaft Assembly for Single-Range A: REMOVAL

(A)

(B)

1) Remove the manual transmission assembly from vehicie. <Ref. to MT-33, REMOVAL, Manual Transmission Assembly.> (C)

11) Tighten the lock nuts to the specified torque using ST1 and ST2.

NOTE: Secure the lock nuts in two places after tightening.

ST1 498937000 TRANSMISSION HOLDER ST2 499987003 SOCKET WRENCH (35) (E)

(D)

(F)

Tightening torque: 118 N m (12.0 kgf-m, 86.8 ft-lb)

(G)

(H)

ST2

ST1

HU-00020

(A) (B) (C)

Component Process Reference

(D) (E) (F)

Cautions Tool number of special tool Name of special tool

HU-4

(G) (H)

Tightening torque Illustration

How to Use This Manuals HOW TO USE THIS MANUALS

7. DIAGNOSIS Tables showing a step-by-step process make it easy to conduct diagnosis.

8. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included.

Example: Tightening torque: 44 N·m (4.5 kgf-m, 33 ft-lb) Item Force Mass (Weight) Capacity Torque Rotating speed Pressure

SI units N (Newton) kg, g 2, m2 or cm3 N·m rpm kPa (kilopascal)

Power Calorie Fuel consumption rate

W W·h g/kw·h

Conventional unit kgf kg, g 2or cc kgf-m, kgf-cm rpm kgf/cm2 mmHg PS cal g/PS·h

Remarks 1 kgf = 9.80655 N 1 cc = 1 cm3 = 1 m2 1 kgf-m = 9.80655 N·m 1 kgf/cm2 = 98.0655 kPa 1 mmHg = 0.133322 kPa 1 PS = 0.735499 kW 1 kcal = 1.16279 W·h 1 g/PS·h = 1.3596 g/kW·h

The figure used in these manuals are described in the SI units and conventional units are described in (

HU-5

).

How to Use This Manuals HOW TO USE THIS MANUALS

9. EXPLANATION OF TERMINOLOGY â&#x20AC;¢ List AAI A/B ABS A/C ADA A/F ALT APS ASSY AT ATF AVCS AWD BATT BJ CAN CD COMPL CPU DOHC DOJ DTC EBJ ECM EDJ EGI E/G EGR ETC EX F/B Ft FWD GPS HID

: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :

Air Assist Injection Airbag Anti-lock Brake System Air Conditioner Active Driving Assist Air Fuel Ratio Generator Accessory power supply socket Assembly Automatic Transmission Automatic Transmission Fluid Active Valve Control System All Wheel Drive Battery Bell Joint Communication Area Network Compact Disc Complete Central Processing Unit Double Overhead Camshaft Double Offset Joint Diagnostic code High-Efficiency Compact Ball Fixed Joint Engine Control Module High-Efficiency Compact Double Offset Joint Electronic Gasoline Injection Engine Exhaust Gas Recirculation Electronic Throttle Control Exhaust Fuse & Joint Box Front Front Wheel Drive Global Positioning System High-Intensity Discharge

H/U HVAC IG IN INT I/O ISC LAN LH LSD M/B MID MFI MP-T MT NA OP PC PCV P/S PTJ P/W RH Rr SDI SI-DRIVE SOHC SRS ST SW TCS TGV VDC VTD

HU-6

: : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :

Hydraulic Unit Heater, Ventilator and Air Conditioner Ignition Intake Intermittent Input / Output Idle Speed Control Local Area Network LH (Left Hand) Limited Slip Differential Main Fuse & Relay Box Multi-information Display Multi Point Injection Multi-Plate Transfer Manual Transmission Natural Aspiration Option Parts Personal Computer Positive Crankcase Ventilation Power Steering Pillow Tripod Joint Power Window RH (Right Hand) Rear SUBARU Diagnostic Interface SUBARU Intelligent Drive Single Overhead Camshaft Supplemental Restraint System Special Tool Switch Traction Control System Tumble Generator Valve Vehicle Dynamics Control Variable Torque Distribution

LEGACY SPECIFICATIONS

1. LEGACY A: DIMENSION 1. SEDAN MODEL Model Overall length Overall width Overall height (at C.W.) Compartment

Length Width Height

Wheelbase Front Rear Minimum road clearance Tread

*1: *2:

2.5 L SOHC mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

1,425 (56.1)

2.5 L DOHC turbo 4,700 (185.0) 1,730 (68.1) 1,425 (56.1), 1,435 (56.5)*2

150 (5.9)

1,900 (74.8) 1,445 (56.9) 1,165 (45.9), 1,100 (43.3)*1 2,670 (105.1) 1,495 (58.9) 1,485 (58.5) 150 (5.9), 160 (6.3)*2

3.0 L DOHC

1,435 (56.5)

160 (6.3)

With sunroof 2.5 GT spec. B model

2. WAGON MODEL Model Overall length Overall width Overall height (at C.W.) Length Compartment Width Height Wheelbase Front Tread Rear Minimum road clearance *1:

2.5 L SOHC mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

2.5 L DOHC turbo 4,785 (188.4) 1,730 (68.1) 1,475 (58.1) 1,840 (72.4) 1,445 (56.9) 1,190 (46.9), 1,145 (45.1)*1 2,670 (105.1) 1,495 (58.9) 1,485 (58.5)

150 (5.9)

With sunroof

SPC-2

155 (6.1)

LEGACY SPECIFICATIONS

B: ENGINE Model

2.5 L SOHC

2.5 L DOHC turbo

Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine

Engine type Valve arrangement

Overhead camshaft

Bore × stroke

mm (in)

Displacement Compression ratio Ignition order Idle speed at Park or Neutral position Maximum output Maximum torque

3.0 L DOHC Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine

99.5 × 79.0 (3.917 × 3.110)

cm3 (cu in)

2,457 (149.9) 10.0

8.4 1—3—2—4

rpm kW (HP)/rpm N·m (kgf-m, ft-lb)/rpm

650 (MT) 700 (AT) 125 (170)/6,000 230 (23.5, 170)/4,400

89.2 × 80.0 (3.512 × 3.150) 3,000 (183.06) 10.7 1—6—3—2—5—4

750

650

184 (243)/6,000 327 (33.3, 241)/3,600

185 (245)/6,600 291 (29.7, 215)/4,200

2.5 L DOHC turbo MT: 12° AT: 17° NGK: SILFR6A 12 V — 110 A 12V — 48AH (55D23L) 12V — 52AH (75D23L)

3.0 L DOHC

C: ELECTRICAL Model Ignition timing (at idling) Spark plug Generator Battery

BTDC

Type and manufacturer Type and capacity (5HR)

2.5 L SOHC MT: 10° AT: 15° NGK: FR5AP-11

MT AT

SPC-3

15° NGK: ILFR6B

LEGACY SPECIFICATIONS

D: TRANSMISSION 1. MT Model Transmission type Clutch type

Gear ratio

Reduction gear (Front)

Reduction gear (Rear)

Transfer reduction Final reduction

1st 2nd 3rd 4th 5th 6th Rev. Type of gear Gear ratio Type of gear

2.5 L SOHC 5MT DSPD 3.454 2.062 1.448 1.088 0.780 — 3.333 Hypoid 3.900 Helical

5MT DSPD 3.166 1.882 1.296 0.972 0.738 — 3.333 Hypoid 3.900 Helical

2.5 L DOHC turbo 6MT DSPD 3.636 2.235 1.521 1.137 0.891 0.707 3.545 Hypoid 3.900 Helical

Gear ratio Type of gear Gear ratio

1.000 Hypoid 3.900

1.000 Hypoid 3.900

1.100 Hypoid 3.545

5MT: 5-forward speeds with synchromesh and 1-reverse 6MT: 6-forward speeds with synchromesh and 1-reverse DSPD: Dry Single Plate Diaphragm

2. AT Model

2.5 L SOHC

2.5 L DOHC turbo

1st 2nd

4AT TCC 2.785 1.545

5AT TCC 3.540 2.264

3rd 4th 5th 6th Rev. Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio

1.000 0.694 — — 2.272 Helical 1.000 Hypoid 4.111 Hypoid 4.111

1.471 1.000 0.834 — 2.370 Helical 1.000 Hypoid 3.083 Hypoid 3.083

Transmission type Clutch type

Gear ratio

Reduction gear (Front)

1st reduction Final reduction

Reduction gear (Rear)

4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse 5AT: Electronically controlled fully-automatic, 5-forward speeds and 1-reverse TCC: Torque Converter Clutch

SPC-4

3.0 L DOHC 3.0 R 3.0 R LTD 5AT TCC 3.540 2.264 1.471 1.000 0.834 — 2.370 Helical 1.000 Hypoid 3.083

3.272 Hypoid

3.083

3.272

LEGACY SPECIFICATIONS

E: STEERING Model Type Turns, lock to lock Minimum turning diameter

2.5 L DOHC turbo GT spec. B GT Rack and pinion 2.6 2.8 11.6 (38.0) 10.8 (35.4) 12.4 (40.7) 11.6 (35.4)

2.5 L SOHC

Curb to curb m (ft) Wall to wall

3.2 10.8 (35.4) 11.6 (38.1)

3.0 L DOHC 3.0 R LTD 3.0 R 2.6 11.6 (38.0) 12.4 (40.7)

2.8 10.8 (35.4) 11.6 (35.4)

F: SUSPENSION Front Rear

Macpherson strut type suspension Multi-link type suspension

G: BRAKE Model Service brake system Front Rear Parking brake

2.5 L SOHC 2.5 L DOHC turbo 3.0 L DOHC Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Disc brake Ventilated disc brake Mechanical on rear brakes

H: TIRE Model Wheel size

2.5 L SOHC Except CanCanada model ada model 16 × 6 1/2JJ 17 × 7JJ P205/55 R16 89H

Tire size

P205/50 R17 88V

Type

I:

2.5 L DOHC turbo 2.5 GT spec. Except 2.5 GT B spec.B 18 × 7JJ 17 × 7JJ 215/45 R18 215/45 R17 89Y 91W Tubeless, Steel belted radial

3.0 L DOHC 3.0 R

3.0 R LTD

17 × 7JJ 215/45 R17 91W

18 × 7JJ P215/45 R18 89W

CAPACITY 2.5 L SOHC

Model

5MT

4AT

2 (US gal, Imp gal)

Fuel tank Total capacity (Overhaul) Engine oil

2.5 L DOHC turbo

Filling amount of engine oil 2 (US qt, Imp qt)

2 (US qt, Imp qt) When replacing engine oil and oil filter When replacing engine oil only

4.2 (4.4, 3.7)

7.0 (7.4, 6.2) 5.7 (6.0, 5.0)

4.3 (4.5, 3.8)

5.5 (5.8, 4.8)

4.0 (4.2, 3.5)

2 (US qt, Imp qt)

3.5 (3.7, 3.1)

ATF

2 (US qt, Imp qt)

—

Front differential gear oil

2 (US qt, Imp qt)

—

Rear differential gear oil

2 (US qt, Imp qt)

Power steering fluid

2 (US qt, Imp qt) 2 (US qt, Imp qt)

6MT

5.0 (5.3, 4.4)

Transmission gear oil

Engine coolant

5MT 5AT 64 (16.9, 14.1)

— 9.3 (9.8, 8.2) 1.2 (1.3, 1.1)

3.5 (3.7, 3.1)

—

4.1 (4.3, 3.6)

—

—

9.8 (10.4, 8.6)

—

9.8 (10.4, 8.6)

—

1.4 (1.5, 1.2)

—

0.8 (0.8, 0.7)

6.4 (6.8, 5.6)

6.3 (6.7, 5.5)

SPC-5

3.0 L DOHC 5AT

0.7 (0.7, 0.6) 7.3 7.2 (7.7, 6.4) (7.6, 6.3)

1.0 (1.1, 0.9)

1.4 (1.5, 1.2) 0.8 (0.8, 0.7)

7.3 (7.7, 6.4)

7.2 (7.6, 6.3)

LEGACY SPECIFICATIONS

J: WEIGHT 1. US MODEL Sedan 2.5 L Non-turbo Model

2.5 i BASE 5MT

Destination code OP code kg (lb)

Rear

kg (lb)

Total

kg (lb)

Front

kg (lb)

Rear

kg (lb)

Gross vehicle weight (G.V.W.)

Total

kg (lb)

Option

Vehicle dynamics control Power package Side airbag Curtain airbag Sunroof Navigation system Dark colored glass

Gross axle weight ratio (G.A.W.R.)

4AT

5MT U5, U6

DC Front

Curb weight (C.W.)

2.5 i 4AT DW

2.5 i Limited 4AT EW

821 (1,810) 664 (1,465) 1,485 (3,275) 1,040 (2,295) 1,060 (2,340)

841 (1,855) 669 (1,475) 1,510 (3,330) 1,040 (2,295) 1,060 (2,340)

825 (1,819) 673 (1,483) 1,498 (3,302) 1,040 (2,295) 1,060 (2,340)

845 (1,864) 677 (1,493) 1,522 (3,357) 1,040 (2,295) 1,060 (2,340)

854 (1,884) 682 (1,503) 1,536 (3,387) 1,040 (2,295) 1,060 (2,340)

1,960 (4,325)

1,960 (4,325)

1,960 (4,325)

1,960 (4,325)

1,960 (4,325)

—

—

—

—

— — —

— — —

— —

— —

SPC-6

— —

Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING

NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

LEGACY SPECIFICATIONS Sedan 2.5 L Turbo Model

3W

EW

EK

DW

EW

EK

872 (1,922) 683 (1,506) 1,555 (3,428) 1,040 (2,295) 1,060 (2,340)

901 (1,987) 688 (1,516) 1,589 (3,503) 1,040 (2,295) 1,060 (2,340)

903 (1,992) 688 (1,516) 1,591 (3,508) 1,040 (2,295) 1,060 (2,340)

912 (2,012) 694 (1,531) 1,607 (3,543) 1,040 (2,295) 1,060 (2,340)

911 (2,008) 682 (1,503) 1,592 (3,511) 1,040 (2,295) 1,060 (2,340)

926 (2,042) 685 (1,511) 1,611 (3,553) 1,040 (2,295) 1,060 (2,340)

928 (2,047) 685 (1,511) 1,614 (3,558) 1,040 (2,295) 1,060 (2,340)

2,010 (4,435)

2,010 (4,435)

2,010 (4,535)

2,010 (4,435)

2,010 (4,435)

2,010 (4,435)

2,010 (4,535)

— —

—

2.5 GT LTD 5MT

Destination code OP code

Curb weight (C.W.)

Gross axle weight ratio (G.A.W.R.) Gross vehicle weight (G.V.W.)

Option

Front

kg (lb)

Rear

kg (lb)

Total

kg (lb)

Front

kg (lb)

Rear

kg (lb)

Total

kg (lb)

Vehicle dynamics control Power package Side airbag Curtain airbag Sunroof Navigation system Dark colored glass

3.0 L Non-turbo 2.5 GT spec. B 6MT U4 EK

5AT

3.0 R

3.0 R LTD 5AT

— —

— —

— —

—

SPC-7

—

— —

LEGACY SPECIFICATIONS

2. CANADA MODEL Sedan 2.5 L Turbo

2.5 L Non-turbo Model

2.5 GT spec. B 6MT

2.5 i 5MT Destination code OP code Front

kg (lb)

Rear

kg (lb)

Total

kg (lb)

Front

kg (lb)

Rear

kg (lb)

Gross vehicle weight (G.V.W.)

Total

kg (lb)

Option

Vehicle dynamics control Power package Side airbag Curtain airbag Sunroof Navigation system Dark colored glass

Curb weight (C.W.)

Gross axle weight ratio (G.A.W.R.)

4AT

C0 DW

C5 UC

C0 DW

C5 UC

828 (1,826) 678 (1,495) 1,506 (3,321) 1,040 (2,295) 1,060 (2,340)

812 (1,790) 660 (1,455) 1,472 (3,246) 1,040 (2,295) 1,060 (2,340)

848 (1,870) 682 (1,504) 1,530 (3,374) 1,040 (2,295) 1,060 (2,340)

832 (1,835) 664 (1,464) 1,496 (3,299) 1,040 (2,295) 1,060 (2,340)

1,960 (4,325)

1,960 (4,325)

1,960 (4,325)

1,960 (4,325)

—

3.0 L Non-turbo 3.0 R 5AT

EK

C0 EW

EK

913 (2,013) 695 (1,532) 1,608 (3,546) 1,040 (2,295) 1,060 (2,340)

913 (2,013) 684 (1,508) 1,597 (3,521) 1,040 (2,295) 1,060 (2,340)

916 (2,020) 684 (1,508) 1,600 (3,528) 1,040 (2,295) 1,060 (2,340)

2,010 (4,435)

2,010 (4,435)

2,010 (4,435)

—

— —

—

—

—

—

—

—

— —

— — —

— —

— — —

SPC-8

LEGACY SPECIFICATIONS Wagon 2.5 L Non-turbo 2.5 i

Model 5MT Destination code OP code

Curb weight (C.W.)

Gross axle weight ratio (G.A.W.R.) Gross vehicle weight (G.V.W.)

Front

kg (lb)

Rear

kg (lb)

Total

kg (lb)

Front

kg (lb)

Rear

kg (lb)

Total

kg (lb)

Vehicle dynamics control Power package Option

Side airbag Curtain airbag Sunroof Navigation system Dark colored glass

4AT

C0 DW

C5 UC

C0 DW

C5 UC

823 (1,815) 697 (1,537) 1,520 (3,352) 1,040 (2,295) 1,060 (2,340)

806 (1,777) 670 (1,477) 1,476 (3,255) 1,040 (2,295) 1,060 (2,340)

843 (1,859) 697 (1,537) 1,540 (3,396) 1,040 (2,295) 1,060 (2,340)

826 (1,821) 670 (1,477) 1,496 (3,299) 1,040 (2,295) 1,060 (2,340)

1,960 (4,325)

1,960 (4,325)

1,960 (4,325)

1,960 (4,325)

— —

—

— —

— — —

— —

—

— —

— — —

SPC-9

OUTBACK SPECIFICATIONS

2. OUTBACK A: DIMENSION 1. WAGON MODEL Model Overall length Overall width Overall height (at C.W.) Length Compartment Width Height Wheelbase Front Tread Rear Minimum road clearance *1:

2.5 L SOHC mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

3.0 L DOHC

215 (8.5)

2.5 L DOHC turbo 4,800 (189.0) 1,770 (69.7) 1,605 (63.2) 1,840 (72.4) 1,445 (56.9) 1,190 (46.9), 1,145 (45.1)*1 2,670 (105.1) 1,495 (58.9) 1,490 (58.7) 220 (8.7)

2.5 L SOHC

2.5 L DOHC turbo

3.0 L DOHC

215 (8.5)

With sunroof

B: ENGINE Model

Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine

Engine type Valve arrangement Bore × stroke mm (in) Displacement cm3 (cu in) Compression ratio Ignition order Idle speed at Park or Neutral rpm position Maximum kW (HP)/rpm output Maximum N·m (kgf-m, ft-lb)/rpm torque

Overhead camshaft 99.5 × 79.0 (3.917 × 3.110) 2,457 (149.9) 10.0 8.4 1—3—2—4

Horizontally opposed, liquid cooled, 6-cylinder, 4-stroke gasoline engine 89.2 × 80.0 (3.512 × 3.150) 3,000 (183.06) 10.7 1—6—3—2—5—4

650 (MT) 700 (AT)

750

650

125 (170)/6,000

184 (243)/6,000

185 (245)/6,600

230 (23.5, 170)/4,400

327 (33.3, 241)/3,600

291 (29.7, 215)/4,200

2.5 L SOHC MT: 10° AT: 15° NGK: FR5AP-11

2.5 L DOHC turbo MT: 12° AT: 17° NGK: SILFR6A 12 V — 110 A

3.0 L DOHC

C: ELECTRICAL Model Ignition timing (at idling) Spark plug Generator Battery

BTDC

Type and manufacturer Type and capacity (5HR)

MT AT

12V — 48AH (55D23L) 12V — 52AH (75D23L)

SPC-10

15° NGK: ILFR6B