brake SUBARU OUTBACK 2009 5.G Repair Manual

10-2Appearance care
Exterior care &Washing
CAUTION
. When washing the vehicle, the
brakes may get wet. As a result,
the brake stopping distance will
be longer. To dry the brakes,
drive the vehicle at a safe speed
while lightly pressing the brake
pedal to heat up the brakes.
. Do not wash the engine compart-
ment and areas adjacent to it. If
water enters the engine air in-
take, electrical parts or the power
steering fluid reservoir, it will
cause engine trouble or faulty
power steering respectively. .
Since your vehicle is equipped
with a rear wiper, automatic car-
wash brushes could become
tangled around it, damaging the
wiper arm and other compo-
nents. Ask the automatic car-
wash operator not to let the
brushes touch the wiper arm or
to fix the wiper arm on the rear
window glass with adhesive tape
before operating the machine.
(Station wagon models only)
NOTE
When having your vehicle washed in
an automatic car wash, make sure
beforehand that the car wash is of
suitable type.
The best way to preserve your vehicle ’s
beauty is frequent washing. Wash the
vehicle at least once a month to avoid
contamination by road grime.
Wash dirt off with a wet sponge and plenty
of lukewarm or cold water. Do not wash
the vehicle with hot water and in directsunlight.
Salt, chemicals, insects, tar, soot, tree
sap, and bird droppings should be washed
off by using a light detergent, as required.
If you use a light detergent, make certain that it is a neutral detergent. Do not use
strong soap or chemical detergents. All
cleaning agents should be promptly
flushed from the surface and not allowed
to dry there. Rinse the vehicle thoroughly
with plenty of lukewarm water. Wipe the
remaining water off with a chamois or softcloth. !
Washing the underbody
Chemicals, salts and gravel used for
deicing road surfaces are extremely cor-
rosive, accelerating the corrosion of un-
derbody components, such as the exhaust
system, fuel and brake lines, brake
cables, floor pan and fenders, and sus-pension.
Thoroughly flush the underbody and in-
side of the fenders with lukewarm or cold
water at frequent intervals to reduce the
harmful effects of such agents.
Mud and sand adhering to the underbody
components may accelerate their corro-sion.
After driving off-road or muddy or sandy
roads, wash the mud and sand off the
underbody.
Carefully flush the suspension and axle
parts, as they are particularly prone to
mud and sand buildup. Do not use a
sharp-edged tool to remove caked mud.

NOTE
Be careful not to damage brake hoses,
sensor harnesses, and other parts
when washing suspension compo-nents. !Using a warm water washer
. Keep a good distance of 12 in (30 cm)
or more between the washer nozzle and
the vehicle. . Do not wash the same area continu-
ously.. If a stain will not come out easily, wash
by hand. Some warm water washers are
of the high temperature, high pressure
type, and they can damage or deform the
resin parts such as mouldings, or cause
water to leak into the vehicle. & Waxing and polishing
Always wash and dry the vehicle before
waxing and polishing.
Use a good quality polish and wax and
apply them according to the manufac-turer ’s instructions. Wax or polish when
the painted surface is cool.
Be sure to polish and wax the chrome trim,
as well as the painted surfaces. Loss of
wax on a painted surface leads to loss of
the original luster and also quickens the
deterioration of the surface. It is recom- mended that a coat of wax be applied at
least once a month, or whenever the
surface no longer repels water.
If the appearance of the paint has dimin-
ished to the point where the luster or tone
cannot be restored, lightly polish the
surface with a fine-grained compound.
Never polish just the affected area, but
include the surrounding area as well.
Always polish in only one direction. A
No. 2000 grain compound is recom-
mended. Never use a coarse-grained
compound. Coarser grained compounds
have a smaller grain-size number and
could damage the paint. After polishing
with a compound, coat with wax to restore
the original luster. Frequent polishing with
acompoundoranincorrectpolishing
technique will result in removing the paint
layer and exposing the undercoat. When
in doubt, it is always best to contact your
SUBARU dealer or an auto paint specia-list.
NOTE
Be careful not to block the windshield
washer nozzles with wax when waxing
the vehicle. &
Cleaning aluminum wheels
. Promptly wipe the aluminum wheels
clean of any kind of grime or agent. If dirt
is left on too long, it may be difficult to
clean off. . Do not use soap containing grit to
clean the wheels. Be sure to use a neutral
cleaning agent, and later rinse thoroughly
with water. Do not clean the wheels with a
stiff brush or expose them to a high-speed
washing device. . Clean the vehicle (including the alumi-
num wheels) with water as soon as
possible when it has been splashed with
sea water, exposed to sea breezes, or
driven on roads treated with salt or otheragents. Appearance care
10-3

10-4Appearance care
Corrosion protection
Your SUBARU has been designed and
built to resist corrosion. Special materials
and protective finishes have been used on
most parts of the vehicle to help maintain
fine appearance, strength, and reliableoperation. &Most common causes of corrosion
The most common causes of corrosion are:
1. The accumulation of moisture retain-
ing dirt and debris in body panel sections,
cavities, and other areas.
2. Damage to paint and other protective
coatings caused by gravel and stone
chips or minor accidents.
Corrosion is accelerated on the vehicle when:
1. It is exposed to road salt or dust
control chemicals, or used in coastal
areas where there is more salt in the air,
or in areas where there is considerable
industrial pollution.
2. It is driven in areas of high humidity,
especially when temperatures range just
above freezing.
3. Dampness in certain parts of the
vehicle remains for a long time, even though other parts of the vehicle may be
dry.
4. High temperatures will cause corro-
sion to parts of the vehicle which cannot
dry quickly due to lack of proper ventila-tion.
& To help prevent corrosion
Wash the vehicle regularly to prevent
corrosion of the body and suspension
components. Also, wash the vehicle
promptly after driving on any of the
following surfaces: . roads that have been salted to prevent
them from freezing in winter. mud, sand, or gravel
. coastal roads
After the winter has ended, it is recom-
mended that the underbody be given a
very thorough washing.
Before the beginning of winter, check the
condition of underbody components, such
as the exhaust system, fuel and brake
lines, brake cables, suspension, steering
system, floor pan, and fenders. If any of
them are found to be rusted, they should
be given an appropriate rust prevention
treatment or should be replaced. Contact
your SUBARU dealer to perform this kind
of maintenance and treatment if you need assistance.
Repair chips and scratches in the paint as
soon as you find them.
Check the interior of the vehicle for water
and dirt accumulation under the floor mats
because that could cause corrosion.
Occasionally check under the mats to
make sure the area is dry.
Keep your garage dry. Do not park your
vehicle in a damp, poorly ventilated
garage. In such a garage, corrosion can
be caused by dampness. If you wash the
vehicle in the garage or put the vehicle
into the garage when wet or covered with
snow, that can cause dampness.
If your vehicle is operated in cold weather
and/or in areas where road salts and other
corrosive materials are used, the door
hinges and locks, trunk lid lock, and hood
latch should be inspected and lubricated
periodically.

Maintenance schedule....................................... 11-3
Maintenance precautions ................................... 11-3
Before checking or servicing in the engine compartment .................................................... 11-4
When you do checking or servicing in the engine compartment while the engine is running .......... 11-4
Engine hood ....................................................... 11-4
Engine compartment overview .......................... 11-6
2.5 L non-turbo models ...................................... 11-6
2.5 L turbo models ............................................. 11-7
3.0 L models ...................................................... 11-8
Engine oil ............................................................ 11-9
Checking the oil level ......................................... 11-9
Changing the oil and oil filter ............................ 11-10
Recommended grade and viscosity .................. 11-12
Recommended grade and viscosity under severe driving conditions .......................................... 11-13
Cooling system ................................................ 11-14
Cooling fan, hose and connections ................... 11-14
Engine coolant ................................................. 11-14
Air cleaner element .......................................... 11-17
Replacing the air cleaner element ..................... 11-18
Spark plugs ...................................................... 11-20
Recommended spark plugs .............................. 11-20
Drive belts ........................................................ 11-20
2.5 L models .................................................... 11-20
3.0 L models .................................................... 11-21
Manual transmission oil .................................. 11-21
Checking the oil level ....................................... 11-21
Recommended grade and viscosity .................. 11-22Automatic transmission fluid
.......................... 11-22
Checking the fluid level .................................... 11-22
Recommended fluid ......................................... 11-23
Front differential gear oil (AT models) ........... 11-24
Checking the oil level ...................................... 11-24
Recommended grade and viscosity .................. 11-25
Rear differential gear oil .................................. 11-25
Checking the gear oil level ............................... 11-25
Recommended grade and viscosity .................. 11-27
Power steering fluid ........................................ 11-27
Checking the fluid level .................................... 11-27
Recommended fluid ......................................... 11-28
Brake fluid ........................................................ 11-28
Checking the fluid level .................................... 11-28
Recommended brake fluid ............................... 11-29
Clutch fluid (MT models) ................................. 11-29
Checking the fluid level .................................... 11-29
Recommended clutch fluid ............................... 11-30
Brake booster .................................................. 11-30
Brake pedal ...................................................... 11-31
Checking the brake pedal free play .................. 11-31
Checking the brake pedal reserve distance....... 11-31
Clutch pedal (MT models) ............................... 11-31
Checking the clutch function ............................ 11-31
Checking the clutch pedal free play .................. 11-32
Replacement of brake pad and lining ............ 11-32
Breaking-in of new brake pads and linings ....... 11-32
Parking brake stroke ....................................... 11-33
Tires and wheels .............................................. 11-33
Types of tires ................................................... 11-33
Maintenance and service
11

11-4Maintenance and service
guard against getting oil or fluids
in your eyes. If something does
get in your eyes, thoroughly
wash them out with clean water.
. Do not tamper with the wiring of
the SRS airbag system or seat-
belt pretensioner system, or at-
tempt to take its connectors
apart, as that may activate the
system or it can render it inop-
erative. NEVER use a circuit
tester for these wiring. If your
SRS airbag or seatbelt preten-
sioner needs service, consult
your nearest SUBARU dealer.
& Before checking or servicing
in the engine compartment
WARNING
. Always stop the engine and set
the parking brake firmly to pre-
vent the vehicle from moving.
. Always let the engine cool down.
Engine parts become very hot
when the engine is running and
remain hot for some time after
the engine is stopped.
. Do not spill engine oil, engine
coolant, brake fluid or any other fluid on hot engine components.
This may cause a fire.
. Always remove the key from the
ignition switch. When the ignition
switch is in the “ON ”position,
thecoolingfanmayoperate
suddenly even when the engine
is stopped.
& When you do checking or
servicing in the engine com-
partment while the engine is running
WARNING
A running engine can be dangerous.
Keep your fingers, hands, clothing,
hair and tools away from the cooling
fan, belts and any other moving
engine parts. Removing rings,
watches and ties is advisable. Engine hood
To open the hood:
1. If the wiper blades are lifted off the
windshield, return them to their originalpositions.
2. Pull the hood release knob under the
instrument panel.

11-6Maintenance and service
Engine compartment overview &2.5 L non-turbo models1) Power steering fluid reservoir
(page 11-27)
2) Manual transmission oil level gauge (MT) (page 11-21) or Differential gear oil level
gauge (AT) (page 11-24)
3) Clutch fluid reservoir (page 11-29)
4) Automatic transmission fluid level gauge (page 11-22)
5) Brake fluid reservoir (page 11-28)
6) Fuse box (page 11-47)
7) Battery (page 11-46)
8) Windshield washer tank (page 11-41)
9) Engine oil filler cap (page 11-9)
10) Engine coolant reservoir (page 11-14)
11) Radiator cap (page 11-14)
12) Engine oil level gauge (page 11-9)
13) Air cleaner element (page 11-17)

&2.5 L turbo models1) Power steering fluid reservoir
(page 11-27)
2) Manual transmission oil level gauge (MT) (page 11-21) or Differential gear oil level
gauge (AT) (page 11-24)
3) Clutch fluid reservoir (page 11-29)
4) Brake fluid reservoir (page 11-28)
5) Automatic transmission fluid level gauge (page 11-22)
6) Fuse box (page 11-47)
7) Battery (page 11-46)
8) Windshield washer tank (page 11-41)
9) Engine oil filler cap (page 11-9)
10) Engine coolant reservoir (page 11-14)
11) Engine oil level gauge (page 11-9)
12) Radiator cap (page 11-14)
13) Air cleaner element (page 11-17) Maintenance and service
11-7
– CONTINUED –

11-8Maintenance and service
& 3.0 L models
1) Power steering fluid reservoir
(page 11-27)
2) Differential gear oil level gauge (AT) (page 11-24)
3) Automatic transmission fluid level gauge (page 11-22)
4) Brake fluid reservoir (page 11-28)
5) Fuse box (page 11-47)
6) Battery (page 11-46)
7) Windshield washer tank (page 11-41)
8) Engine oil filler cap (page 11-9)
9) Engine coolant reservoir (page 11-14)
10) Radiator cap (page 11-14)
11) Engine oil level gauge (page 11-9)
12) Air cleaner element (page 11-17)

11-22Maintenance and service
and insert it again.
1) Upper level
2) Lower level
3. Pull out the level gauge again and
check the oil level on it. If it is below the
lower level, add oil through the level
gauge hole to bring the level up to the
upper level.
CAUTION
Be careful not to spill manual trans-
mission oil when adding it. If oil
touches the exhaust pipe, it may
cause a bad smell, smoke, and/or a
fire. If oil gets on the exhaust pipe,
be sure to wipe it off. &
Recommended grade and viscosity
Each oil manufacturer has its own base
oils and additives. Never use different
brands together.
Oil grade: API classification GL-5SAE viscosity No. and applicable tempera- ture Automatic transmission fluid &
Checking the fluid level
The automatic transmission fluid expands
largely as its temperature rises; the fluid
level differs according to fluid temperature.
Therefore, there are two different scales
for checking the level of hot fluid and cold
fluid on the level gauge.
Though the fluid level can be checked
without warming up the fluid on the“ COLD ”range, we recommend checking
the fluid level when the fluid is at operatingtemperature. ! Checking the fluid level when the
fluid is hot
Check the fluid level monthly.
1. Drive the vehicle several miles to raise
the temperature of the transmission fluid
up to normal operating temperature; 158
to 176 8F (70 to 80 8C) is normal.
2. Park the vehicle on a level surface and
set the parking brake.
3. First shift the selector lever in each
position. Then shift it in the “P ” position,
and run the engine at idling speed.

11-28Maintenance and service
.Be careful not to spill power
steering fluid when adding it. If
power steering fluid touches the
exhaust pipe, it may cause a bad
smell, smoke, and/or a fire. If
power steering fluid gets on the
exhaust pipe, be sure to wipe itoff.
The power steering fluid expands greatly
as its temperature rises; the fluid level
differs according to fluid temperature.
Therefore, the reservoir tank has two
different checking ranges for hot and coldfluids.
Check the power steering fluid level
monthly.
1. Park the vehicle on a level surface,
and stop the engine.
2. Check the fluid level of the reservoir tank.
When the fluid is hot after the vehicle has
been run: Check that the oil level isbetween “HOT MIN ”and “HOT MAX ”on
the surface of the reservoir tank.
When the fluid is cool before the vehicle is
run: Check that the oil level is between“ COLD MIN ”and “COLD MAX ”on the
surface of the reservoir tank.
3. If the fluid level is lower than the
applicable “MIN ”line, add the recom- mended fluid as necessary to bring the
level between the
“MIN ”and “MAX ”line.
If the fluid level is extreme low, it may
indicate possible leakage. Consult your
SUBARU dealer for inspection.
& Recommended fluid
Use one of the following types of auto-
matic transmission fluid. –SUBARU ATF Type-HP
– IDEMITSU ATF HP Brake fluid &
Checking the fluid level
WARNING
. Never let brake fluid contact your
eyes because brake fluid can be
harmful to your eyes. If brake
fluid gets in your eyes, immedi-
ately flush them thoroughly with
clean water. For safety, when
performing this work, wearing
eye protection is advisable.
. Brake fluid absorbs moisture
from the air. Any absorbed moist-
ure can cause a dangerous loss
of braking performance.
. If the vehicle requires frequent
refilling, there may be a leak. If
you suspect a problem, have the
vehicle checked at your SUBARU
dealer.
CAUTION
. Never use different brands of
brake fluid together. Also, avoid
mixing DOT 3 and DOT 4 brake
fluids even if they are of the samebrand.