2004 Subaru Outback Service & Repair Manual Software

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🏷️ Basic Information Identification Make: Subaru Model: Outback Year: 2004 Trim Levels Covered: All trims (e.g., Base, Limited, LL Bean Edition) Generation Vehicle Generation: Second Generation (BP/BL Chassis) Generation Years: 2004-2009 Codes Chassis Code: BP (Wagon), BL (Sedan) 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV / Station Wagon with AWD capability Target Audience: Families, outdoor enthusiasts, those prioritizing safety and all-weather capability Competitive Analysis Key Competitors: Toyota RAV4, Honda CR-V, Ford Escape, Mazda CX-5 (though some are later models), Nissan Xterra, Volkswagen Passat Alltrack (conceptually similar) Key Features Differentiating Features: Standard Symmetrical All-Wheel Drive, Boxer engine layout, reputation for reliability and durability, comfortable ride, practical interior space. Manual Value Proposition: Provides access to comprehensive factory-level repair data, enabling significant cost savings on maintenance and repairs compared to dealership service. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, maintenance, repair, and diagnostics Regions Covered: North America (USDM/CDM specifications primarily, with general global applicability) Page Count Estimated Page Count: 2000+ pages (typical for official factory service manuals in digital format) Manual Type Manual Format Type: Official Factory Service Manual (FSM) / Electronic Service Manual (ESM) Language Language: English Format Software Format: Proprietary Software/Database (typically viewable via a dedicated application or web interface within the software) Delivery Method: Digital Download / Online Access 📖 Manual Coverage Systems Covered Engine: 2.5L EJ253 (SOHC), 3.0L EZ30D (DOHC) - Full repair, diagnostics, timing belt replacement, component testing Transmission: 4-speed Automatic (4EAT), 5-speed Manual - Overhaul procedures, diagnostic codes, fluid specifications, component replacement Drivetrain: Symmetrical All-Wheel Drive (AWD) system, differentials (front and rear), viscous coupling unit, axle shafts, CV joints Brakes: ABS, EBD, Front ventilated discs, Rear solid discs - Hydraulic system, caliper and rotor replacement, bleeding procedures, sensor diagnostics Suspension: Front MacPherson struts with lower control arms, Rear multi-link - Component replacement, alignment specifications, shock absorber/strut assembly service Steering: Hydraulic power steering - Pump, rack and pinion, fluid specifications, troubleshooting Electrical System: Battery, charging system, starter motor, ignition system, lighting, fuses, relays, wiring diagrams for all circuits Climate Control: HVAC system, A/C compressor, refrigerant, blower motor, heater core, climate control panel operation and repair Body And Interior: Body panels, doors, windows, glass, seats, trim, headliner, sunroof (if equipped), external/internal lighting Safety Systems: Airbags (SRS), seatbelt pre-tensioners, ABS sensors, Brake Light Switch Diagnostic Trouble Codes: OBD-II diagnostic codes (DTCs) with detailed descriptions and troubleshooting flowcharts Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and changes, tire rotations, brake inspections, spark plug replacement, timing belt service Repair Procedures: Step-by-step guides for component removal, installation, and overhaul (e.g., engine rebuild, transmission repair, brake caliper replacement) Troubleshooting: Systematic diagnostic procedures for identifying and resolving faults and issues Electrical Diagnostics: Wiring diagrams, component testing, signal tracing, multimeter usage, fuse/relay testing Specifications Data: Torque specifications for all fasteners, clearances, fluid capacities, electrical resistance values, etc. Technical Depth Depth Of Coverage: Complete factory-level repair and diagnostic information, suitable for professional technicians and advanced DIYers. Advanced Diagnostics: Includes procedures for using Subaru's Select Monitor (SSM) diagnostic tool or equivalent, and interpreting sensor data. Rebuild Information: Detailed procedures for complete engine and transmission overhauls, including clearances and tolerances. 📊 Manual Specifications File Format Software Requirements: Requires a compatible operating system (e.g., Windows XP/Vista/7) and potentially specific browser plugins or runtime environments. Check software publisher for exact requirements. Print Quality Digital Clarity: High-resolution, clear digital renderings of all text, diagrams, and illustrations. Printable Pages: Typically allows for selective printing of relevant sections or pages, subject to software licensing. Binding Type Digital Interface: Interactive software interface with navigation, search functionality, and bookmarking. Paper Type Digital Medium: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ253 Engine Type 1: 2.5L SOHC 16-valve Flat-4 (Boxer) Horsepower 1: 165 hp @ 5,600 rpm Torque 1: 166 lb-ft @ 4,000 rpm Fuel Delivery 1: Multi-port Fuel Injection (MPI) Compression Ratio 1: 9.7:1 Timing Belt 1: Yes, requires replacement every 105,000 miles or 105 months (critical maintenance item) Secondary Engine Engine Code 2: EZ30D Engine Type 2: 3.0L DOHC 24-valve Flat-6 (Boxer) Horsepower 2: 210 hp @ 6,000 rpm Torque 2: 205 lb-ft @ 4,000 rpm Fuel Delivery 2: Multi-port Fuel Injection (MPI) Compression Ratio 2: 10.7:1 Timing Belt 2: No, uses a timing chain (lower maintenance requirement) Fuel System Fuel Type: Unleaded gasoline, 87 octane (minimum recommended) Fuel Tank Capacity: 15.9 US gallons 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission Optional Optional Transmission: 4-speed Automatic Transmission with Electronic Control (4EAT) - Standard on 3.0R, optional on 2.5X Features AWD System: Symmetrical All-Wheel Drive (Active Torque Split AWD on manual, Variable Valve Control AWD on automatic) Automatic Transmission Modes: Sportshift (driver-selectable gear changes on some models) 📐 Dimensions Exterior Length: 187.8 inches Width: 70.1 inches Height: 61.6 inches Wheelbase: 104.0 inches Ground Clearance: 8.1 inches Interior Passenger Volume: 101.3 cu ft Cargo Cargo...

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Sku: 332430

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Tags: 2004 Car Cars Misc Outback Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Outback

Year:

Trim Levels Covered:

All trims (e.g., Base, Limited, LL Bean Edition)

Generation

Vehicle Generation:

Second Generation (BP/BL Chassis)

Generation Years:

2004-2009

Codes

Chassis Code:

BP (Wagon), BL (Sedan)

👋 Introduction

Market Position

Vehicle Segment:

Compact Crossover SUV / Station Wagon with AWD capability

Target Audience:

Families, outdoor enthusiasts, those prioritizing safety and all-weather capability

Competitive Analysis

Key Competitors:

Toyota RAV4, Honda CR-V, Ford Escape, Mazda CX-5 (though some are later models), Nissan Xterra, Volkswagen Passat Alltrack (conceptually similar)

Key Features

Differentiating Features:

Standard Symmetrical All-Wheel Drive, Boxer engine layout, reputation for reliability and durability, comfortable ride, practical interior space.

Manual Value Proposition:

Provides access to comprehensive factory-level repair data, enabling significant cost savings on maintenance and repairs compared to dealership service.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service, maintenance, repair, and diagnostics

Regions Covered:

North America (USDM/CDM specifications primarily, with general global applicability)

Page Count

Estimated Page Count:

2000+ pages (typical for official factory service manuals in digital format)

Manual Type

Manual Format Type:

Official Factory Service Manual (FSM) / Electronic Service Manual (ESM)

Language

Language:

English

Format

Software Format:

Proprietary Software/Database (typically viewable via a dedicated application or web interface within the software)

Delivery Method:

Digital Download / Online Access

📖 Manual Coverage

Systems Covered

Engine:

2.5L EJ253 (SOHC), 3.0L EZ30D (DOHC) - Full repair, diagnostics, timing belt replacement, component testing

Transmission:

4-speed Automatic (4EAT), 5-speed Manual - Overhaul procedures, diagnostic codes, fluid specifications, component replacement

Drivetrain:

Symmetrical All-Wheel Drive (AWD) system, differentials (front and rear), viscous coupling unit, axle shafts, CV joints

Brakes:

ABS, EBD, Front ventilated discs, Rear solid discs - Hydraulic system, caliper and rotor replacement, bleeding procedures, sensor diagnostics

Suspension:

Front MacPherson struts with lower control arms, Rear multi-link - Component replacement, alignment specifications, shock absorber/strut assembly service

Steering:

Hydraulic power steering - Pump, rack and pinion, fluid specifications, troubleshooting

Electrical System:

Battery, charging system, starter motor, ignition system, lighting, fuses, relays, wiring diagrams for all circuits

Climate Control:

HVAC system, A/C compressor, refrigerant, blower motor, heater core, climate control panel operation and repair

Body And Interior:

Body panels, doors, windows, glass, seats, trim, headliner, sunroof (if equipped), external/internal lighting

Safety Systems:

Airbags (SRS), seatbelt pre-tensioners, ABS sensors, Brake Light Switch

Diagnostic Trouble Codes:

OBD-II diagnostic codes (DTCs) with detailed descriptions and troubleshooting flowcharts

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and changes, tire rotations, brake inspections, spark plug replacement, timing belt service

Repair Procedures:

Step-by-step guides for component removal, installation, and overhaul (e.g., engine rebuild, transmission repair, brake caliper replacement)

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving faults and issues

Electrical Diagnostics:

Wiring diagrams, component testing, signal tracing, multimeter usage, fuse/relay testing

Specifications Data:

Torque specifications for all fasteners, clearances, fluid capacities, electrical resistance values, etc.

Technical Depth

Depth Of Coverage:

Complete factory-level repair and diagnostic information, suitable for professional technicians and advanced DIYers.

Advanced Diagnostics:

Includes procedures for using Subaru's Select Monitor (SSM) diagnostic tool or equivalent, and interpreting sensor data.

Rebuild Information:

Detailed procedures for complete engine and transmission overhauls, including clearances and tolerances.

📊 Manual Specifications

File Format

Software Requirements:

Requires a compatible operating system (e.g., Windows XP/Vista/7) and potentially specific browser plugins or runtime environments. Check software publisher for exact requirements.

Print Quality

Digital Clarity:

High-resolution, clear digital renderings of all text, diagrams, and illustrations.

Printable Pages:

Typically allows for selective printing of relevant sections or pages, subject to software licensing.

Binding Type

Digital Interface:

Interactive software interface with navigation, search functionality, and bookmarking.

Paper Type

Digital Medium:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ253

Engine Type 1:

2.5L SOHC 16-valve Flat-4 (Boxer)

Horsepower 1:

165 hp @ 5,600 rpm

Torque 1:

166 lb-ft @ 4,000 rpm

Fuel Delivery 1:

Multi-port Fuel Injection (MPI)

Compression Ratio 1:

9.7:1

Timing Belt 1:

Yes, requires replacement every 105,000 miles or 105 months (critical maintenance item)

Secondary Engine

Engine Code 2:

EZ30D

Engine Type 2:

3.0L DOHC 24-valve Flat-6 (Boxer)

Horsepower 2:

210 hp @ 6,000 rpm

Torque 2:

205 lb-ft @ 4,000 rpm

Fuel Delivery 2:

Multi-port Fuel Injection (MPI)

Compression Ratio 2:

10.7:1

Timing Belt 2:

No, uses a timing chain (lower maintenance requirement)

Fuel System

Fuel Type:

Unleaded gasoline, 87 octane (minimum recommended)

Fuel Tank Capacity:

15.9 US gallons

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Transmission

Optional

Optional Transmission:

4-speed Automatic Transmission with Electronic Control (4EAT) - Standard on 3.0R, optional on 2.5X

Features

AWD System:

Symmetrical All-Wheel Drive (Active Torque Split AWD on manual, Variable Valve Control AWD on automatic)

Automatic Transmission Modes:

Sportshift (driver-selectable gear changes on some models)

📐 Dimensions

Exterior

Length:

187.8 inches

Width:

70.1 inches

Height:

61.6 inches

Wheelbase:

104.0 inches

Ground Clearance:

8.1 inches

Interior

Passenger Volume:

101.3 cu ft

Cargo

Cargo Volume Behind Rear Seats:

31.7 cu ft

Cargo Volume With Rear Seats Folded:

67.4 cu ft

Weights

Curb Weight Min 2.5X:

3,340 lbs

Curb Weight Min 3.0R:

3,565 lbs

Towing Capacity:

2,000 lbs (when properly equipped)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Rating:

★★★★★ (5/5 stars)

NHTSA Side Impact Crash Test Rating:

★★★★★ (5/5 stars)

IIHS Front Offset Crash Test:

IIHS Side Impact Crash Test:

Active Features

Standard Anti-lock Braking System

Standard Electronic Brake-force Distribution

Traction Control:

Available Traction Control System (TCS)

Stability Control:

Available Vehicle Stability Control (VDC)

Passive Features

Airbags:

Front dual-stage airbags, front side-impact airbags, available side curtain airbags (front and rear)

Seatbelts:

3-point height-adjustable front seatbelts with pretensioners, rear 3-point seatbelts

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player. Optional premium audio systems with more speakers and amplifier may be present on higher trims.

Navigation:

Optional factory-installed GPS navigation system available on Limited trims.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Keyless Entry:

Available keyless entry system.

Power Accessories:

Power windows, power door locks, power mirrors are standard on most trims.

Connectivity

Auxiliary Input:

Not typically standard; may have been an aftermarket addition or available on specific late-production models.

Bluetooth:

Not available from the factory for the 2004 model year.

🔧 Maintenance

Service Intervals

Engine Oil And Filter Change:

Every 3,750 miles or 3.75 months (severe duty) / 7,500 miles or 7.5 months (normal duty)

Timing Belt Replacement Ej253:

Every 105,000 miles or 105 months

Engine Coolant Replacement:

Initial: 30,000 miles or 30 months. Subsequent: 15,000 miles or 15 months.

Automatic Transmission Fluid Change:

Every 30,000 miles or 30 months (severe duty recommended, especially for towing)

Manual Transmission Fluid Change:

Every 30,000 miles or 30 months

Brake Fluid Replacement:

Every 30,000 miles or 30 months

Differential Fluid Change:

Every 30,000 miles or 30 months

Fluid Specifications

Engine Oil Type 2.5L:

SAE 5W-30, API SG or higher (preferred: Synthetic)

Engine Oil Type 3.0L:

SAE 5W-30, API SG or higher (preferred: Synthetic)

Engine Coolant Type:

Subaru Super Coolant (Blue) or equivalent silicate-free, ethylene glycol-based antifreeze

Automatic Transmission Fluid Type:

Subaru ATF-HP (High Performance)

Manual Transmission Fluid Type:

SAE 75W-90 GL-5 gear oil

Front Differential Fluid Type:

SAE 75W-90 GL-5 gear oil

Rear Differential Fluid Type:

SAE 75W-90 GL-5 gear oil

Power Steering Fluid Type:

Subaru Vehicle Power Steering Fluid or Dexron III ATF

Known Issues

Head Gaskets Ej25:

While less prevalent than on some earlier EJ engines, internal coolant leaks from head gaskets can occur. The 2004 model is generally more robust than earlier generations.

Catalytic Converter Failure:

Premature failure due to internal breakdown can occur, often indicated by a check engine light and reduced engine performance.

Susceptibility To Rust:

Rust can form on the undercarriage, brake lines, and rocker panels, especially in areas with road salt. Regular inspection and rustproofing are advised.

Automatic Transmission Issues:

The 4EAT can sometimes exhibit rough shifting or hesitation. Proper fluid maintenance is crucial.

Wheel Bearing Wear:

Wheel bearings can wear out over time, producing humming or grinding noises. Replacement is a common repair.

📚 Vehicle History

Brand Heritage

Subaru Origins:

Founded in 1953, Subaru (a division of Fuji Heavy Industries) is known for its automotive engineering, particularly its use of the boxer engine and Symmetrical All-Wheel Drive.

Model Evolution

Outback Genesis:

The Outback originated as a trim level for the Subaru Legacy station wagon in 1995, featuring increased ground clearance and ruggedized styling. It became its own model line in 1996.

Second Gen Introduction:

The second generation (BP/BL) Outback debuted for the 2005 model year, but the 2004 model year represents the final year of the first generation (BG/BH chassis).

2004 Model Year Notes:

The 2004 model year is part of the first generation's facelift. It saw minor updates, including revised front styling and interior features.

Production

Assembly Location:

Gunma Seisakusho, Japan

Production Years For Bh Chassis:

1999-2004

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

The 2004 Outback received 'Good' ratings from IIHS in front and side impact tests, contributing to its strong safety reputation.

Consumer Reports Ratings:

Consistently rated well by Consumer Reports for reliability and owner satisfaction during its production run, though specific model year ratings vary.

Certifications

Emissions Standards:

Meets EPA and California Air Resources Board (CARB) emissions standards for its model year.