2004 Subaru Outback Service and Repair Manual

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Factory-Grade Data

2004 Subaru Outback service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • Limited Wagon 4-Door
  • L.L. Bean Wagon 4-Door
  • H6 Wagon 4-Door
  • H6 VDC Sedan 4-Door
  • H6 VDC Wagon 4-Door
  • H6 Sedan 4-Door
  • Limited Sedan 4-Door
  • Base Wagon 4-Door
  • H6 35th Anniversary Edition Wagon 4-Door

Engines covered

  • 2.5L 2458CC H4 GAS SOHC Naturally Aspirated
  • 3.0L 3000CC H6 GAS DOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2004 Subaru Outback Recalls & Complaints

NHTSA #13E06500029/11/2013Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

Airtex Products LP (Airtex) is recalling certain model E8598M, E8518M, E8600M, E8596M, and E8597M fuel pumps manufactured July 26, 2013, and July 29, 2013 and used as aftermarket replacements on Subar

Consequence

A fuel leak in the presence of an ignition source increases the risk of a fire.

Remedy

Airtex will notify owners, and will replace the fuel pump, free of charge. Recall is expected to be

NHTSA #16V35900025/05/2016Component: AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Subaru of America, Inc. (Subaru) is recalling certain model year 2003-2004 Legacy, Outback, 2006-2008 Impreza, Tribeca, 2006 Saab 9-2x, and 2003-2006 Baja vehicles originally sold or that have ever be

Consequence

An inflator rupture may result in metal fragments striking the vehicle occupants resulting in seriou

Remedy

Subaru will notify their owners. General Motors will notify Saab owners. Dealers will replace the

NHTSA #16V35800025/05/2016Component: AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Subaru of America, Inc. (Subaru) is recalling certain model year 2003-2004 Legacy, Outback, 2009-2011 Legacy, Outback, Forester, 2006-2011 Impreza, Tribeca, 2003-2006 Baja, and 2006 Saab 9-2x vehicles

Consequence

An inflator rupture may result in metal fragments striking the vehicle occupants resulting in seriou

Remedy

Subaru will notify their owners. General Motors will notify Saab owners. Dealers will replace the

NHTSA #16V36100025/05/2016Component: AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Subaru of America, Inc. (Subaru) is recalling certain model year 2003-2004 Legacy, Outback, and Baja vehicles originally sold or that have ever been registered in Alaska, Colorado, Connecticut, Idaho,

Consequence

An inflator rupture may result in metal fragments striking the vehicle occupants resulting in seriou

Remedy

Subaru will notify owners, and dealers will replace the passenger frontal air bag inflator, free of

NHTSA #03V30300020/08/2003Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

CERTAIN PASSENGER OR SPORT UTILITY VEHICLES MAY HAVE A LOOSE OR OUT OF POSITION FUEL FILLER HOSE CLAMP.

Consequence

THIS COULD RESULT IN FUEL LEAKAGE. FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT

Remedy

DEALERS WILL INSPECT AND TIGHTEN THE CLAMP ON THE FUEL FILLER HOSE. OWNER NOTIFICATION BEGAN AUGUST

NHTSA #04V12800016/03/2004Component: VEHICLE SPEED CONTROL:CABLES

ON CERTAIN PASSENGER SEDANS, WAGONS, AND SPORT UTILITY VEHICLES, THE CRUISE CONTROL CABLE COULD COME OUT OF ITS TRACK ON THE CRUISE CONTROL LEVER AND LODGE ON THE CONTROL LEVER TAB WHEN THE ACCELERATO

Consequence

IF THIS OCCURS DURING VEHICLE OPERATION, THE DRIVER COULD LOSE CONTROL OF THE VEHICLE, WHICH COULD R

Remedy

DEALERS WILL INSTALL A CRUISE CONTROL CABLE RETAINING CLIP TO THE CRUISE CONTROL LEVER TAB ON THE TH

NHTSA #20V00200002/01/2020Component: AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Subaru of America, Inc. (Subaru) is recalling certain 2009-2013 Forester, 2003-2006 Baja, 2004-2011 Impreza, 2004-2014 WRX (including STI), 2003-2014 Legacy and Outback, and 2006 Saab 9-2X vehicles or

Consequence

An inflator explosion may result in sharp metal fragments striking the driver or other occupants res

Remedy

Subaru will notify their owners. General Motors will notify Saab owners. Dealers will replace the

NHTSA #20V00100002/01/2020Component: AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Subaru of America, Inc. (Subaru) is recalling certain 2009-2013 Forester, 2003-2006 Baja, 2004-2011 Impreza, 2004-2014 WRX (STI included), 2003-2014 Legacy and Outback, and 2005-2006 Saab 9-2X vehicle

Consequence

An inflator explosion may result in sharp metal fragments striking the driver or other occupants res

Remedy

Subaru will notify their owners. General Motors will notify Saab owners. Dealers will replace the

NHTSA #20V00300002/01/2020Component: AIR BAGS:FRONTAL:PASSENGER SIDE:INFLATOR MODULE

Subaru of America, Inc. (Subaru) is recalling certain 2009-2013 Forester, 2003-2006 Baja, 2004-2011 Impreza, 2004-2014 WRX (including STI), 2003-2014 Legacy and Outback, and 2005-2006 Saab 9-2X vehicl

Consequence

An inflator explosion may result in sharp metal fragments striking the driver or other occupants res

Remedy

Subaru will notify their owners. General Motors will notify Saab owners. Dealers will replace the

TSB #11032040

This bulletin announces the service manual correction regarding clutch master cylinder reservoir service procedures.

TSB #11032039

This bulletin contains additional information for recommended materials listed in the Service Manuals for individual models.

TSB #11032035

This Bulletin provides the diagnostic procedures to be followed when addressing customer concerns of steering wheel/vehicle body vibration when driving at highway speeds when tire/wheel balance is suspected.

TSB #11032034

This Service Information Bulletin was developed to provide interim guidance for vehicles exhibiting DTC B2A20.

TSB #11030567

This bulletin contains information to help when attempting to complete the STARLINK Telematics subscription process, an Error Code 202 and / or 204 may occur preventing the process from completing successfully

TSB #11030561

This announcement provides information on the use of aftermarket services or tools for programming immobilizer keys/fobs.

TSB #11030560

This bulletin announces the new procedure and Warranty Fail Code for FirstTime air conditioning (A/C) performance concerns possibly resulting from an undetected A/C refrigerant leak.

TSB #11030557

This bulletin contains additional information for recommended materials listed in the Service Manuals for individual models.

Showing the 8 most recent of 182 technical service bulletins on file with NHTSA.

20110609Component: VEHICLE SPEED CONTROLCrash reported1 injured

TL*THE CONTACT OWNS A 2004 SUBARU OUTBACK. THE CONTACT STATED WHILE DRIVING INTO A PARKING SPACE THE VEHICLE SUDDENLY ACCELERATED FORWARD WHILE THE CONTACT APPLIED THE BRAKES AND CRASHED INTO A BUILD

20060710Component: AIR BAGSCrash reported1 injured

2002 L.L. BEAN OUTBACK ACCELERATED UNCONTROLLABLY, MAKING THE VEHICLE VIBRATE. VEHICLE WENT UP OVER PARKING BARRIERS AND SHRUBBERY AND ROLLED OVER. *KB THE AIR BAGS DID NOT DEPLOY DURING THE ACCIDENT

20060710Component: VEHICLE SPEED CONTROLCrash reported1 injured

2002 L.L. BEAN OUTBACK ACCELERATED UNCONTROLLABLY, MAKING THE VEHICLE VIBRATE. VEHICLE WENT UP OVER PARKING BARRIERS AND SHRUBBERY AND ROLLED OVER. *KB THE AIR BAGS DID NOT DEPLOY DURING THE ACCIDENT

20060509Component: POWER TRAIN:AUTOMATIC TRANSMISSIONCrash reported1 injured

DT*: THE CONTACT STATED WHILE THE VEHICLE WAS PARKED WITH THE ENGINE STILL ON, THE TRANSMISSION SLIPPED OUT OF GEAR. THE VEHICLE ROLLED FORWARD AND STRUCK A TREE. BECAUSE THE SEAT BELTS WERE NOT WOR

20031203Component: AIR BAGS:SIDE/WINDOWCrash reported1 injured

MY 2004 SUBARU OUTBACK COMES EQUIPPED WITH FRONT SIDE AIRBAGS. WITH ONLY 900 MILES ON MY CAR, I WAS "T-BONED" BY A FORD EXPLORER UNDER FULL ACCELERATION. WE WERE STRUCK ON THE DRIVERS SIDE WITH ENO

Showing the 5 most serious of 108 complaints filed with NHTSA.

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