Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2002 Subaru Outback Base, 4D SedanFACTORY OEM SERVICE PROCEDURE
Torque Specifications
TORQUE SPECIFICATION
| Application | Ft. Lbs. (N.m) | |||||||
|---|---|---|---|---|---|---|---|---|
| Generator (1) | ||||||||
| Bearing Retainer Screw (T1) | (2) | |||||||
| Nut-To-Rear Cover (T1) | (2) | |||||||
| Pulley Nut (T2) | 47 (63.7) | |||||||
| Through-Bolt & Screw-To-Front Cover (T1) | (2) | |||||||
| Through-Bolt-To-Rear Cover (T1) | (2) | |||||||
| V-Belt | ||||||||
| Lock Bolt Through Bolt (Generator Belt Tensioner Lock Bolt) | 18 (25) | |||||||
| Slider Bolt (Generator Belt Tensioner Adjustment Bolt) | (3) | |||||||
|
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BRUSH SPECIFICATIONS
| Application (1) |
Specification | ||||
|---|---|---|---|---|---|
| Baja | |||||
| Brush Length | |||||
| Standard | .807" (20.5 mm) | ||||
| Limit | .059" (1.5 mm) | ||||
| Brush Spring Pressure | |||||
| New | 17.26-21.60 oz. (4.8-6.0 N) | ||||
| Limit | 7.91 oz. (2.2 N) | ||||
| Legacy | |||||
| Brush Length | |||||
| Standard | .807" (20.5 mm) | ||||
| Limit | .059" (1.5 mm) | ||||
| Brush Spring Pressure | |||||
| New | 17.26-21.60 oz. (4.8-6.0 N) | ||||
| Limit | 7.91 oz. (2.2 N) | ||||
| Outback 2.5L (2002) | |||||
| Brush Length | |||||
| Standard | .807" (20.5 mm) | ||||
| Limit | .059" (1.5 mm) | ||||
| Brush Spring Pressure | |||||
| New | 17.26-21.60 oz. (4.8-6.0 N) | ||||
| Limit | 7.91 oz. (2.2 N) | ||||
| Outback 3.0L (2002) | |||||
| Brush Length | |||||
| Standard | .728" (18.5 mm) | ||||
| Limit | .197" (5 mm) | ||||
| Brush Spring Pressure | |||||
| New | 16.58-20.81 oz. (4.609-5.786 N) | ||||
| Limit | 9.52 oz. (2.648 N) | ||||
| Outback (2003) | |||||
| Brush Length | |||||
| Standard | .807" (20.5 mm) | ||||
| Limit | .059" (1.5 mm) | ||||
| Brush Spring Pressure | |||||
| New | 17.26-21.60 oz. (4.8-6.0 N) | ||||
| Limit | 7.91 oz. (2.2 N) | ||||
|
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ROTOR ASSEMBLY SPECIFICATIONS
| Application | Specification | ||
|---|---|---|---|
| Slip Ring Continuity Test | |||
| Specified Resistance | 2.7-3.2 ohms | ||
| Slip Ring Outer Diameter | |||
| Except Legacy & Outback (2002) | |||
| Standard | .894" (22.7 mm) | ||
| Limit | .87" (22.1 mm) | ||
| Legacy & Outback (2002) | |||
| Standard | 1.06" (27 mm) | ||
| Limit | 1.02" (26 mm) | ||
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.