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.

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HOMESERVICE MANUALSSUBARU2005OUTBACK I, STANDARDREPAIR AND DIAGNOSISENGINE MECHANICALSTARTERSTARTING/CHARGING SYSTEMS (H4SO)GENERATORDISASSEMBLY

2005 Subaru Outback i, Standard

Starting/Charging Systems (H4SO): Generator: Disassembly

2005 Subaru Outback i, StandardSECTION Disassembly

Remove the four through-bolts.

Fig 1: Removing Four Through-Bolts
Courtesy of SUBARU OF AMERICA, INC.
Heat portion (A) of rear cover to 50° (122°) with a heater drier.

Fig 2: Heating Portion Of Rear Cover To 50°
Courtesy of SUBARU OF AMERICA, INC.
Then insert the tip of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

Fig 3: Inserting Tip Of A Flat Tip Screwdriver Into Gap Between Stator Core And Front Cover
Courtesy of SUBARU OF AMERICA, INC.
Hold the rotor with a vise and remove pulley nut.

Fig 4: Removing Pulley Nut
Courtesy of SUBARU OF AMERICA, INC.

RENDER: 1.0x

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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.