Information that I have collected for my 2005 Subaru Outback XT Limited.
Update: Engine has blown. Currently at Horizontal Motor Sports.
EJ255 Version 1: Used in the 2005 and 2006 Legacy, as well as the 2004 and 2005 Forester. This engine uses the AB440 shortblock, which is the same shortblock as the 2004-2006 STI EJ257. The heads on these EJ255 are the AB650s, while the US 04-06 STI is the familiar AB640/910. The cams are the same between the EJ255 Version 1 and the EJ257.
A list of things to check and/or change out.
- Banjo bolt
- Oil and filter
- Fluid change
- Rear differential
- Air filter
- Spark plugs
- Coil packs
- Seafoam (Top-end cleaning?)
- Inner/Outer tie rods and ball joints
Oil and filter
Popular recommendation seems to be Full Synthetic with turbo cars.
- K&N HP-1008 Filter
- Rotella T6
Transmission and Rear differential
Both use synthetic 75W-90 gear oil. Make sure its GL-5 rated.
You'll need 4QTs of fluid for the front and 1QT for the rear.
You will need a T70 Torx bit to take off the front drain plug. Remove dipstick, remove and clean plug, drain fluid, re-install plug, use funnel and fill, then re-install dipstick. Check levels afterwards.
The rear plugs are 1/2". A pump will be useful for flushing the rear fluids. Remove both plugs, drain, then pump/fill until fluid runs clean out of bottom hole, insert bottom plug, pump until fluid comes out of top hole, then plug top hole.
If you have a torque wrench:
- Oil Drain Plug: 33 ft-lb
- Transmission Drain Plug (T70): 50.6 ft-lb
- Rear Drain and Filler Plugs: 36.2 ft-lb
- Skid plate
- Sway bar
The stock uppipe comes with a catalytic converter that is known to disintegrate and send pieces into your turbo, which then feeds into your engine.
It should be replaced with an uppipe that does not have a catalytic converter and it does not require a 'bung' for the EGT sensor.
The EGT sensor is only there to monitor whether the cat is working properly. You can disconnect the sensor and use a resistor to trick the ECU to not throw a code.