How to Replace the Oil Pan Gasket in a Subaru Outbackby Contributor; Updated November 07, 2017
Items you will need
Replacement drain plug gasket
Clean shop rags
Replacement oil pan gasket
5.5 to 6 qt. clean motor oil
Empty milk carton
How to Replace the Oil Pan Gasket in a Subaru Outback. A puddle of oil underneath the engine of your Subaru Outback could mean that it's time to change a worn out oil pan gasket. Unfortunately, changing the oil pan gasket in any Outback is a challenging job, no matter what the year. Here's how to change the oil pan gasket on a 2000 to 2004 model Subaru Outback.
Disconnect the negative battery cable and remove the air intake duct. If your Subaru Outback is turbocharged, remove the mass air flow sensor, air intake boot and air cleaner upper cover and intercooler. Remove the front oxygen sensor, pitching stopper and upper radiator brackets.
Support the engine safely with a hoist and remove the front wheel and tire. Lift the engine enough to remove the engine undercover.
Place a bucket under the oil pan drain plug and remove the plug with a socket wrench. Let the oil drain into the bucket and once it's drained, replace the drain plug, along with a new drain plug gasket.
Remove the rear O2S oil connector, exhaust pipe and the nuts that hold the front engine mounts to the crossmember and the nuts and bolts holding the oil pan in place. Divide the upper and lower oil pans with a cutting tool, and use a rubber mallet to remove the pan from the engine.
Clean the old gasket from the mating surfaces, then wipe them with solvent. Run a thin bead of sealant to the new gasket Reinstall the oil pan and tighten the bolts according to specifications and lower the engine onto the crossmember.
Reattach the remaining engine components in reverse order, attaching the negative battery cable last. Fill the crankcase with fresh oil, and check the level with a dipstick. Subaru Outbacks require between 5.5 and 6 qt.
Funnel the old oil into an empty milk carton and take it to a garage or to your local hazardous waste facility for proper disposal.