SUBARU BOXER DIESEL

Subaru Legacy/Outback 2.0D

Press information
March 2008

Fuji Heavy Industries Ltd.

SUBARU BOXER DIESEL: Aims of Development

A commitment to developing Subarus very own diesel engine
Subaru has forged a new style of driving focusing on our philosophy of providing a safe,
exhilarating, comfort and confident ride at all times. One way this has been achieved is
through the unique Symmetrical AWD drivetrain layout, which mounts the Subaru
Horizontally-Opposed Engine and transmission longitudinally, coupled with the highly
efficient AWD system. Customers who choose Subaru over cars produced by the many
different manufacturers available in Europe are sure to be fully content with the comfortable
and reliable driving experience that only Subaru can offer.
There is reasoning behind this level of devotion to develop our own diesel enginethe
driving experience that Subaru has been striving for, perfected by the ideal combination of
the lightweight and compact Horizontally-Opposed Diesel Engine and the symmetrical AWD
system. The various features of the SUBARU BOXER engine, such as reduced vibration,
low centre of gravity and high rigidity, are also ideally suited to the diesel engine Subaru
worked towards creating.
There is yet another major reason. The sporty feel, one of the main characteristics of the
Horizontally-Opposed Engine, is also available with the BOXER DIESEL engine. The
superior accelerator response places the SUBARU BOXER DIESEL miles ahead of the
rest.
Increasing Subarus appeal to a broader range of customers by incorporating the
worlds first Horizontally-Opposed Diesel Engine in a passenger vehicle
Both the Legacy and the Outback receive the diesel engine as part of the 2008 model
lineup for the European market. Subaru is looking to make this engine one of the major
driving forces within the European market. The BOXER DIESEL will be made available in a
wider range of vehicles in future models.
The SUBARU BOXER DIESEL is the worlds first Horizontally-Opposed diesel engine
designed for passenger vehicles. It retains not only the advantages of typical diesel engines
but also offers the various performance advantages Subaru has incorporated into its
Horizontally-Opposed Engine design. Europe has always had a long affinity with vehicles,
and diesel engines are becoming more popular in this market as they are economical and
well-suited to driving conditions in Europe. Subaru has made a firm commitment to the
development of the diesel engine without sacrificing the benefits that are originally
promised to its customers. To meet the demands of todays customers, incorporating the
BOXER DIESEL engine into passenger vehicles has been the centrepiece of a new
challenge facing Subaru. The benefits only Subaru can offer will be available to a greater
number and a wider range of customers.

SUBARU BOXER DIESEL: Features

The worlds first Horizontally-Opposed Diesel Engine for passenger car
The Horizontally-Opposed engine technology that has been continually perfected by
Subaru and the forced induction expertise developed for the FIA World Rally Championship
has been

combined with the new diesel

engine to

create the worlds

first

Horizontally-Opposed Diesel Engine for passenger car, offering both on-the-road and
environmental performance.
Lightweight, compact and highly rigid
The bore pitch has been decreased and the left and right blocks holding the crankshaft
provide a highly rigid design, which has also allowed use of an aluminium alloy cylinder
block for weight savings. The result is the class-leading light weight diesel engine in the
2.0-litre class.
Low vibrations and noise
The movements of the horizontally-opposed pistons work in unison to effectively cancel out
the second harmonic vibration (vibration with twice frequencies as engine revolution) with
which human being feels uncomfortable. The layout results in minimal vibrations meaning a
balance shaft found in many conventional straight and V-type engine layouts is not required.
The crankshaft is short and highly rigid, minimising the vibrational noise characteristic of
many ordinary diesel engines.
Superior engine response
The superior balance of the Horizontally-Opposed Engine layout leads to low rotational
inertia and friction within the engine itself. The result is exceptional accelerator response.
Outstanding environmental performance
The engine offers the powerful torque output of a diesel while complying with European
EURO 4 regulations. The design also results in the best fuel efficiency in the 4WD
passenger vehicle class.

SUBARU BOXER DIESEL: Mechanisms

1. Cylinder block
Cylinder block
An aluminium alloy cylinder block has been used to maximise the potential of the highly
rigid Horizontally-Opposed Engine layout. To obtain an ideal diesel combustion, the piston
stroke was extended by 11mm while the bore was shortened by 6mm compared to the
petrol engine. Subaru achieved longer stroke arrangement without increasing the overall
engine width. On top of that, the bore pitch has been shortened to 98.4mm , which is
similar to that of 6-cylinder Subaru Boxer petrol engine (EZ30), while the 4-cylinder Subaru
Boxer petrol engine (EJ20) has 113.0 mm. This has led to a 61.3 mm reduction in engine
block length for even more compact design.
BOXER DIESEL H4 (EE20)

BOXER Petrol H4 (EJ20)

Preliminary Specifications
EE20
EJ20
EZ30
(BOXER DIESEL)
Engine type
Horizontally-Opposed Horizontally-Opposed Horizontally-Opposed
4-cylinder diesel
4-cylinder petrol
6-cylinder petrol
engine
engine
engine
Displacement
1,998
1,994
2,999
Bore stroke mm
86.086.0
92.075.0
89.280.0
Bore pitch
mm
98.4
113
98.4
Engine
mm
353.5
414.8
438.4
length

Semi-closed deck
The block design uses the semi-closed deck type that has proven its durability in the
turbocharged petrol models. This increases rigidity around the head gasket mating areas.

Metal matrix composite journal:

All 5 main bearings (journals) in the cylinder block incorporate metal matrix composite
journals (which are inserted during the casting process), resulting in superior levels of
quietness due to its high rigidity and similarity in the thermal expansion ratio to that of
crankshaft.
Metal matrix composite journals

Extra cooling channels

Cooling slits have been given between the cylinder bores to operate as water cooling
channels, thus improving cooling performance.
Pistons
High strength materials have been used to withstand the high combustion pressures of the
diesel engine. Cooling channels within the pistons have been incorporated, with engine oil
squirted via oil jets, which enhances piston cooling.

Combustion Chamber

Cooling Channel

Connecting rods

Oil Jet

The large ends of the connecting rods feature asymmetrical profile, which increases
precision during assembly and in roundness of the surface connecting the crankpin for
reduced friction. It has also contributed to minimize the rotational path thus enabled to
employ extended piston stroke inside the compact cylinder block.

Crankshaft
The high strength crankshafts have undergone surface treatment to withstand the high
combustion pressures that are found in a diesel engine. The superior layout of the
Horizontally-Opposed Engine results in a much lighter weight than a similar straight engine
layout.

2. Valve system / intake and exhaust system

Cylinder head
High strength cylinder heads have been used to withstand the high combustion pressures.
Roller rocker arms: compact and low friction end pivot type roller rocker arms have been
used in combination with double overhead cam (DOHC) system.
Valve System
The diameter of the intake valves have been optimised for enhanced breathing
performance and swirl ratios, resulting in improved combustion efficiency.
Intake ports
Intake ports: the combination of an intake swirl pot system and optimised intake valve
diameter results in ample swirl performance.
Cam Drive System
A highly durable chain system has been used to drive the camshaft to handle the variations
in torque produced by the diesel engine.

3. Common rail system

A common rail system has been used for fuel delivery for better performance. The fuel is
pressurised to 180 MPa before being fed into the common rail.
Solenoid injectors
Specially designed injectors have been used. A shorter overall length of the injector has
contributed to maintain overall engine width as that of the regular petrol engine despite the
longer piston stroke.

4. Turbocharger
A variable nozzle turbocharger has been specially designed to deliver ample turbocharged
performance across the entire engine range. The turbocharger itself has been positioned
under the engine and mounted directly to the catalytic converters for increased
environmental performance. Response has been improved while also helping to lower the
centre of gravity.

5. Exhaust
The exhaust system has been fine tuned for use with the diesel engine.

6. Exhaust Emission Control System

The exhaust emission control system mainly employs Oxidation catalytic converters, Diesel
Particulate Filter (DPF) and Exhaust Gas Recirculation (EGR) system. gas purifier has
been positioned below the engine together with the turbocharger. The unit delivers cleaner
exhaust gas performance without affecting the low centre of gravity obtained through the
combination of Subarus Horizontally-Opposed engine and Symmetrical AWD system.
Complies with EURO4 Exhaust gas regulations.
Oxidation catalytic converter
The oxidation catalytic converter has been positioned below the engine together with the
turbocharger. The catalytic converter separates un-burnt fuel into water and carbon dioxide.
The unit has been made compact enough to be activated soon after the engine has been
started... If the temperature rises to 300 C under certain driving conditions, the oxidation
catalytic converter generates NO2 which oxidize the collected Diesel Particulate inside the
DPF.
Diesel Particulate Filter (DPF)
Diesel particulate is collected effectively by carbon filters inside the DPF. If the temperature
rises to 600 C under certain driving conditions, the collected particulate is burnt off and
emitted through the exhaust pipe.
EGR (Exhaust Gas Recirculation) system
An EGR system has been used to comply with European EURO 4 exhaust gas regulations.
The cooled exhaust gas is fed back into the combustion chamber to lower the combustion
temperature and reduce NOx emissions.

7. Engine mounting system

Liquid-filled engine mounting system has been employed for even less vibration and better
handling performance.

Main engine specifications

Displacement
Maximum power output
Maximum torque output
CO2 emissions
Compression ratio
Bore stroke
Bore pitch
Bank offset
Deck height
Journal diameter
Crankpin diameter
Effective
Length
of
Connecting Rod
Piston pin diameter
Compression height
Fuel injection system
Turbo charger
EGR layout
Diesel Particulate Filter
Engine length

cc
kW(PS)/rpm
Nm(kgfm)/rpm
(g/km)
mm
mm
mm
mm
mm
mm
mm
mm
mm

mm

EE20
(BOXER DIESEL)
1,998
110(150)/3,600
350(35.7)/1,800
148 (Sedan)
16.3
86.086.0
98.4
46.8
220
67
55
134

EJ20 (petrol)

EZ30 (petrol)

1,994
110(150)/6,000
196(20.0)/3200
209 (Sedan MT)
10.2
92.075.0
113
54.5
201
60
52
130.5

2,999
180(245)/6,600
297(30.3)/4.200
243 (Sedan MT)
10.7
89.280.0
98.4
46.8
202
64
50
131.7

23
33.5
MPI

22
30.0
MPI

414.8

438.4

31
43.0
Common rail type
Variable nozzle
turbocharger
Water cooled
Open Type
353.5

Engine Performance Curves

Torque (Nm)

Output (kW)

Output
Torque
Engine R.P.M

Subaru Legacy/Outback 2.0D

1. Features
Levels of comfort, sportiness and silence unlike a diesel, while offering both driving
and environmental performance
The combination of SUBARUs BOXER DIESEL and the Symmetrical AWD power train
provide the Legacy/Outback with the following outstanding features.
The thrill of the drive
Superior driving stability: a superior weight balance, low centre of gravity and exceptional
drivability achieved with the Symmetrical AWD and the lightweight and compact
Horizontally-Opposed Diesel Engine centrepiece. By mounting the weight of the
transmission and drive train within the wheelbase, outstanding drivability and linear
handling are achieved, allowing the driver to control the car exactly as desired.
Sporty diesel
Outstanding accelerator response: the outstanding accelerator response of the BOXER
DIESEL makes it a sporty package that is miles ahead of any other diesel powered vehicle.
Environmentally friendly and economical
Better fuel efficiency: friction loss within the engine, transmission and AWD system has
been minimised, thus improving fuel efficiency.
Reduced CO2 emissions: the improved fuel efficiency means the boxer diesel is the most
environmentally friendly vehicle in the same AWD class of passenger vehicles. The
BOXER DIESEL also complies with European EURO4 regulations.
Comfort and silence levels
Major reductions in vibrations and noise: reduced vibration thanks to the layout of the
Horizontally-Opposed engine and vibration proofing installed throughout the vehicles
interior ensure that the vibrations and noise usually associated with diesel powered
vehicles have been drastically reduced.
Clarity of conversations when cruising on the motorway: the exceptional levels of silence
mean conversations can be had clearly with fellow passengers even when cruising at 200
km/h.
Electric power steering for driving and environmental performance: the Legacy features an
electronic power steering system to improve fuel efficiency. The system has been
meticulously designed to improve driving pleasure and reduce noise within the vehicle.

2. Transmission
A special 5-speed manual transmission for the BOXER DIESEL
A special manual transmission for the BOXER DIESEL has been designed. The gear ratios
have been fine tuned to match the output characteristics of the diesel engine, and the shift
feel has also been improved.
A special flywheel and clutch
A dual mass flywheel and the clutch damper character have been fine tuned to suit the
diesel engine, reducing the uncomfortable sounds produced at low engine speeds.
Special gear ratios
The gear ratios have been optimised to suit the lower rev limit and higher torque output
throughout the entire engine range of the diesel engine, covering urban driving to high
speed driving on the motorway. By limiting the engine speed during high speed driving, (the
engine speed is approximately 3,000 rpm when cruising at 150 km/h), exceptional levels of
silence have been achieved.
2nd
3rd
1st
Sedan/wagon
3.454 2.062 1.448
G
Outback

Sedan/wagon

1.750 1.096
D
Outback

* G = petrol vehicles, D = diesel vehicles

4th
1.088

0.785

5th
0.825

0.634

Rev
3.333

FINAL
4.111
3.900
3.700
3.900

3. Chassis and body

In parallel to the development of quality diesel engine, which has innately low noise and
vibration character compared to other diesels, Subaru has further developed the chassis
and body performance to achieve quality ride performance as its petrol models.
For this purpose, sound absorbing and sound proofing material has been added and
increased throughout the vehicle. Vibrations and sound has been limited throughout the
powertrain to result in the same levels of silence as the petrol powered vehicle. The
exceptional levels of silence mean conversations can be had clearly with other passengers
even when cruising at 200 km/h. A new electric power steering system has been specially
developed to improve fuel efficiency and driving feel. Other parts, the front suspension and
brakes in particular, have been fine tuned to improve drivability and silence levels.
Vibration and sound proofing
Sound proofing has been added within the newly designed fender protector. The lower
cover has been increased in size to extend to below the transmission, and the silencer floor
has been changed to use double layer sound proof materials. The cowl panel insulator now
has Thinsulate added to improve protection against the high frequency noises of the engine.
The toe board thickness has been increased to improve silence levels within the vehicle.

Electric power steering

A pinion type electric power steering system has been used to improve fuel efficiency. The
steering gearbox is mounted to the crossmember in four points using floating bushes,
limiting the amount of transmitted vibrations and increasing rigidity. The steering feel has
been fine tuned for easier drivability across the entire engine range to provide the driving
and environmental performance befitting of the Legacy and Outback.
Special suspension tuning
The front suspension has undergone special tuning to suit the changes to the front axle
load with the installation of the diesel engine and the electric power steering. This has led to
improved stability and better response for better drivability.
Axles
The size of the front drive shaft outer joints (constant velocity joints) has been increased to
cope with the increase in torque of the diesel engine. The shaft diameter has been
optimised to reduce vibrations and improve silence levels within the vehicle when driving at
low speeds in a high gear.
Fine tuned braking system
With the additional weight over the front axle, the front brakes have been upgraded to
16-inch discs to improve braking performance. Brake booster performance has also been
optimised to deliver reliable braking at any speed and increase braking feel.

4. Safety Features

SRS Front & Side Airbags are standard.

SRS Curtain Airbags are optional.

Vehicle Dynamics Control System is standard.

5. Equipment
A gear shift boot and shift knob designed specially for the diesel engine have been
used. This provides a sporty yet luxurious looking interior.
The gear shift lever has been shortened by 10 mm of that of the petrol models to
improve the overall shift feel of the gearbox, resulting in better drivability.
The fabric seat material and surface pattern are available exclusively for the diesel
model for a unique appearance.

 A special air-conditioning system has been developed, providing ample heating

immediately after starting the engine or in areas with extremely cold climates.
Winter package including seat heaters and front wiper de-icer is standard.
A Keyless Access and Push Button Start System has been incorporated for the same
ease of use as the petrol vehicle.
An engine collector cover and rear decorations have been used especially for the diesel
powered vehicle.

Specifications: Subaru Legacy 2.0D Sedan

Dimensions (Length / Width / Height):

Wheel Base:
Minimum Round Clearance:
Minimum Turning Circle at tire:
Engine Type:
Cam Drive System:
Displacement:
Maximum Output:
Maximum Torque:
Compression Ratio:
Transmission Type:
Fuel Economy (CO2 emissions):
Urban:
Extra-urban:
Combined:
Fuel Consumption:
Urban:
Extra-urban:
Combined:
Fuel tank capacity:
Maximum Speed:
All Wheel Drive Type:
Suspension Type:
Front:
Rear:
Front Brake System:
Rear Brake System:
Tires:
Towing Capacity:
Seating Capacity:
Kerb Weight:

4,665mm / 1,730mm / 1,425mm

2,670mm
145mm
10.8m
Horizontally-Opposed, 4-cylinder, 4-stroke, diesel engine
Doubled Overhead Cam (DOHC)
1,998cc
110kw (150PS) / 3,600rpm
350Nm (35.7kgfm) / 1,800rpm
16.3
5-speed Manual Transmission
184 g/km
128 g/km
148 g/km
7.0 lit./100km
4.8 lit./100km
5.6 lit./100km
64 lit.
208 km/h (at 5th gear)
Center Differential Gear with Viscous-coupling type LSD
MacPherson strut type
Multi link type
Ventilated disc brakes
Solid disk brakes
205/55R16
1,700 kg
5 Persons
1,460 kg

Safety Features:
Standard SRS Front & Side Airbags
Optional SRS Curtain Airbags
Standard 4-sensor / 4-channel type ABS with Electronic Brake-force Distribution (EBD)
Standard Vehicle Dynamics Control System

Exterior Standard Equipment

Front fog lights
Power-folding door mirrors with built-in LED turn signal

Interior Standard Equipment:

Leather-wrapped steering wheels, shift knob and parking brake lever
Tilt & Telescopic-adjustable steering wheel with Cruise Control Switches,
Full-auto AC
Winter Package (Front wiper de-icer, Heated mirrors, Seat Heaters)
Radio (AM/FM/MW) + 6-CD Audio Unit

Major Optional Equipment:

HID headlamps & washers

215/45R17 Tires
17-inch Alloy Wheels (instead of standard 16-inch Steel Wheels + Hub Caps)
Audio & Visual Integrated DVD Satellite Navigation System (AVN) with 7-inch VGA monitor
Moonroof (glass lid / tilt & slide open functions)
Leather Interior Package
Power Seat (Drivers seat)
Key-less access and push button start system

Specifications: Subaru Legacy 2.0D Station Wagon

Dimensions (Length / Width / Height): 4,720mm / 1,730mm / 1,470mm

Wheel Base:
2,670mm
Minimum Round Clearance:
145mm
Minimum Turning Circle at tire:
10.8m
Engine Type:
Horizontally-Opposed, 4-cylinder, 4-stroke, diesel engine
Cam Drive System:
Doubled Overhead Cam (DOHC)
Displacement:
1,998cc
Maximum Output:
110kw [150PS] / 3,600rpm
Maximum Torque:
350Nm [35.7kgfm] / 1,800rpm
Compression Ratio:
16.3
Transmission Type:
5-speed Manual Transmission
Fuel Economy (CO2 emissions):
Urban:
186 (189) g/km
Extra-urban:
131 (134) g/km
Combined:
151 (154) g/km
Fuel Consumption:
Urban:
7.1 (7.2) lit./100km
Extra-urban:
5.0 (5.1) lit./100km
Combined:
5.7 (5.8) lit./100km
Fuel tank capacity:
64 lit.
Maximum Speed:
203 km/h (at 5th gear)
All Wheel Drive Type:
Center Differential Gear with Viscous-coupling type LSD
Suspension Type:
Front:
MacPherson strut type
Rear:
Multi link type
Front Brake System:
Ventilated disc brakes
Rear Brake System:
Solid disk brakes
Tires:
205/55R16
Towing Capacity:
1,700 kg
Seating Capacity:
5 Persons
Kerb Weight:
1,510 (1,565) kg
*Note Specifications in (parenthesis) are applicable to the versions equipped with tandem moonroof.
Safety Features:
Standard SRS Front & Side Airbags
Optional SRS Curtain Airbags
Standard 4-sensor / 4-channel type ABS with Electronic Brake-force Distribution (EBD)
Standard Vehicle Dynamics Control System

Exterior Standard Equipment

Front fog lights
Power-folding door mirrors with built-in LED turn signal

Interior Standard Equipment:

Leather-wrapped steering wheels, shift knob and parking brake lever
Tilt & Telescopic-adjustable steering wheel with Cruise Control Switches,
Full-auto AC
Winter Package (Front wiper de-icer, Heated mirrors, Seat Heaters)
Radio (AM/FM/MW) + 6-CD Audio Unit

Major Optional Equipment:

HID headlamps & washers

215/45R17 Tires
17-inch Alloy Wheels (instead of standard 16-inch Steel Wheels + Hub Caps)
Audio & Visual Integrated DVD Satellite Navigation System (AVN) with 7-inch VGA monitor
Tandem Moonroof (glass lid / Front tilt & Rear slide open functions)
Leather Interior Package
Power Seat (Drivers seat)
Key-less access and push button start system

Specifications: Subaru Outback 2.0D

Dimensions (Length / Width / Height): 4,730mm / 1,770mm / 1,545mm

Wheel Base:
2,670mm
Minimum Round Clearance:
195mm
Minimum Turning Circle at tire:
10.8m
Engine Type:
Horizontally-Opposed, 4-cylinder, 4-stroke, diesel engine
Cam Drive System:
Doubled Overhead Cam (DOHC)
Displacement:
1,998cc
Maximum Output:
110kw [150PS] / 3,600rpm
Maximum Torque:
350Nm [35.7kgfm] / 1,800rpm
Compression Ratio:
16.3
Transmission Type:
5-speed Manual Transmission
Fuel Economy (CO2 emissions):
Urban:
186 (189)g/km
Extra-urban:
135 (137)g/km
Combined:
153 (156)g/km
Fuel Consumption:
Urban:
7.1 (7.2)lit./100km
Extra-urban:
5.1 (5.2)lit./100km
Combined:
5.8 (5.9)lit./100km
Fuel tank capacity:
64 lit.
Maximum Speed:
200 km/h (at 5th gear)
All Wheel Drive Type:
Center Differential Gear with Viscous-coupling type LSD
Suspension Type:
Front:
MacPherson strut type
Rear:
Multi link type
Front Brake System:
Ventilated disc brakes
Rear Brake System:
Solid disk brakes
Tires:
215/60R16
Towing Capacity:
1,700 kg
Seating Capacity:
5 Persons
Kerb Weight:
1,505 (1,570)kg
*Note Specifications in (parenthesis) are applicable to the versions equipped with tandem moonroof.
Safety Features:
Standard SRS Front & Side Airbags
Optional SRS Curtain Airbags
Standard 4-sensor / 4-channel type ABS with Electronic Brake-force Distribution (EBD)
Standard Vehicle Dynamics Control System

Exterior Standard Equipment

Front fog lights
Power-folding door mirrors with built-in LED turn signal

Interior Standard Equipment:

Leather-wrapped steering wheels, shift knob and parking brake lever
Tilt & Telescopic-adjustable steering wheel with Cruise Control Switches,
Full-auto AC
Winter Package (Front wiper de-icer, Heated mirrors, Seat Heaters)
Radio (AM/FM/MW) + 6-CD Audio Unit

Major Optional Equipment:

HID headlamps & washers

215/55R17 Tires
17-inch Alloy Wheels (instead of standard 16-inch Alloy Wheels)
Audio & Visual Integrated DVD Satellite Navigation System (AVN) with 7-inch VGA monitor
Tandem Moonroof (glass lid / Front tilt & Rear slide open functions)
Leather Interior Package
Power Seat (Drivers seat)
Key-less access and push button start system