Subaru Baja 2006 Service Guide

Maintenance and service

Maintenance schedule ................................. 11-3

Maintenance precautions ............................ 11-3

Before checking or servicing in the engine

compartment .................................................. 11-4

When you do checking or servicing in the

engine compartment while the engine is

running ............................................................ 11-5

Engine hood .................................................. 11-5

Engine compartment overview ................... 11-8

Non-turbo models ............................................. 11-8

Turbo models .................................................... 11-9

Engine oil ...................................................... 11-10

Checking the oil level ....................................... 11-10

Changing the oil and oil filter .......................... 11-12

Recommended grade and viscosity ................ 11-15

Recommended grade and viscosity under

severe driving conditions .............................. 11-16

Cooling system ............................................. 11-17

Hose and connections ...................................... 11-18

Engine coolant .................................................. 11-18

Air cleaner element ...................................... 11-23

Replacing the air cleaner element ................... 11-23

Spark plugs ................................................... 11-25

Recommended spark plugs ............................. 11-26

Drive belts ..................................................... 11-26

Manual transmission oil ............................... 11-27

Checking the oil level ....................................... 11-27

Recommended grade and viscosity ................ 11-29

Automatic transmission fluid ...................... 11-29

Checking the fluid level .................................... 11-29

Recommended fluid ......................................... 11-31

Front differential gear oil (AT vehicles) ...... 11-32

Checking the oil level ....................................... 11-32

Recommended grade and viscosity ............... 11-33

Rear differential gear oil ............................... 11-33

Checking the gear oil level .............................. 11-33

Recommended grade and viscosity ............... 11-35

Power steering fluid ...................................... 11-36

Checking the fluid level .................................... 11-36

Recommended fluid ......................................... 11-38

Brake fluid ..................................................... 11-38

Checking the fluid level .................................... 11-38

Recommended brake fluid ............................... 11-39

Clutch fluid (MT vehicles) ............................ 11-40

Checking the fluid level .................................... 11-40

Recommended clutch fluid .............................. 11-41

Brake booster ................................................ 11-42

Brake pedal .................................................... 11-42

Checking the brake pedal free play ................ 11-42

Checking the brake pedal reserve distance ... 11-43

Clutch pedal (Manual transmission

vehicles) ..................................................... 11-43

Checking the clutch function .......................... 11-43

Checking the clutch pedal free play ............... 11-44

Replacement of brake pad and lining ......... 11-44

Breaking-in of new brake pads and linings .... 11-45

Parking brake stroke .................................... 11-46

Tires and wheels ........................................... 11-46

11-1

Maintenance and service

Types of tires .................................................... 11-46

Tire inspection .................................................. 11-47

Tire pressures and wear .................................. 11-47

Wheel balance ................................................... 11-50

Wear indicators ................................................. 11-50

Tire rotation ....................................................... 11-51

Tire replacement ............................................... 11-51

Wheel replacement ........................................... 11-52

Aluminum wheels ......................................... 11-53

Windshield washer fluid .............................. 11-53

Replacement of windshield wiper blades .. 11-55

Battery ........................................................... 11-58

Fuses ............................................................. 11-59

Main fuse ....................................................... 11-61

Installation of accessories .......................... 11-62

Replacing bulbs ............................................ 11-63

Headlight ........................................................... 11-66

Front fog light ................................................... 11-70

Front turn signal light, parking light and side

marker light .................................................... 11-71

Rear combination lights ................................... 11-72

Tail light (on the tailgate) ................................. 11-74

License plate light ............................................ 11-76

Map light, dome light and door step light ...... 11-78

High mount stop and cargo light assembly ... 11-79

Sport activity lights (if equipped) .................... 11-81

11-2

Maintenance and service

Maintenance schedule

MaintenanceSchedule

The scheduled maintenance items required to be serviced at regular intervals are shown in the “Warranty and Maintenance Booklet”.

For details of your maintenance schedule, read the separate “Warranty and Maintenance Booklet”.

Maintenance and service

Maintenance precautions

MaintenancePrecautions

When maintenance and service are required, it is recommended that all work be done by an authorized SUBARU dealer.

If you perform maintenance and service by yourself, you should familiarize yourself with the information provided in this section on general maintenance and service for your SUBARU.

Incorrect or incomplete service could cause improper or unsafe vehicle operation. Any problems caused by improper maintenance and service performed by you are not eligible for warranty coverage.

y Testing of an All-Wheel Drive vehicle must NEVER be performed on a single two-wheel dynamometer or similar apparatus. Attempting to do so will result in transmission damage and in uncontrolled vehicle movement and may cause an accident or injuries to persons nearby. y Always select a safe area when performing maintenance on your vehicle. y Always be very careful to avoid injury when working on the vehicle. Remember that some of

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11-3

Maintenance and service

the materials in the vehicle may be hazardous if improperly used or handled, for example, battery acid. y Your vehicle should only be serviced by persons fully competent to do so. Serious personal injury may result to persons not experienced in servicing vehicles. y Always use the proper tools and make certain that they are well maintained. y Never get under the vehicle supported only by a jack. Always use a safety stands to support the vehicle. y Never keep the engine running in a poorly ventilated area, such as a garage or other closed areas. y Do not smoke or allow open flames around the fuel or battery. This will cause a fire. y Because the fuel system is under pressure, replacement of the fuel filter should be performed only by your SUBARU dealer. y Wear adequate eye protection to guard against getting oil or fluids in your eyes. If something does get in your eyes, thoroughly wash them out with clean water. y Do not tamper with the wiring of the SRS airbag system or seatbelt pretensioner system, or attempt to take its connectors apart, as that

may activate the system or it can render it inoperative. The wiring and connectors of these systems are yellow for easy identification. NEVER use a circuit tester for these wiring. If your SRS airbag or seatbelt pretensioner needs service, consult your nearest SUBARU dealer.

 Before checking or servicing in the en-

gine compartment

y Always stop the engine and set the parking brake firmly to prevent the vehicle from moving. y Always let the engine cool down. Engine parts become very hot when the engine is running and remain hot for some time after the engine is stopped. y Do not spill engine oil, engine coolant, brake fluid or any other fluid on hot engine components. This may cause a fire. y Always remove the key from the ignition switch. When the ignition switch is in the “ON” position, the cooling fan may operate suddenly

11-4

Maintenance and service

even when the engine is stopped.

 When you do checking or servicing in

the engine compartment while the engine is running

A running engine can be dangerous. Keep your fingers, hands, clothing, hair and tools away from the cooling fan, belts and any other moving engine parts. Removing rings, watches and ties is advisable.

Engine hood

EngineHood

UBB008EA

To open the hood:

1. If the wiper blades are lifted off the windshield, return them to their original positions.

2. Pull the hood release knob under the instrument panel.

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11-5

Maintenance and service

UBB094BA UBB003BA

3. Release the secondary hood release located under the front grille by moving the lever toward the left.

11-6

4. Lift up the hood, release the hood prop from its retainer and put the end of the hood prop into the slot in the hood.

To close the hood:

1. Lift the hood slightly and remove the hood prop from the slot in the hood and return the prop to its retainer.

2. Lower the hood until it approaches approximately 6 in (15 cm) from the closed position and let it drop.

3. After closing the hood, be sure the hood is securely locked.

If this does not close the hood, release it from a slightly higher position. Do not push the hood forcibly to close

it. It could deform the metal.

Always check that the hood is properly locked before you start driving. If it is not, it might fly open while the vehicle is moving and block your view, which may cause an accident and serious bodily injury.

Maintenance and service

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11-7

Maintenance and service

Engine compartment overview

EngineCompartment overview

 Non-turbo models

12 34567

8910111213

UBB106BB

1) Manual transmission oil level gauge (MT) (page 11-27) or Differential gear oil level gauge (AT) (page 11-32)

2) Air cleaner element (page 11-

23)

3) Clutch fluid reservoir (page 11-

40)

4) Automatic transmission fluid level gauge (page 11-29)

5) Brake fluid reservoir (page 11-

38)

6) Windshield washer tank (page 11-53)

7) Fuse box (page 11-59)

8) Battery (page 11-58)

9) Engine oil filler cap (page 11-10)

10) Engine coolant reservoir (page 11-18)

11) Radiator cap (page 11-18)

12) Engine oil level gauge (page 11-

10)

13) Power steering fluid reservoir (page 11-36)

11-8

Maintenance and service

 Turbo models

234567

11 10 9 81213

UBB098CB

1) Air cleaner element (page 11-

23)

2) Manual transmission oil level gauge (MT) (page 11-27) or Differential gear oil level gauge (AT) (page 11-32)

3) Clutch fluid reservoir (page 11-

40)

4) Automatic transmission fluid level gauge (page 11-29)

5) Brake fluid reservoir (page 11-

38)

6) Windshield washer tank (page 11-53)

7) Fuse box (page 11-59)

8) Battery (page 11-58)

9) Engine oil filler cap (page 11-10)

10) Engine coolant reservoir (page 11-18)

11) Engine oil level gauge (page 11-

10)

12) Radiator cap (page 11-18)

13) Power steering fluid reservoir (page 11-36)

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11-9

Maintenance and service

Engine oil

EngineOilOil levelEngine

 Checking the oil level

Checking Engine oil l evel



Check the engine oil level at each fuel stop.

1. Park the vehicle on a level surface and stop the engine.

UBB004MA

Non-turbo models

HGB056BA

Turbo models

2. Pull out the dipstick, wipe it clean, and insert it again.

3. Be sure the dipstick is correctly inserted until it stops with the graphic symbol on its top appearing as shown in the illustration.

11-10

Maintenance and service

Non-turbo models

1) Notch

2) Upper level

3) Lower level

UGB081BB

Turbo models

1) Notch

2) Upper level

3) Lower level

UGB082BB

4. Pull out the dipstick again and check the oil level on it. If it is below the lower level, add oil to bring the level up to the upper level.

y Use only engine oil with the recommended grade and viscosity. y Be careful not to spill engine oil when adding it. If oil touches the exhaust pipe, it may cause

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11-11

Maintenance and service

a bad smell, smoke, and/or a fire. If engine oil gets on the exhaust pipe, be sure to wipe it off.

If you check the oil level just after stopping the engine, wait a few minutes for the oil to drain back into the oil pan before checking the level. To prevent overfilling the engine oil, do not add any additional oil above the upper level when the engine is cold.

The dipstick has a notch above the upper level. Just after driving or while the engine is warm, the engine oil level reading may be in a range between the upper level and the notch mark. This is caused by thermal expansion of the engine oil.

 Changing the oil and oil filter



Changing Oil and oil f ilter

Change the oil and oil filter according to the maintenance schedule in the “Warranty and Maintenance Booklet”. The engine oil and oil filter must be changed more frequently than listed in the maintenance schedule when driving on dusty roads, when short trips are frequently made, or when driving in extremely cold whether.

1. Warm up the engine by letting the engine idle for approximately 10 minutes to ease draining the engine

oil.

2. Park the vehicle on a level surface and stop the engine.

3. Remove the oil filler cap.

UBB005BB

1) Drain plug

4. Drain out the engine oil by removing the drain plug while the engine is still warm. The used oil should be drained into an appropriate container and disposed of properly.

Be careful not to burn yourself with hot engine

11-12

oil.

Maintenance and service

UBB054BA

1) Sealing washer

2) Drain plug

UBB051BB

5. Wipe the seating surface of the drain plug with a clean cloth and tighten it securely with a new sealing washer after the oil has completely drained out.

6. Remove three clips at the front of the cover under the oil filter.

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11-13

Maintenance and service

UBB055BA

7. Slide the cover toward the vehicle front to remove it.

8. Remove the oil filter with an oil filter wrench.

9. Before installing a new oil filter, apply a thin coat of engine oil to the seal.

10.Clean the rubber seal seating area of the bottom of engine and install the oil filter by hand turning. Be careful not to twist or damage the seal.

11.Tighten the oil filter by the amount indicated in the following table after the seal makes contact with the bottom of engine.

11-14

Model Oil filter color Part number

Black 15208AA100 1 rotation

Non-turbo

models

Turbo mod-

els

White

Black 15208AA100 1 rotation

White 15208AA09A

15208AA09A

15208AA060

Amount of

rotation

2/3 – 3/4 ro-

tation

2/3 – 3/4 ro-

tation

y Never over tighten the oil filter because that can result in an oil leak. y Thoroughly wipe off any engine oil that has spilled over the exhaust pipe and/or under-cover. If left unremoved, the oil could catch fire.

12.Reinstall the cover under the oil filter.

13.Pour engine oil through the filler neck.

Maintenance and service

Oil capacity (Guideline):

4.2 US qt (4.0 liters, 3.5 Imp qt)

The oil quantity indicated above is only a guideline. The necessary quantity of oil depends on the quantity of oil that has been drained. The quantity of drained oil differs slightly depending on the temperature of the oil and the time the oil is left flowing out. After refilling the engine with oil, therefore, you must use the dipstick to confirm that the level is correct.

14.Start the engine and make sure that no oil leaks appear around the filter’s rubber seal and drain plug.

15.Run the engine until it reaches the normal operating temperature. Then stop the engine and wait a few minutes to allow the oil drain back. Check the oil level again and if necessary, add more engine oil.

 Recommended grade and viscosity



Recommended Oil grade and viscosity

Use only engine oil with the recommended grade and viscosity.

Oil grade:

ILSAC GF-4, which can be identified with the ILSAC certification mark (Starburst mark) or API classification SM with the words “ENERGY CONSERVING”

These recommended oil grades can be identified by looking for either or both of the following marks displayed on the oil container.

HSB023AA

ILSAC Certification Mark (Starburst Mark)

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11-15

Maintenance and service

SAE

5W-30

API Service label

1) Indicates the oil quality by API designations

2) Indicates the SAE oil viscosity grade

3) Indicates that the oil has fuel saving capabilities

In choosing an oil, you want the proper quality and viscosity, as well as one that will add to fuel economy. The following table lists the recommended viscosities and applicable temperatures. When adding oil, different brands may be used together as long as they are the same API classification and SAE viscosity as those recommended by SUBARU.

11-16

B00446

-30 -20 -10 0 10 20 30 40

06020 80 10040

-20

5W-30*

10W-30, 10W-40

HSB024BA

SAE viscosity No. and applicable temperature

*: 5W-30 is preferred.

Engine oil viscosity (thickness) affects fuel economy. Oils of lower viscosity provide better fuel economy. However, in hot weather, oil of higher viscosity is required to properly lubricate the engine.

 Recommended grade and viscosity

under severe driving conditions



Recommended Oil grade and viscosity

If the vehicle is used in desert areas, in areas with very high temperatures, or used for heavy-duty applications such as towing a trailer, use of oil with the following grade and viscosities is recommended.

Maintenance and service

API classification SM (or SL):

SAE viscosity No.:

30, 40, 10W-50, 20W-40, 20W-50

Cooling system

Never attempt to remove the radiator cap until the engine has been shut off and has cooled down completely. Since the coolant is under pressure, you may suffer serious burns from a spray of boiling hot coolant when the cap is removed.

y The cooling system has been filled at the factory with a high quality, corrosion-inhibiting, year-around coolant which provides protection against freezing down to –33°F (–36°C). For adding, use genuine SUBARU coolant or an equivalent: a mixture of 50% soft water and 50% ethylene-glycol basis coolant. Use of improper coolants may result in corrosion in the cooling system. It is important to maintain protection against freezing and corrosion, even if freezing temperatures are not expected. Never mix different kinds of coolant. y Do not splash the engine coolant over paint-

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11-17

Maintenance and service

ed parts. The alcohol contained in the engine coolant may damage the paint surface.

 Hose and connections

Hose and connections



Your vehicle employs an electric cooling fan which is thermostatically controlled to operate when the engine coolant reaches a specific temperature. If the radiator cooling fan does not operate even when the engine coolant temperature gauge exceeds the normal operating range, the cooling fan circuit may be defective. Check the fuse and replace it if necessary. If the fuse is not blown, have the cooling system checked by your SUBARU dealer.

If frequent addition of coolant is necessary, there may be a leak in the engine cooling system. It is recommended that the cooling system and connections be checked for leaks, damage, or looseness.

 Engine coolant



Engine Coolant

T Checking the coolant level

FULL

LOW

1) “FULL” level mark

2) “LOW” level mark

Check the coolant level at each fuel stop.

1. Check the coolant level on the outside of the reservoir while the engine is cool.

2. If the level is close to or lower than the “LOW” level mark, add coolant up to the “FULL” level mark. If the reserve tank is empty, remove the radiator cap and refill as required.

UBB004FB

11-18

Maintenance and service

coolant may damage the paint surface.

HSB026BB

1) Rubber gaskets

3. After refilling the reserve tank and the radiator, reinstall the caps and check that the rubber gaskets inside the radiator cap are in the proper position.

y Be careful not to spill engine coolant when adding it. If coolant touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. If engine coolant gets on the exhaust pipe, be sure to wipe it off. y Do not splash the engine coolant over painted parts. The alcohol contained in the engine

T Changing the coolant

Always add genuine SUBARU cooling system conditioner whenever the coolant is replaced. Change the engine coolant and add genuine SUBARU cooling system conditioner using the following procedures according to the maintenance schedule in the “Warranty and Maintenance Booklet”.

1. Remove the under cover.

UBB006CA

Non-turbo models

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11-19

Maintenance and service

3. Loosen the radiator cap to drain the coolant from the radiator. Then drain the coolant from the reserve tank. Tighten the drain plug securely.

NOTE (Turbo models)

The cap (without tabs) on top of the radiator does not need to be removed. To add coolant, remove the cap (with tabs) on the coolant tank on top of the engine.

UBB104BA

Turbo models

2. Place a proper container under the drain plug and loosen the drain plug.

11-20

UBB007CB

Non-turbo models

1) Filler neck

2) Fill up to here

Maintenance and service

Turbo models

1) Filler neck

2) Fill up to here

USB518BB

4. Slowly pour the coolant and fill up to just below the filler neck, allowing enough room to add genuine SUBARU cooling system conditioner in the radiator. Add genuine SUBARU cooling system conditioner until the coolant level reaches the filler neck. Do not pour the coolant too quickly, as this may lead to insufficient air bleeding and trapped air in the system.

Coolant capacity (Guideline):

Non-turbo models:

MT. 7.2 US qt (6.8 liters, 6.0 Imp qt) AT. 7.1 US qt (6.7 liters, 5.9 Imp qt)

Turbo models:

MT. 8.1 US qt (7.7 liters, 6.8 Imp qt) AT. 8.0 US qt (7.6 liters, 6.7 Imp qt)

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11-21

Maintenance and service

FULL

LOW

UBB004FB

1) “FULL” level mark

2) “LOW” level mark

5. Pour the coolant and fill to the reservoir tank’s “FULL” level mark.

11-22

HSB026BB

1) Rubber gaskets

6. Put the radiator cap back on and tighten firmly. At this time, make sure that the rubber gasket in the radiator cap is correctly in place.

7. Start and run the engine for more than five minutes at 2,000 to 3,000 rpm.

8. Stop the engine and wait until the coolant cools down (122 to 140°F [50 to 60°C]). If there is any loss of coolant, add coolant to the radiator’s filler neck and to the reserve tank’s “FULL” level.

9. Put the radiator cap and reservoir cap back on and tighten firmly.

Maintenance and service

Air cleaner element

Do not operate the engine with the air cleaner element removed. The air cleaner element not only filters intake air but also stops flames if the engine backfires. If the air cleaner element is not installed when the engine backfires, you could be burned.

The air cleaner element functions as a filter screen. When the element is perforated or removed, engine wear will be excessive and engine life shortened.

The air cleaner element is a viscous type. It is unnecessary to clean or wash the element.

 Replacing the air cleaner element

Replacing Air clea ner element



T Non-turbo models

Replace the air cleaner element according to the maintenance schedule in the “Warranty and Maintenance Booklet”. Under extremely dusty conditions, replace it more frequently. It is recommended that you always use genuine SUBARU parts.

UBB063BB

1) Bolt

1. Remove the bolt securing the rear air cleaner element case.

2. Unsnap the three clamps holding the rear air cleaner element case.

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11-23

Maintenance and service

UBB064BB

1) Air cleaner element

3. Separate the rear air cleaner element case from the front air cleaner element case and remove the air cleaner element.

4. Clean the inside of the front and rear air cleaner element cases with a damp cloth and install a new air cleaner element.

5. Insert the four projections on the rear air cleaner element case into the slits on the front air cleaner element case and snap the three clamps on the rear air cleaner element case and then tighten the bolt.

T Turbo models

USB521BA

1. Unsnap the two clamps holding the air cleaner case cover.

11-24

Maintenance and service

USB522BB

1) Air cleaner case cover

2) Air cleaner element

2. Open the air cleaner case cover and remove the air cleaner element.

3. Clean the inside of the air cleaner cover and case with a damp cloth and install a new air cleaner element.

To install the air cleaner case cover, insert two projections on the air cleaner case into the slits on the air cleaner case cover and then snap the two clamps on the air cleaner case cover.

Spark plugs

y When disconnecting the spark plug cables, always grasp the spark plug cap, not the cables. y Make sure the cables are replaced in the correct order.

HSB032BA

It may be difficult to replace the spark plugs. It is recommended that you have the spark plugs replaced by your SUBARU dealer.

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11-25

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