2004 Subaru Impreza Owners Manual

2. Lower the hood until it approaches about 6 in. (15
cm) from the closed position and let it drop. WRX and WRX-STi: 1. Lift the hood slightly and remove the hood prop

11-6

from the slot in the hood and return the prop to its re- tainer. 2. Lower the hood until it approaches about 12 in. (30
cm) from the closed position and let it drop. 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

– CONTINUED – 11-7

Maintenance and service

Engine compartment overview ! 2.5 liter model

4 5

13

12

11

10

UGB505BB

11-8

1) Manual transmission oil level

gauge (MT) (page 11-28) or Dif- ferential gear oil level gauge (AT) (page 11-33)

2) Air cleaner element (page 11-

3) Clutch fluid reservoir (page 11-

4) Automatic transmission fluid lev-

el gauge (page 11-31)

5) Brake fluid reservoir (page 11-

6) Windshield washer tank (page

7) Fuse box (page 11-60) 8) Battery (page 11-58) 9) Engine oil filler cap (page 11-11) 10) Engine coolant reservoir (page

11) Radiator cap (page 11-19) 12) Engine oil level gauge (page 11-

23)

38)

37)

11-54)

11-19)

11)

13) Power steering fluid reservoir

(page 11-36)

! 2.0 liter (Turbo) model

3 4 5

13

12

11

10 9

HGB005CB

Maintenance and service

1) Manual transmission oil level

gauge (MT) (page 11-28) or Dif- ferential gear oil level gauge (AT) (page 11-33)

2) Air cleaner element (page 11-

3) Clutch fluid reservoir (page 11-

4) Automatic transmission fluid lev-

el gauge (page 11-31)

5) Brake fluid reservoir (page 11-

6) Windshield washer tank (page

7) Fuse box (page 11-60) 8) Battery (page 11-58) 9) Engine oil filler cap (page 11-11) 10) Engine coolant reservoir (page

11) Engine oil level gauge (page 11-

23)

38)

37)

11-54)

11-19)

11)

12) Radiator cap (page 11-19) 13) Power steering fluid reservoir

(page 11-36)

– CONTINUED – 11-9

Maintenance and service

! 2.5 liter (Turbo) model

12

11

10

UGB070BB

11-10

1) Manual transmission oil level

gauge (MT) (page 11-28)

2) Air cleaner element (page 11-

3) Clutch fluid reservoir (page 11-

4) Brake fluid reservoir (page 11-

5) Windshield washer tank (page

6) Fuse box (page 11-60) 7) Battery (page 11-58) 8) Engine oil filler cap (page 11-11) 9) Engine coolant reservoir (page

10) Engine oil level gauge (page 11-

11) Radiator cap (page 11-19) 12) Power steering fluid reservoir

(page 11-36)

23)

38)

37)

11-54)

11-19)

11)

Engine oil ! Checking the oil level Check the engine oil level at each fuel stop. 1. Park the vehicle on a level surface and stop the en- gine.

HGB056BA

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 appear- ing as shown in the illustration.

Maintenance and service

UGB081BB

2.5-liter turbo models 1) Notch 2) Upper level 3) Lower level

– CONTINUED – 11-11

Maintenance and service

UGB082BB

2.5-liter and 2.0-liter turbo models 1) Notch 2) Upper level 3) Lower level 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.

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

11-12

a bad smell, smoke, and/or a fire.

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. Just after driving or while the engine is warm, the en- gine oil level reading may be in a range between the upper level and the notch mark. This is caused by ther- mal expansion of the engine oil. To prevent overfilling the engine oil, do not add any additional oil above the upper level when the engine is cold.

! Changing the oil and oil filter Change the oil and oil filter according to the mainte- nance schedule in the “Warranty and Maintenance Booklet”. The engine oil and oil filter must be changed more fre- quently 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 about 10 minutes to ease draining the engine oil. 2. Park the vehicle on a level surface and stop the en- gine.

3. Remove the oil filler cap.

Maintenance and service

2.5-liter turbo models

UGB071BA

2.0-liter turbo models

UGB085BA

– CONTINUED – 11-13

Maintenance and service

washer after the oil has completely drained out. 6. Remove under cover (For turbo).

Turbo models

UGB083BA

UGB057DA

Non-turbo models 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 oil.

5. Wipe the seating surface of the drain plug with a clean cloth and tighten it securely with a new sealing

11-14

Maintenance and service

Never over tighten the oil filter because that can result in an oil leak.

11.Reinstall under cover (For Turbo). 12.Pour engine oil through the filler neck.

Oil capacity (guideline):

Non-turbo models:

4.2 US qt (4.0 liters, 3.5 Imp qt)

Turbo models:

4.8 US qt (4.5 liters, 4.0 Imp qt)

The oil quantity indicated above is only 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 the dipstick to con- firm that the level is correct. 13.Start the engine and make sure that no oil leaks ap- pear around the filter’s rubber seal and drain plug. 14.Run the engine until it reaches the normal operat- ing temperature. Then stop the engine and wait a few minutes to allow the oil drain back. Check the oil level

– CONTINUED – 11-15

UGB057EA

Non-turbo models 7. Remove the oil filter with an oil filter wrench. 8. Before installing a new oil filter, apply a thin coat of engine oil to the seal. 9. Clean the rubber seal seating area of the lower crank case/oil cooler (For Turbo) and install the oil fil- ter by hand turning. Be careful not to twist or damage the seal. 10.Tighten it approximately two-thirds of a turn after the seal makes contact with the lower crank case/oil cooler (For Turbo).

1

A PI S E RVICE

SAE

5W 30

GY CO N S E

R VIN

HSB022BB

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

Maintenance and service

again and if necessary, add more engine oil.

Be careful not to spill engine oil when adding it. If oil touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire.

! Recommended grade and viscosity

Oil grade:

ILSAC GF-3, which can be identified with the new API certification mark (Starburst mark) or API classification SL with the words “ENERGY CONSERVING” (if you cannot obtain the oil with SL grade, you may use SJ grade “ENERGY CON- SERVING” oil).

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

11-16

Maintenance and service

-30 -20 -10

10 20 30 40

-20

20

40

60

80 100

5W-30*

10W-30, 10W-40

HSB023AA

UGB084BA

PE T R

L E UM

IN IT

AN IC

CERTIF I

New API Certification Mark (Starburst Mark) In choosing an oil, you want the proper quality and vis- cosity, 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 togeth- er as long as they are the same API classification and SAE viscosity as those recommended by SUBARU.

SAE viscosity number 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 re- quired to properly lubricate the engine.

Use only engine oil with the recommended grade and viscosity.

– CONTINUED – 11-17

Maintenance and service

! Recommended grade and viscosity

under severe driving conditions

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

API classification SL (or SJ):

SAE viscosity No.: 30, 40, 10W-50, 20W-40, 20W-50

! Synthetic oil You can use synthetic engine oil that meets the same requirements given for conventional engine oil. When using synthetic oil, you must use oil of the same clas- sification, viscosity and grade shown in this owner’s manual, and must follow the oil and filter changing in- tervals shown in the maintenance schedule.

11-18

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 re- moved.

" The cooling system has been filled at the fac- tory 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 dif- ferent kinds of coolant. " Do not splash the engine coolant over paint-

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

! Engine coolant ! Checking the coolant level

Maintenance and service

! Cooling fan, 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 recom- mended that the cooling system and connections be checked for leaks, damage, or looseness.

FULL

LOW

HGB056CB

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 reser- voir 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 re- fill as required.

– CONTINUED – 11-19

Maintenance and service

coolant may damage the paint surface.

! Changing the coolant

HSB026BB

1) Rubber gaskets 3. After refilling the reserve tank and the radiator, re- install the caps and check that the rubber gaskets in- side the radiator cap are in the proper position.

" 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. " Do not splash the engine coolant over paint- ed parts. The alcohol contained in the engine

11-20

HSB027BB

1) Drain plug Change the engine coolant using the following proce- dures according to the maintenance schedule. 1. Remove the under cover. 2. Place a proper container under the drain plug and loosen the drain plug. 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.

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 re- moved.

4. Install the under cover.

UGB508BB

Non-turbo models 1) Filler neck 2) Fill up to this level

Maintenance and service

USB518BB

Turbo models 1) Filler neck 2) Fill up to this level 5. Slowly pour the coolant and fill to the radiator filler neck. Do not pour the coolant too quickly, as this may lead to insufficient air bleeding and trapped air in the system.

– CONTINUED – 11-21

Maintenance and service

Guideline of coolant quantity (including coolant in reservoir tank):

Non-turbo models:

MT. 7.4 US qt (7.0 liters, 6.2 Imp qt) AT. 7.3 US qt (6.9 liters, 6.1 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)

" 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. " Do not splash the engine coolant over paint- ed parts. The alcohol contained in the engine coolant may damage the paint surface.

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

FULL

LOW

1) “FULL” level mark 2) “LOW” level mark

HGB056CB

1) Rubber gaskets

HSB026BB

11-22

7. Put the radiator cap back on and tighten firmly. At this time, make sure that the rubber gasket in the radi- ator cap is correctly in place. 8. Start and run the engine for more than five minutes at 2,000 to 3,000 rpm. 9. 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. 10.Put the radiator cap and reservoir cap back on and tighten firmly.

Maintenance and service

Air cleaner element 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 unnec- essary to clean or wash the 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.

! Replacing the air cleaner element ! Non-turbo models Replace the air cleaner element according to the maintenance schedule in the “Warranty and Mainte- nance Booklet”. Under extremely dusty conditions, re- place it more frequently. It is recommended that you always use genuine SUBARU parts.

– CONTINUED – 11-23

Maintenance and service

HSB030BB

1) Bolt 1. Remove the bolt securing the rear air cleaner ele- ment case. 2. Unsnap the three clamps holding the rear air clean- er element case.

11-24

HSB031BB

1) Air cleaner element 3. Separate the rear air cleaner element case from the front cleaner element case and remove the air cleaner element. 4. Clean the inside of the front and rear air cleaner el- ement cases with a damp cloth and install a new air cleaner element. 5. Insert the four projections on the rear air cleaner el- ement case into the slits on the front air cleaner ele- ment case and snap the three clamps on the rear air cleaner element case and then tighten the bolt.

! Turbo models

Maintenance and service

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

USB521BA

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 ele- ment.

– CONTINUED – 11-25

Maintenance and service

Spark plugs

USB523BA

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

11-26

HSB032BA

It may be difficult to replace the spark plugs. It is rec- ommended that you have the spark plugs replaced by your SUBARU dealer. The spark plugs should be replaced according to the maintenance schedule in the “Warranty and Mainte- nance Booklet”.

" When disconnecting the spark plug cables, always grasp the spark plug cap, not the ca-

bles. " Make sure the cables are replaced in the cor- rect order.

Drive belts

Maintenance and service

! Recommended spark plugs

Non-turbo models:

RC10YC4 (Champion) BKR6E-11 (NGK) BKR5E-11 (NGK) 2.0-liter turbo models:

PFR6G (NGK)

2.5-liter turbo models:

IFLR6B (NGK)

HSB033BB

1) Power steering pump pulley 2) Air conditioner compressor pulley 3) Crank pulley The alternator, power steering pump, and air condi- tioner compressor depend on drive belts. Satisfactory performance requires that belt tension be correct. To check belt tension, place a straightedge (ruler) across two adjacent pulleys and apply a force of 22 lb (98 N, 10 kg) midway between the pulleys by using a spring scale. Belt deflection should be the amount specified. If a belt is loose, cracked, or worn, contact – CONTINUED – 11-27

in (mm)

Manual transmission oil ! Checking the oil level

5 speed transmission (Non-turbo model) 1) Yellow handle

HGB056DB

Maintenance and service

your SUBARU dealer.

Deflection

New belt

Used belt

0.28 — 0.35 (7.0 — 9.0) 0.35 — 0.43 (9.0 — 11.0)

0.30 — 0.33 (7.5 — 8.5) 0.35 — 0.40 (9.0 — 10.0)

11-28

Maintenance and service

5 speed transmission (Turbo model)

HGB055BA

UGB548CA

6 speed transmission 1. Park the vehicle on a level surface and stop the en- gine. 2. Pull out the dipstick, wipe it clean, and insert it again.

– CONTINUED – 11-29

Maintenance and service

-30 -20 -10

10

20

30

40

-20

20

40

60

80

100

90

85W

80W

75W/90

USB526BB

HSB036BA

SAE viscosity No. and Applicable Temperature

1) Upper level 2) Lower level 3. Pull out the dipstick again and check the oil level on it. If it is below the lower level, add oil through the dip- stick hole to bring the level up to the upper level.

! Recommended grade and viscosity Each oil manufacturer has its own base oils and addi- tives. Never use different brands together.

Oil grade:

API classification GL-5

11-30

Automatic transmission fluid ! Checking the fluid level The automatic transmission fluid expands largely as its temperature rises; the fluid level differs according to fluid temperature. Therefore, there are two different scales for checking the level of hot fluid and cold fluid on the dipstick. Though the fluid level can be checked without warm- ing up the fluid on the “COLD” range, we recommend checking the fluid level when the fluid is at operating temperature. ! Checking the fluid level when the fluid is hot 1. Drive the vehicle several miles to raise the temper- ature of the transmission fluid up to normal operating temperature; 158 to 176°F (70 to 80°C) is normal. 2. Park the vehicle on a level surface and set the park- ing brake. 3. First shift the selector lever in each position. Then shift it in the “P” position, and run the engine at idling speed.

1) Yellow handle

Maintenance and service

HGB056JB

– CONTINUED – 11-31

fluid up to the upper level. Be careful not to overfill.

! Recommended fluid

“Dexron III” Type Automatic Transmission Fluid

Maintenance and service

HGB061BB

A) HOT range B) COLD range 1) Upper level 2) Lower level 4. Pull out the dipstick and check the fluid level on the gauge. If it is below the lower level on the “HOT” range, add the recommended automatic transmission fluid up to the upper level. ! Checking the fluid level when the fluid is cold When the fluid level has to be checked without time to warm up the automatic transmission, check to see that the fluid level is between the lower level and upper lev- el on the “COLD” range. If it is below that range, add

11-32

Front differential gear oil (AT vehi- cles) ! Checking the oil level

HGB056FB

1) Yellow handle 1. Park the vehicle on a level surface and stop the en- gine. 2. Pull out the dipstick, wipe it clean, and insert it again.

Maintenance and service

HSB040BB

1) Upper level 2) Lower level 3. 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.

! Recommended grade and viscosity Each oil manufacturer has its own base oils and addi- tives. Never use different brands together.

Oil grade:

API classification GL-5

– CONTINUED – 11-33

Maintenance and service

-30

-20 -10

10 20 30 40

-20

20 40

60

80 100

90

85W

80W

80W/90

SAE viscosity No. and Applicable Temperature

HSB041AA

Rear differential gear oil ! Checking the gear oil level Your vehicle may be equipped with a rear differential protector. The differential protector provides protec- tion to the rear differential assembly during off-road use. Removal of the rear differential protector is not re- quired when checking the oil level.

HSB042BB

1) Filler plug 2) Drain plug

11-34

Maintenance and service

er.

! Recommended grade and viscosity Each oil manufacturer has its own base oils and addi- tives. Never use different brands together.

Oil grade:

API classification GL-5

HSB043BB

-30 -20 -10

10

20

30

40

1) Filler hole 2) Drain hole 3) Oil level Remove the plug from the filler hole and check the oil level. The oil level should be kept even with the bottom of the filler hole. If the oil level is below the bottom edge of the hole, add oil through the filler hole to raise the level.

If the vehicle requires frequent refilling, there may be an oil leak. If you suspect a problem, have the vehicle checked at your SUBARU deal-

-20

20

40

60

80

100

90

85W

80W

75W/90

SAE viscosity No. and Applicable Temperature

HSB036BA

– CONTINUED – 11-35

Maintenance and service

Power steering fluid ! Checking the fluid level

HSB045BB

1) Specified range 2. Check the fluid level of the reservoir tank. When the fluid is hot after the vehicle has been run: Check that the oil level is between “HOT MIN” and “HOT MAX” on the surface of the reservoir tank. When the fluid is cool before the vehicle is run: Check that the oil level is between “COLD MIN” and “COLD MAX” on the surface of the reservoir tank. 3. If the fluid level is lower than the applicable “MIN” line, add the recommended fluid as necessary to bring the level between the “MIN” and “MAX” line. If the fluid level is extreme low, it may indicate possible leakage. Consult your SUBARU dealer for inspection.

HGB058BB

1) Reservoir tank The power steering fluid expands greatly as its tem- perature rises; the fluid level differs according to fluid temperature. Therefore, the reservoir tank has two dif- ferent checking ranges for hot and cold fluids. Check the power steering fluid level monthly. 1. Park the vehicle on a level surface, and stop the en- gine.

11-36

Be careful not to burn yourself because the flu- id may be hot.

" When power steering fluid is being added, use only clean fluid, and be careful not to allow any dirt into the tank. And never use different brands together. " Avoid spilling fluid when adding it in the tank.

! Recommended fluid

“Dexron III” Type Automatic Transmission Fluid

Maintenance and service

Brake fluid ! Checking the fluid level

MAXMAX

MINMIN

HGB056GB

1) “MAX” level mark 2) “MIN” level mark Check the fluid level monthly. Check the fluid level on the outside of the reservoir. If the level is below “MIN”, add the recommended brake fluid to “MAX”. Use only brake fluid from a sealed container.

– CONTINUED – 11-37

Clutch fluid (MT vehicles) ! Checking the fluid level

1) “MAX” level mark 2) “MIN” level mark

MAX M IN

HGB056HB

Maintenance and service

" Brake fluid absorbs moisture from the air. Any absorbed moisture can cause a dangerous loss of braking performance. " If the vehicle requires frequent refilling, there may be a leak. If you suspect a problem, have the vehicle checked at your SUBARU dealer.

" Never use different brands of brake fluid to- gether. " When adding brake fluid, be careful not to al- low any dirt into the reservoir. " Never splash the brake fluid over painted sur- faces or rubber parts. Alcohol contained in the brake fluid may damage them.

! Recommended brake fluid

FMVSS No. 116, fresh DOT 3 brake fluid

11-38

MAX

MIN

HGB055CB

1) “MAX” level mark 2) “MIN” level mark Check the fluid level on the outside of the reservoir. If the level is below “MIN” level mark, add the recom- mended clutch fluid to “MAX” level mark. Use only clutch fluid from a sealed container.

" Clutch fluid absorbs moisture from the air. Any absorbed moisture can cause improper clutch operation. " If the vehicle requires frequent refilling, there may be a leak. If you suspect a problem, have

Maintenance and service

the vehicle checked at your SUBARU dealer. " Never use different brands of clutch fluid to- gether. " When clutch fluid is added, be careful not to allow any dirt into the tank.

! Recommended clutch fluid

FMVSS No. 116, fresh DOT 3 brake fluid

– CONTINUED – 11-39

Maintenance and service

Brake booster If the brake booster does not operate as described be- low, have it checked by your SUBARU dealer. 1. With the engine off, depress the brake pedal sever- al times, applying the same pedal force each time. The distance the pedal travels should not vary. 2. With the brake pedal depressed, start the engine. The pedal should move slightly down to the floor. 3. With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds. The pedal height should not change. 4. Start the engine again and run for about one minute then turn it off. Depress the brake pedal several times to check the brake booster. Brake booster operates properly if the pedal stroke decreases with each de- pression.

11-40

Brake pedal Check the brake pedal free play and reserve distance according to the maintenance schedule in the “War- ranty and Maintenance Booklet”.

! Checking the brake pedal free play

HSB049BB

1) 0.04 – 0.12 in (1.0 – 3.0 mm) Stop the engine and firmly depress the brake pedal several times. Lightly press the brake pedal down with one finger to check the free play with a force of less than 2 lb (10 N, 1 kg). If the free play is not within proper specification, con-

tact your SUBARU dealer.

! Checking the brake pedal reserve dis-

tance

HSB050BB

1) More than 2.56 in (65 mm) Depress the pedal with a force of approximately 66 lb (294 N, 30 kg) and measure the distance between the upper surface of the pedal pad and the floor. When the measurement is smaller than the specifica- tion, or when the pedal does not operate smoothly, contact with your SUBARU dealer.

Maintenance and service

Clutch pedal (MT vehicles) Check the clutch pedal free play and reserve distance according to the maintenance schedule in the “War- ranty and Maintenance Booklet”.

! Checking the clutch function Check the clutch engagement and disengagement. 1. With the engine idling, check that there are no ab- normal noises when the clutch pedal is depressed, and that shifting into 1st or reverse feels smooth. 2. Start the vehicle by releasing the pedal slowly to check that the engine and transmission smoothly cou- ple without any sign of slippage.

– CONTINUED – 11-41

Maintenance and service

! Checking the clutch pedal free play

Replacement of brake pad and lining

HSB049BB

1) 0.16 – 0.51 in (4.0 –13.0 mm) Lightly press the clutch pedal down with your finger until you feel resistance, and check the free play. If the free play is not within proper specification, con- tact your SUBARU dealer.

11-42

HS7012BA

The front disc brakes and the right rear disc brake have an audible wear indicators on the brake pads. If the brake pads wear close to their service limit, the wear indicator makes a very audible scraping noise when the brake pedal is applied. If you hear this scraping noise each time you apply the brake pedal, have the brake pads serviced by your SUBARU dealer as soon as possible.

If you continue to drive despite the scraping noise from the audible brake pad wear indica- tor, it will result in the need for costly brake ro- tor repair or replacement.

! Breaking-in of new brake pads and lin-

ings

When replacing the brake pad or lining, use only gen- uine SUBARU parts. After replacement, the new parts must be broken in as follows: ! Brake pad and lining While maintaining a speed of 30 to 40 mph (50 to 65
km/h), step on the brake pedal lightly. Repeat this five or more times. ! Parking brake lining 1. Drive the vehicle at a speed of about 22 mph (35
km/h). 2. With the parking brake release button pushed in, pull the parking brake lever SLOWLY and GENTLY. (Pulling with a force of approximately 33 lb [147 N, 15
kg].) 3. Drive the vehicle for about 220 yards (200 meters)

Maintenance and service

in this condition. 4. Wait 5 to 10 minutes for the parking brake to cool down. Repeat this procedure. 5. Check the parking brake stroke. If the parking brake stroke is out of the specified range, adjust it by turning the adjusting nut located on the parking brake lever.

Parking brake stroke:

7 – 8 notches / 44 lb (196 N, 20 kg)

A safe location and situation should be select- ed for break-in driving.

Pulling the parking brake lever too forcefully may cause the rear wheels to lock. To avoid this, be certain to pull the lever up slowly and gently.

– CONTINUED – 11-43

Maintenance and service

Parking brake stroke

UG7509CA

Check the parking brake stroke according to the main- tenance schedule in the “Warranty and Maintenance Booklet”. When the parking brake is properly adjusted, braking power is fully applied by pulling the lever up seven to eight notches gently but firmly (about 44 lb, 196 N, 20 kg). If the parking brake lever stroke is not within the specified range, have the brake system checked and adjusted at your SUBARU dealer.

11-44

Tires and wheels ! Types of tires You should be familiar with type of tires present on your vehicle. The factory-fitted 17-inch tires on the WRX-STi are summer tires. The factory-fitted tires on other versions are all-season tires. The 17-inch tires that can be deal- er-fitted on the WRX as an option are summer tires. ! All season tires All season tires are designed to provide an adequate measure of traction, handling and braking perfor- mance in year-round driving including snowy and icy road conditions. However all season tires do not offer as much traction performance as winter (snow) tires in heavy or loose snow or on icy roads. All season tires are identified by “ALL SEASON” and/ or “M+S” (Mud & Snow) on the tire sidewall. ! Summer tires Summer tires are high-speed capability tires best suit- ed for highway driving under dry conditions. Summer tires are inadequate for driving on slippery roads such as on snow-covered or icy roads. If you drive your vehicle on snow-covered or icy roads, we strongly recommend the use of winter (snow) tires.

When installing winter tires, be sure to replace all four tires. ! Winter (snow) tires Winter tires are best suited for driving on snow-cov- ered and icy roads. However winter tires do not per- form as well as summer tires and all season tires on roads other than snow-covered and icy roads.

! Tire inspection Check on a daily basis that the tires are free from se- rious damage, nails, and stones. At the same time, check the tires for abnormal wear. Contact your SUBARU dealer immediately if you find any problem. NOTE " When the wheels and tires strike curbs or are subjected to harsh treatment as when the vehicle is driven on a rough surface, they can suffer dam- age that cannot be seen with the naked eye. This type of damage does not become evident until time has passed. Try not to drive over curbs, pot- holes or on other rough surfaces. If doing so is un- avoidable, keep the vehicle’s speed down to a walking pace or less, and approach the curbs as squarely as possible. Also, make sure the tires are

Maintenance and service

not pressed against the curb when you park the vehicle. " If you feel unusual vibration while driving or find it difficult to steer the vehicle in a straight line, one of the tires and/or wheels may be damaged. Drive slowly to the nearest authorized SUBARU dealer and have the vehicle inspected.

! Tire pressures and wear Maintaining the correct tire pressures helps to maxi- mize the tires’ service lives and is essential for good running performance. Check and, if necessary, adjust the pressure of each tire (including the spare) at least once a month (for example, during a fuel stop) and be- fore any long journey.

– CONTINUED – 11-45

NOTE " The air pressure in a tire increases by approxi- mately 4.3 psi (30 kPa, 0.3 kg/cm2) when the tire becomes warm. " The tires are considered cold when the vehicle has been parked for at least three hours or has been driven less than one mile (1.6 km).

Do not let air out of warm tires to adjust press- rue. Doing so will result in low tire pressure.

Incorrect tire pressures detract from controllability and ride comfort, and they cause the tires to wear abnor- mally.

Maintenance and service

UGB510BA

Check the tire pressures when the tires are cold. Use a pressure gauge to adjust the tire pressures to the values shown on the tire placard. The tire placard is lo- cated on the door pillar on the driver’s side. Driving even a short distance warms up the tires and increases the tire pressures. Also, the tire pressures are affected by the ambient temperature. It is best to check tire pressure outdoors before driving the vehi- cle. When a tire becomes warm, the air inside it expands, causing the tire pressure to increase. Be careful not to mistakenly release air from a warm tire to reduce its pressure.

11-46

" Correct tire pressure (tread worn evenly)

" Abnormally low tire pressure (tread worn at shoulders)

Maintenance and service

Roadholding is good, and steering is responsive. Roll- ing resistance is low, so fuel consumption is also low- er.

HSB052AA

Rolling resistance is high, so fuel consumption is also higher.

HSB053AA

– CONTINUED – 11-47

Maintenance and service

" Abnormally high tire pressure (tread worn in cen- ter)

HSB054AA

Ride comfort is poor. Also, the tire magnifies the ef- fects of road-surface bumps and dips, possibly result- ing in vehicle damage. If the tire placard shows tire pressures for the vehicle when fully loaded and for the vehicle when towing a trailer, adjust the tire pressures to the values that match current loading conditions.

Driving at high speeds with excessively low tire pressures can cause the tires to deform severe-

11-48

ly and to rapidly become hot. A sharp increase in temperature could cause tread separation, and destruction of the tires. The resulting loss of vehicle control could lead to an accident.

! Wheel balance Each wheel was correctly balanced when your vehicle was new, but the wheels will become unbalanced as the tires become worn during use. Wheel imbalance causes the steering wheel to vibrate slightly at certain vehicle speeds and detracts from the vehicle’s straight-line stability. It can also cause steering and suspension system problems and abnormal tire wear. If you suspect that the wheels are not correctly bal- anced, have them checked and adjusted by your SUB- ARU dealer. Also have them adjusted after tire repairs and after tire rotation. NOTE Loss of correct wheel alignment* causes the tires to wear on one side and reduces the vehicle’s run- ning stability. Contact your SUBARU dealer if you notice abnormal tire wear. *: The suspension system is designed to hold each wheel at a certain alignment (relative to the other wheels and to the road) for optimum straight-line stability and cornering perfor-

mance.

! Wear indicators

HSB055BB

A) New tread B) Worn tread 1) Tread wear indicator Each tire incorporates a tread wear indicator, which becomes visible when the depth of the tread grooves decreases to 0.063 in. (1.6 mm). A tire must be re- placed when the tread wear indicator appears as a solid band across the tread.

Maintenance and service

When a tire’s tread wear indicator becomes vis- ible, the tire is worn beyond the acceptable limit and must be replaced immediately. With a tire in this condition, driving at high speeds in wet weather can cause the vehicle to hydroplane. The resulting loss of vehicle control can lead to an accident.

NOTE For safety, inspect tire tread regularly and replace the tires before their tread wear indicators become visible.

– CONTINUED – 11-49

Maintenance and service

! Tire rotation

HSB056BA

Tire wear varies from wheel to wheel. To maximize the life of each tire and ensure that the tires wear uniform- ly, it is best to rotate the tires every 7,500 miles (12,500 km). Rotating the tires involves switching the front and rear tires on the right-hand side of the vehicle and similarly switching the front and rear tires on the left-hand side of the vehicle. (Each tire must be kept on its original side of the vehicle.) Replace any damaged or unevenly worn tire at the time of rotation. After tire rotation, adjust the tire pres- sures and make sure the wheel nuts are correctly tightened.

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After driving approximately 600 miles (1,000 km), check the wheel nuts again and retighten any nut that has become loose.

! Tire replacement The wheels and tires are important and integral parts of your vehicle’s design; they cannot be changed arbi- trarily. The tires fitted as standard equipment are opti- mally matched to the characteristics of the vehicle and were selected to give the best possible combination of running performance, ride comfort, and service life. It is essential for every tire to have a size and construc- tion matching those shown on the tire placard and to have a speed symbol and load index matching those shown on the tire placard. Using tires of a non-specified size detracts from con- trollability, ride comfort, braking performance, speed- ometer accuracy and odometer accuracy. It also cre- ates incorrect body-to-tire clearances and inappropri- ately changes the vehicle’s ground clearance. All four tires must be the same in terms of manufactur- er, brand (tread pattern), construction, and size. You are advised to replace the tires with new ones that are identical to those fitted as standard equipment. For safe vehicle operation, SUBARU recommends re-

placing all four tires at the same time. NOTE

HGB062BA

Unidirectional tires: Some tires have a specified direction of rotation. A tire of this type has an ar- row or other mark on its side wall to indicate the direction of rotation. Install it so that the direction of rotation is correct when the vehicle is driven forward.

" All four tires must be the same in terms of manufacturer, brand (tread pattern), construc- tion, degree of wear, speed symbol, load index

Maintenance and service

and size. Mixing tires of different types, sizes or degrees of wear can result in damage to vehi- cle’s power train. Use of different types or sizes of tires can also dangerously reduce controlla- bility and braking performance and can lead to an accident. " Use only radial tires. Do not use radial tires together with belted bias tires and/or bias-ply tires. Doing so can dangerously reduce control- lability, resulting in an accident.

! Wheel replacement When replacing wheels due, for example, to damage, make sure the replacement wheels match the specifi- cations of the wheels that are fitted as standard equip- ment. Replacement wheels are available from SUBA- RU dealers.

Use only those wheels that are specified for your vehicle. Wheels not meeting specifica- tions could interfere with brake caliper opera- tion and may cause the tires to rub against the wheel well housing during turns. The resulting loss of vehicle control could lead to an acci- – CONTINUED – 11-51

Maintenance and service

dent.

! Installing the wheel cover

! Wheel covers ! Removing the wheel cover

UGB512BA

Align the valve with the valve hole in the cover, then fit the cover on the wheel by tapping your hand evenly around the circumference of the cover. NOTE When any of the wheels is removed and replaced for tire rotation or to change a flat tire, always check the tightness of the wheel nuts after driving approximately 600 miles (1,000 km). If any nut is loose, tighten it to the specified torque.

Insert the wheel cover remover into the notch provid- ed, and pry the wheel cover off.

UG9506BA

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Aluminum wheels (If equipped) Aluminum wheels can be scratched and damaged easily. Handle them carefully to maintain their appear- ance, performance, and safety. " When any of the wheels is removed and replaced for tire rotation or to change a flat, always check the tightness of the wheel nuts after driving approximately 600 miles (1,000 km). If any nut is loose, tighten it to the specified torque. " Never apply oil to the threaded parts, wheel nuts, or tapered surface of the wheel. " Never let the wheel rub against sharp protrusions or curbs. " Be sure to fit tire chains on uniformly and completely around the tire, otherwise the chains may scratch the wheel. " When wheel nuts, balance weights, or the center cap is replaced, be sure to replace them with genuine SUBARU parts designed for aluminum wheels.

Maintenance and service

Intercooler water spray

UGB079BA

Add water to the intercooler water spray tank when the intercooler water spray warning light in the combina- tion meter comes on. The warning light comes on when the water in the tank has decreased to approxi- mately 0.4 liters (0.4 US qt, 0.4 Imp qt).

– CONTINUED – 11-53

Maintenance and service

Windshield washer fluid

UGB514BA

The tank is located on the right-hand side of the trunk. NOTE " Use only pure water for refilling. " In cold weather (when you do not use the inter- cooler water spray), keep the tank half-empty in case the water freezes. A larger amount of water could break the tank if it froze.

11-54

HGB056IA

Check the level of the washer fluid at each fuel stop. If the level is low, fill the fluid up to the neck of the reser- voir. Use windshield washer fluid. If windshield washer fluid is unavailable use clean water. In areas where water freezes in winter, use an anti- freeze type windshield washer fluid. SUBARU Wind- shield Washer Fluid contains 58.5% methyl alcohol and 41.5% surfactant, by volume. Its freezing temper- ature varies according to how much it is diluted, as in- dicated below.

Washer Fluid Concentration

Freezing Temperature

30% 50% 100%

10.4°F (–12°C) –4°F (–20°C) –49°F (–45°C)

Never use engine coolant as washer fluid be- cause it could cause paint damage.

Maintenance and service

Replacement of windshield wiper blades Grease, wax, insects, or other material on the wind- shield or the wiper blade results in jerky wiper opera- tion and streaking on the glass. If you cannot remove the streaks after operating the windshield washer or if the wiper operation is jerky, clean the outer surface of the windshield (or rear window) and the wiper blades using a sponge or soft cloth with a neutral detergent or mild-abrasive cleaner. After cleaning, rinse the wind- shield and wiper blades with clean water. The wind- shield is clean if beads do not form when you rinse the windshield with water.

Do not clean the wiper blades with gasoline or a solvent, such as paint thinner or benzene. This will cause deterioration of the wiper blades.

If you cannot eliminate the streaking even after follow- ing this method, replace the wiper blades using the fol- lowing procedures: 1. Raise the wiper arm off the windshield.

– CONTINUED – 11-55

Maintenance and service

HSB058CB

HSB059BB

1) Stopper 2. Remove the wiper blade assembly by holding its pivot area and pushing it in the direction shown by the arrow while depressing the wiper blade stopper.

1) Metal support 3. Grasp the locked end of the blade rubber assembly and pull it firmly until the stoppers on the rubber are free of the metal support.

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Maintenance and service

HSB060BB

HSB061BA

1) Metal spines 4. If the new blade rubber is not provided with two metal spines, remove the metal spines from the old blade rubber and install them in the new blade rubber.

5. Align the claws of the metal support with the grooves in the rubber and slide the blade rubber as- sembly into the metal support until it locks.

– CONTINUED – 11-57

Maintenance and service

HSB062BB

1) Stopper Be sure to position the claws at the end of the metal support between the stoppers on the rubber as shown. If the rubber is not retained properly, the wiper blade may scratch the windshield. 6. Install the wiper blade assembly to the wiper arm. Make sure that it locks in place. 7. Hold the wiper arm by hand and slowly lower it in position.

11-58

Battery

" Before beginning work on or near any bat- tery, be sure to extinguish all cigarettes, match- es, and lighters. Never expose a battery to an open flame or electric sparks. Batteries give off a gas which is highly flammable and explosive. " For safety, in case an explosion does occur, wear eye protection or shield your eyes when working near any battery. Never lean over a bat- tery. " Do not let battery fluid contact eyes, skin, fabrics, or paint because battery fluid is a cor- rosive acid. If battery fluid gets on your skin or in your eyes, immediately flush the area with water thoroughly. Seek medical help immedi- ately if acid has entered the eyes. If battery fluid is accidentally swallowed, imme- diately drink a large amount of milk or water, and seek medical attention immediately. " To lessen the risk of sparks, remove rings, metal watchbands, and other metal jewelry. Never allow metal tools to contact the positive battery terminal and anything connected to it WHILE you are at the same time in contact with

any other metallic portion of the vehicle be- cause a short circuit will result. " Keep everyone including children away from the battery. " Charge the battery in a well-ventilated area. " Battery posts, terminals and related accesso- ries contain lead and lead compounds, chemi- cals known to the State of California to cause cancer and reproductive harm. Wash hands af- ter handling.

Maintenance and service

It is unnecessary to periodically check the battery fluid level or periodically refill with distilled water. However, if the battery fluid level is below the lower level, remove the cap. Fill to the upper level with dis- tilled water.

Never use more than 10 amperes when charg- ing the battery because it will shorten battery life.

HSB063BB

U P P E R L E V E L U P P E R L E V E L L OW E R L E V E L W E R L E V E L

1) Cap 2) Upper level 3) Lower level

– CONTINUED – 11-59

Maintenance and service

Fuses

Never replace a fuse with one having a higher rating or with material other than a fuse be- cause serious damage or a fire could result.

The fuses are designed to melt during an overload to prevent damage to the wiring harness and electrical equipment. The fuses are located in two fuse boxes.

One is located under the instrument panel behind the coin tray on the driver’s seat side.

UGB547BA

11-60

To remove the coin tray, open the cover and pull the coin tray out.

UGB550BA

Maintenance and service

HSB065BA

HSB066BB

The other one is housed in the engine compartment.

1) Fuse puller 2) Spare fuse The fuse puller and spare fuses are stored in the main fuse box cover in the engine compartment.

– CONTINUED – 11-61

Maintenance and service

HSB067BB

HSB068BB

1) Fuse puller 4. Pull out the fuse with the fuse puller. 5. Inspect the fuse. If it has blown, replace it with a spare fuse of the same rating. 6. If the same fuse blows again, this indicates that its system has a problem. Contact your SUBARU dealer for repairs.

A) Good B) Blown If any lights, accessories or other electrical controls do not operate, inspect the corresponding fuse. If a fuse has blown, replace it. 1. Turn the ignition switch to the “LOCK” position and turn off all electrical accessories. 2. Remove the cover. 3. Determine which fuse may be blown. The back side of each fuse box cover and the “Fuses and circuits” section in chapter 12 in this manual show the circuit for each fuse.

11-62

Main fuse

Maintenance and service

Installation of accessories Always consult your SUBARU dealer before installing fog lights or any other electrical equipment in your ve- hicle. Such accessories may cause the electronic sys- tem to malfunction if they are incorrectly installed or if they are not suited for the vehicle.

HSB065BA

Main fuse box The main fuses are designed to melt during an over- load to prevent damage to the wiring harness and electrical equipment. Check the main fuses if any elec- trical component fails to operate (except the starter motor) and other fuses are good. A melted main fuse must be replaced. Use only replacements with the same specified rating as the melted main fuse. If a main fuse blows after it is replaced, have the electrical system checked by your nearest SUBARU dealer.

– CONTINUED – 11-63

Maintenance and service

Replacing bulbs

10 11

15

14 13 12

14 16

15

10

11

UGB075BB

11-64

Maintenance and service

16) Cargo area light

Wattage 12V–13W —

Bulb No.

Bulb No.

Wattage 12V–21W — 12V–8W — — 12V–8W 12V–5W 168

1) Front turn signal 2) Spot light 3) Room light 4) Parking light 5) Low beam head light

U.S. spec. WRX-STi 12V-35W Except U.S. spec. 12V-55W WRX-STi

6) Front fog light 12V–55W 7) High beam head light 12V–60W

8) Trunk room light 9) High mount stop light

12V–16W

D2R H1

H3
9005
(HB3) W16W

Sedan (in compartment) (in rear spoiler) Wagon

10) Backup light 11) Rear turn signal

12) Brake light 13) Tail light 14) Brake/tail light 15) License plate light

12V–18W 921
12V–1.2W — 912
12V–13W 7440
12V–21W 12V–21W — (Amber) 12V–21W 7440
12V–21/5W 7443
12V–21/5W 7443
12V–5W 168

– CONTINUED – 11-65

Maintenance and service

! Headlights (U.S. spec. WRX-STi)

High-intensity-discharge (HID) bulbs are used for the low beams of the headlights on the U.S. spec. WRX-STi. These HID bulbs use an ex- tremely high voltage. To avoid the risk of an electric shock and resulting serious injury, you should not attempt to replace them. Neither should you attempt to replace the high-beam bulbs, remove/refit the headlight assemblies, or remove any headlight-assembly compo- nents. For replacement of the headlight bulbs (low-beam and high-beam), removal and instal- lation of the headlight assemblies, and removal of headlight-assembly components, contact your Subaru dealer.

! Headlight (Except U.S. spec. WRX-STi)

Halogen headlight bulbs become very hot while in use. If you touch the bulb surface with bare hands or greasy gloves, finger prints or grease

11-66

on the bulb surface will develop into hot spots and cause the bulb to break. If there are finger prints or grease on the bulb surface, wipe them away with a soft cloth moistened with alcohol.

NOTE " If headlight aiming is required, consult your SUBARU dealer for proper adjustment of the head- light aim. " It may be difficult to replace the bulbs. Have your SUBARU dealer replace the bulbs if neces- sary. ! Low beam light bulbs

UGB516BA

1. Remove the bulb cover, by turning it counterclock- wise.

Maintenance and service

2. Disconnect the electrical connector.

UGB517BA

UGB518BA

3. Remove the retainer spring. 4. Replace the bulb, then set the retainer spring se- curely. 5. Reconnect the electrical connector. 6. Install the bulb cover.