brake SUBARU OUTBACK 2004 4.G Repair Manual

10-3
Appearance care
– CONTINUED –
Mud and sand adhering to the underbody components
may accelerate their corrosion.
After driving off-road or muddy or sandy roads, wash
the mud and sand off the underbody.
Carefully flush the suspension and axle parts, as they
are particularly prone to mud and sand buildup. Do not
use a sharp-edged tool to remove caked mud.
NOTE
Be careful not to damage brake hoses, sensor har-
nesses, and other parts when washing suspen-
sion components. TUsing a warm water washer
y Keep a good distance of 12 in (30 cm) or more be-
tween the washer nozzle and the vehicle. y Do not wash the same area continuously.
y If a stain will not come out easily, wash by hand.
Some warm water washers are of the high tempera-
ture, high pressure type, and they can damage or de-
form the resin parts such as mouldings, or cause wa-
ter to leak into the vehicle. „ Waxing and polishing
Always wash and dry the vehicle before waxing and
polishing.
Use a good quality polish and wax and apply them ac- cording to the manufacturer’s instructions. Wax or pol-
ish when the painted surface is cool.
Be sure to polish and wax the chrome trim, as well as
the painted surfaces. Loss of wax on a painted surface
leads to loss of the original luster and also quickens
the deterioration of the surface. It is recommended
that a coat of wax be applied at least once a month, or
whenever the surface no longer repels water.
If the appearance of the paint has diminished to the
point where the luster or tone cannot be restored,
lightly polish the surface with a fine-grained com-
pound. Never polish just the affected area, but include
the surrounding area as well. Always polish in only
one direction. A No. 2000 grain compound is recom-
mended. Never use a coarse-grained compound.
Coarser grained compounds have a smaller grain-size
number and could damage the paint. After polishing
with a compound, coat with wax to restore the original
luster. Frequent polishing with a compound or an in-
correct polishing technique will result in removing the
paint layer and exposing the undercoat. When in
doubt, it is always best to contact your SUBARU deal-
er or an auto paint specialist.
NOTE
Be careful not to block the windshield washer noz-
zles with wax when waxing the vehicle.

10-6
Appearance care
proper ventilation. „
To help prevent corrosion
Wash the vehicle regularly to prevent corrosion of the
body and suspension components. Also, wash the ve-
hicle promptly after driving on any of the following sur- faces: y roads that have been salted to prevent them from
freezing in winter y mud, sand, or gravel
y coastal roads
After the winter has ended, it is recommended that the
underbody be given a very thorough washing.
Before the beginning of winter, check the condition of
underbody components, such as the exhaust system,
fuel and brake lines, brake cables, suspension, steer-
ing system, floor pan, and fenders. If any of them are
found to be rusted, they should be given an appropri-
ate rust prevention treatment or should be replaced.
Contact your SUBARU dealer to perform this kind of
maintenance and treatment if you need assistance.
Repair chips and scratches in the paint as soon as you find them.
Check the interior of the vehicle for water and dirt ac- cumulation under the floor mats because that could
cause corrosion. Occasionally check under the mats
to make sure the area is dry.
Keep your garage dry. Do not park your vehicle in a
damp, poorly ventilated garage. In such a garage, cor-
rosion can be caused by dampness. If you wash the
vehicle in the garage or put the vehicle into the garage
when wet or covered with snow, that can cause damp-ness.
If your vehicle is operated in cold weather and/or in ar-
eas where road salts and other corrosive materials are
used, the door hinges and locks, trunk lid lock, and
hood latch should be inspected and lubricated period-
ically.

11 - 1
11
Maintenance and service
Ma inte nan ce sche du le .. ... ... ... .. ... ... ... ... .. ... ... 11-3
Ma in te nan ce precau tio ns ... ... .. ... ... ... ... .. ... ... 11-3
B ef ore checki ng o r servicing in th e e ngi ne
c o m part ment ..... ..................... ..................... ... 11-4
W hen y ou do c h ecking or servic ing in t h e
e ngi ne c omp artme nt while the engi ne is
r u nn ing ............... ..................... ..................... ... 11-5
En gine ho od .. ... ... ... .. ... ... ... ... ... .. ... ... ... ... .. ... ... 11-5
Engine compartment overview ................... 11-8 2.5 liter models .................................................. 11-8
2.5 liter CALIFORNIA spec models ................. 11-9
3.0 liter models .................................................. 11-10
Engine oil ...................................................... 11-11 Checking the oil level ....................................... 11-11
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 ...................................... 11-22 Replacing the air cleaner element ................... 11-22
Spark plugs ................................................... 11-25 Recommended spark plugs ............................. 11-25
Drive belts ..................................................... 11-26 2.5 liter models .................................................. 11-26
3.0 liter models .................................................. 11-26
Manual transmission oil ............................... 11-27 Checking the oil level ....................................... 11-27 Recommended grade and viscosity ............... 11-27
Automatic transmission fluid ...................... 11-28 Checking the fluid level .................................... 11-28
Recommended fluid ......................................... 11-30
Front differential gear oil (AT vehicles) ...... 11-30 Checking the oil level ....................................... 11-30
Recommended grade and viscosity ............... 11-31
Rear differential gear oil ............................... 11-32 Checking the gear oil level .............................. 11-32
Recommended grade and viscosity ............... 11-34
Power steering fluid ...................................... 11-35 Checking the fluid level .................................... 11-35
Recommended fluid ......................................... 11-36
Brake fluid ..................................................... 11-36 Checking the fluid level .................................... 11-36
Recommended brake fluid ............................... 11-37
Clutch fluid (MT vehicles) ............................ 11-38 Checking the fluid level .................................... 11-38
Recommended clutch fluid .............................. 11-38
Brake booster ................................................ 11-39
Brake pedal .................................................... 11-39 Checking the brake pedal free play ................ 11-39
Checking the brake pedal reserve distance ... 11-40
Clutch pedal (Manual transmission vehicles) ............... 11-40Checking the clutch function .......................... 11-40
Checking the clutch pedal free play ............... 11-41
Replacement of brake pad and lining ......... 11-41 Breaking-in of new brake pads and linings .... 11-42

11 - 2
Maintenance and service
Parking brake stroke .................................... 11-43
Tires and wheels .......................................... 11-43Types of tires .................................................... 11-43
Tire inspection .................................................. 11-44
Tire pressures and wear .................................. 11-44
Wheel balance ................................................... 11-47
Wear indicators ................................................. 11-47
Tire rotation ....................................................... 11-48
Tire replacement ............................................... 11-48
Wheel replacement ........................................... 11-49
Wheel covers .................................................... 11-50
Aluminum wheels (if equipped) .................. 11-51
Windshield washer fluid .............................. 11-51
Replacement of wiper blades ...................... 11-52 Replacement wiper blade assembly ............... 11-53
Replacement wiper blade rubber .................... 11-53
Battery ........................................................... 11-58
Fuses ............................................................. 11-59
Main fuse ....................................................... 11-61
Installation of accessories .......................... 11-62
Replacing bulbs ............................................ 11-63 Headlight ........................................................... 11-65
Front fog light (if equipped) ............................. 11-69
Front turn signal light, parking light and side marker light .................................................... 11-69
Rear combination lights ................................... 11-71
License plate light ............................................ 11-76
Map light, dome light, luggage compartment light and door step light ................................ 11-76
Trunk light ......................................................... 11-79
High mount stop light ...................................... 11-79

11 - 4
2Maintenance and service
the materials in the vehicle may be hazardous if
improperly used or handled, for example, bat-tery acid. y
Your vehicle should only be serviced by per-
sons fully competent to do so. Serious person-
al 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 sup-
port 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 per-
formed 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 air-
bag system or seatbelt pretensioner system, or
attempt to take its connectors apart, as that may activate the system or it can render it inop-
erative. The wiring and connectors of these
systems are yellow for easy identification. NEV-
ER 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
yAlways stop the engine and set the parking
brake firmly to prevent the vehicle from mov-
ing. y Always let the engine cool down. Engine
parts become very hot when the engine is run-
ning and remain hot for some time after the en-
gine is stopped.y Do not spill engine oil, engine coolant, brake
fluid or any other fluid on hot engine compo-
nents. 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 - 8
2Maintenance and service
Engine compartment overview „
2.5 liter models
12 3 45678
9
10
11
12
13
14
UBB036BB
1) Manual transmission oil level
gauge (MT) (page 11-27) or Dif-
ferential gear oil level gauge
(AT) (page 11-30)
2) Air cleaner element (page 11- 22)
3) Clutch fluid reservoir (page 11-
38)
4) Automatic transmission fluid lev- el gauge (page 11-28)
5) Brake fluid reservoir (page 11- 36)
6) Fuel filter
7) Windshield washer tank (page 11-51)
8) Fuse box (page 11-59)
9) Battery (page 11-58)
10) Engine oil filler cap (page 11-11)
11) Engine coolant reservoir (page
11-18)
12) Radiator cap (page 11-18)
13) Engine oil level gauge (page 11-
11)
14) Power steering fluid reservoir (page 11-35)

11 - 9
2Maintenance and service
– CONTINUED –
„2.5 liter CALIFORNIA spec models
1
13 12 10 11 9 8
23
45 67
UBB099BB
1) Air cleaner element (page 11-
22)
2) Manual transmission oil level gauge (MT) (page 11-27) or Dif-
ferential gear oil level gauge
(AT) (page 11-30)
3) Clutch fluid reservoir (page 11-
38)
4) Automatic transmission fluid lev- el gauge (page 11-28)
5) Brake fluid reservoir (page 11- 36)
6) Windshield washer tank (page
11-51)
7) Fuse box (page 11-59)
8) Battery (page 11-58)
9) Engine oil filler cap (page 11-11)
10) Engine coolant reservoir (page 11-18)
11) Engine oil level gauge (page 11- 11)
12) Radiator cap (page 11-18)
13) Power steering fluid reservoir (page 11-35)

11 - 1 0
2Maintenance and service „
3.0 liter models
12 3 45 67
8
9
10
11
12
13
UBB058BB
1) Air cleaner element (page 11-
22)
2) Differential gear oil level gauge (AT) (page 11-30)
3) Automatic transmission fluid lev- el gauge (page 11-28)
4) Brake fluid reservoir (page 11-
36)
5) Fuel filter
6) Windshield washer tank (page
11-51)
7) Fuse box (page 11-59)
8) Battery (page 11-58)
9) Engine oil filler cap (page 11-11)
10) Engine coolant reservoir (page 11-18)
11) Engine oil level gauge (page 11- 11)
12) Radiator cap (page 11-18)
13) Power steering fluid reservoir (page 11-35)

11 - 2 8
2Maintenance and service
SAE viscosity No. and Applicable Temperature
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. T Checking the fluid level when the fluid is hot
Check the fluid level monthly.
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.-30 -20 -10 0 10 20 30 40
-20 0 60 20
80W
75W/90 80 100
40
85W 90
HSB036BA

11 - 3 6
2Maintenance and service
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. „
Recommended fluid
“Dexron III” Type Automatic Transmission Fluid
Brake fluid „Checking the fluid level
yNever let brake fluid contact your eyes be-
cause brake fluid can be harmful to your eyes.
If brake fluid gets in your eyes, immediately
flush them thoroughly with clean water. For
safety, when performing this work, wearing eye
protection is advisable. y Brake fluid absorbs moisture from the air.
Any absorbed moisture can cause a dangerous
loss of braking performance. y If the vehicle requires frequent refilling, there
may be a leak. If you suspect a problem, have
the vehicle checked at your SUBARU dealer.
y Never use different brands of brake fluid to-
gether. y When adding brake fluid, be careful not to al-
low any dirt into the reservoir.y Never splash the brake fluid over painted sur-