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SUBARU BAJA 2003-2006 Service Repair Manual 2004 2005

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🏷️ Basic Information Identification Make: Subaru Model: Baja Year: 2003-2006 Generation Generation Name: First Generation (First Facelift) Codes Chassis Code: BH (shared with Outback) 👋 Introduction Market Position Vehicle Segment: Sport Utility Vehicle (SUV) / Ute (Utility Vehicle) Unique Selling Proposition: Unique 'Sport Utility Sedan' concept with a convertible bed (known as the 'Spacious Oval Rear Deck' or S.O.R.D.) Competitive Analysis Key Competitors: Honda Ridgeline (later models), Ford Explorer Sport Trac, Chevrolet Avalanche (conceptually) Key Features Dealership Equivalence: Directly equivalent to the official Subaru dealership service manual used by certified technicians Diagnostic Capability: Enables users to accurately diagnose and repair their vehicle, potentially saving significant labor costs Digital Convenience: Single-source digital manual on CD, eliminating need for multiple physical books and providing print-on-demand functionality 📋 Manual Details Coverage Areas Coverage Scope: All Models and All Repairs A-Z Page Count Estimated Page Count: Extensive (Exact count not specified, but described as 'complete' and 'everything you will ever need') Manual Type Type: Factory Service Repair Manual Language Language: English Format Digital Format: CD-Manual (Printable) 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical, Fuel System, Ignition System, Exhaust System, Engine Control System (ECU) Drivetrain: Transmission (Automatic/Manual), Drivetrain Components (Axles, Driveshafts, Differentials) Suspension Steering: Front Suspension, Rear Suspension, Steering System, Wheel Alignment Brakes: Brake System Components (Front/Rear Brakes), ABS System, Parking Brake Electrical: Wiring Schematics, Charging System, Starting System, Lighting System, Instrument Panel, Body Electrical Components, Audio System, HVAC Controls Body Chassis: Body Exterior Panels, Interior Trim, Doors, Windows, Locks, Seats, Chassis Components HVAC: Heating, Ventilation, and Air Conditioning (HVAC) System Safety Restraints: Airbag System, Seat Belts Procedures Included Maintenance: Scheduled Maintenance, Fluid Checks and Replacements, Filter Changes, Lubrication Points Diagnostics: Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting Repair: Step-by-Step Repair Procedures for All Major Components and Systems Overhaul: Component Disassembly, Reassembly, and Rebuilding Instructions Installation: Component Removal and Installation Procedures Technical Depth Depth: Factory-Level Detail, including intricate electrical schematics and diagnostic procedures 📊 Manual Specifications File Format Digital Medium: CD-ROM Compatibility: Windows Vista (32/64-bit), XP, ME, 98, NT, 2000, and Mac compatible Print Quality Printable: All pages are printable, allowing for enlarged image printing Binding Type Physical Binding: N/A (Digital format on CD) Paper Type Physical Paper: N/A (Digital format on CD) ⚙️ Engine Specifications Primary Engine Engine Code And Type: EJ253 (2.5L SOHC Naturally Aspirated Flat-4 Boxer) Performance Horsepower Output: 165 hp @ 5,600 rpm (approx.) Torque Output: 166 lb-ft @ 3,600 rpm (approx.) Fuel System Induction Type: Multi-Point Fuel Injection (MPI) Cooling System Coolant Type: Subaru Long Life Coolant (Blue) or equivalent silicate-free OAT coolant Lubrication Oil Viscosity: SAE 5W-30 (preferred), SAE 10W-30 (seasonal) - API certified Engine Management ECU Type: Engine Control Unit (ECU) with diagnostic capabilities 🔧 Transmission Standard Transmission Type: 4-Speed Automatic Transmission Optional Transmission Type Optional: None for Baja (Only Automatic offered) Features Drivetrain Layout: Symmetrical All-Wheel Drive (AWD) Fluid Specifications Atf Type: Subaru ATF-HP (High Performance) or equivalent Dexron-III/Mercon compatible fluid 📐 Dimensions Exterior Length: 194.7 inches Width: 70.1 inches Height: 60.4 inches Wheelbase: 104.3 inches Ground Clearance: 7.9 inches Cargo Bed Length: 41.5 inches (with tailgate closed) Bed Width: 47.2 inches (between wheel wells) Weights Curb Weight: 3,375 - 3,490 lbs (depending on trim and options) Towing Capacity: 2,000 lbs 🛡️ Safety Features Ratings NHTSA Front Impact Rating: 4/5 Stars (Driver/Passenger) NHTSA Side Impact Rating: 4/5 Stars (Front/Rear Passenger) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available (Check specific model/year) Passive Features Airbags: Standard Frontal Airbags, Available Side-Curtain Airbags Seatbelts: 3-point seatbelts with pretensioners 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player; optional premium audio available Climate Control: Manual or Automatic Climate Control (depending on trim) Driver Assistance Cruise Control: Standard cruise control system Connectivity Power Accessories: Power windows, power locks, power mirrors (standard on most trims) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 3.75 months (under severe conditions), 7,500 miles or 7.5 months (normal conditions) Air Filter Replacement: Every 15,000 miles or 15 months Spark Plug Replacement: Every 60,000 miles (NGK Platinum recommended) Timing Belt Replacement: Every 105,000 miles or 105 months (Crucial for EJ25 engine due to interference design) Fluid Specifications Brake Fluid Type: DOT 3 Power Steering Fluid: Subaru Genuine Power Steering Fluid or Dexron III ATF Transfer Case Fluid: Subaru Genuine Gear Oil API GL-5 75W-90 Rear Differential Fluid: Subaru Genuine Gear Oil API GL-5 75W-90 Known Issues Head Gaskets: While less common than in earlier EJ engines, potential for head gasket leaks exists; manual provides repair procedures. Wheel Bearings: Can be prone to wear; manual details replacement procedures and torque specifications. Evaporative Emissions System: Issues with EVAP system components (e.g., charcoal canister, purge valve) can trigger check engine lights; manual aids diagnosis. 📚 Vehicle History Brand Heritage Subaru AWD Legacy: Builds upon Subaru's long-standing reputation for Symmetrical All-Wheel...
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SUBARU BAJA 2003-2006 Service Repair Manual 2004 2005
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Baja
Year:
2003-2006
Generation
Generation Name:
First Generation (First Facelift)
Codes
Chassis Code:
BH (shared with Outback)
👋 Introduction
Market Position
Vehicle Segment:
Sport Utility Vehicle (SUV) / Ute (Utility Vehicle)
Unique Selling Proposition:
Unique 'Sport Utility Sedan' concept with a convertible bed (known as the 'Spacious Oval Rear Deck' or S.O.R.D.)
Competitive Analysis
Key Competitors:
Honda Ridgeline (later models), Ford Explorer Sport Trac, Chevrolet Avalanche (conceptually)
Key Features
Dealership Equivalence:
Directly equivalent to the official Subaru dealership service manual used by certified technicians
Diagnostic Capability:
Enables users to accurately diagnose and repair their vehicle, potentially saving significant labor costs
Digital Convenience:
Single-source digital manual on CD, eliminating need for multiple physical books and providing print-on-demand functionality
📋 Manual Details
Coverage Areas
Coverage Scope:
All Models and All Repairs A-Z
Page Count
Estimated Page Count:
Extensive (Exact count not specified, but described as 'complete' and 'everything you will ever need')
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Digital Format:
CD-Manual (Printable)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Mechanical, Fuel System, Ignition System, Exhaust System, Engine Control System (ECU)
Drivetrain:
Transmission (Automatic/Manual), Drivetrain Components (Axles, Driveshafts, Differentials)
Suspension Steering:
Front Suspension, Rear Suspension, Steering System, Wheel Alignment
Brakes:
Brake System Components (Front/Rear Brakes), ABS System, Parking Brake
Electrical:
Wiring Schematics, Charging System, Starting System, Lighting System, Instrument Panel, Body Electrical Components, Audio System, HVAC Controls
Body Chassis:
Body Exterior Panels, Interior Trim, Doors, Windows, Locks, Seats, Chassis Components
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) System
Safety Restraints:
Airbag System, Seat Belts
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Checks and Replacements, Filter Changes, Lubrication Points
Diagnostics:
Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting
Repair:
Step-by-Step Repair Procedures for All Major Components and Systems
Overhaul:
Component Disassembly, Reassembly, and Rebuilding Instructions
Installation:
Component Removal and Installation Procedures
Technical Depth
Depth:
Factory-Level Detail, including intricate electrical schematics and diagnostic procedures
📊 Manual Specifications
File Format
Digital Medium:
CD-ROM
Compatibility:
Windows Vista (32/64-bit), XP, ME, 98, NT, 2000, and Mac compatible
Print Quality
Printable:
All pages are printable, allowing for enlarged image printing
Binding Type
Physical Binding:
N/A (Digital format on CD)
Paper Type
Physical Paper:
N/A (Digital format on CD)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
EJ253 (2.5L SOHC Naturally Aspirated Flat-4 Boxer)
Performance
Horsepower Output:
165 hp @ 5,600 rpm (approx.)
Torque Output:
166 lb-ft @ 3,600 rpm (approx.)
Fuel System
Induction Type:
Multi-Point Fuel Injection (MPI)
Cooling System
Coolant Type:
Subaru Long Life Coolant (Blue) or equivalent silicate-free OAT coolant
Lubrication
Oil Viscosity:
SAE 5W-30 (preferred), SAE 10W-30 (seasonal) - API certified
Engine Management
ECU Type:
Engine Control Unit (ECU) with diagnostic capabilities
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic Transmission
Optional
Transmission Type Optional:
None for Baja (Only Automatic offered)
Features
Drivetrain Layout:
Symmetrical All-Wheel Drive (AWD)
Fluid Specifications
Atf Type:
Subaru ATF-HP (High Performance) or equivalent Dexron-III/Mercon compatible fluid
📐 Dimensions
Exterior
Length:
194.7 inches
Width:
70.1 inches
Height:
60.4 inches
Wheelbase:
104.3 inches
Ground Clearance:
7.9 inches
Cargo
Bed Length:
41.5 inches (with tailgate closed)
Bed Width:
47.2 inches (between wheel wells)
Weights
Curb Weight:
3,375 - 3,490 lbs (depending on trim and options)
Towing Capacity:
2,000 lbs
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
4/5 Stars (Driver/Passenger)
NHTSA Side Impact Rating:
4/5 Stars (Front/Rear Passenger)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available (Check specific model/year)
Passive Features
Airbags:
Standard Frontal Airbags, Available Side-Curtain Airbags
Seatbelts:
3-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player; optional premium audio available
Climate Control:
Manual or Automatic Climate Control (depending on trim)
Driver Assistance
Cruise Control:
Standard cruise control system
Connectivity
Power Accessories:
Power windows, power locks, power mirrors (standard on most trims)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3.75 months (under severe conditions), 7,500 miles or 7.5 months (normal conditions)
Air Filter Replacement:
Every 15,000 miles or 15 months
Spark Plug Replacement:
Every 60,000 miles (NGK Platinum recommended)
Timing Belt Replacement:
Every 105,000 miles or 105 months (Crucial for EJ25 engine due to interference design)
Fluid Specifications
Brake Fluid Type:
DOT 3
Power Steering Fluid:
Subaru Genuine Power Steering Fluid or Dexron III ATF
Transfer Case Fluid:
Subaru Genuine Gear Oil API GL-5 75W-90
Rear Differential Fluid:
Subaru Genuine Gear Oil API GL-5 75W-90
Known Issues
Head Gaskets:
While less common than in earlier EJ engines, potential for head gasket leaks exists; manual provides repair procedures.
Wheel Bearings:
Can be prone to wear; manual details replacement procedures and torque specifications.
Evaporative Emissions System:
Issues with EVAP system components (e.g., charcoal canister, purge valve) can trigger check engine lights; manual aids diagnosis.
📚 Vehicle History
Brand Heritage
Subaru AWD Legacy:
Builds upon Subaru's long-standing reputation for Symmetrical All-Wheel Drive and boxer engines
Model Evolution
Platform Sharing:
Based on the Subaru Outback (BH generation) platform, but with a unique bed design
Design Concept:
An attempt to blend the utility of a pickup truck with the comfort and handling of a car
Production
Production Years:
2003-2006
Manufacturing Location:
Lafayette, Indiana, USA (Subaru of Indiana Automotive, Inc. - SIA)
🏆 Awards & Recognition
Recognitions
Model Niche Recognition:
Recognized for its unconventional design and AWD capability in a niche segment, appealing to outdoor enthusiasts.
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