Repair 7

Park the vehicle on a flat surface and set the parking brake. Open the hood and disconnect the negative battery cable.

Remove the shifter trim with a trim removal tool. A flathead screwdriver can be used, but the silver trim is easily scratched, so using the right tool can prevent damage. Remove the two screws underneath the trim with a Phillips screwdriver.

Grip the bottom of the shifter panel cover on both sides and pull out slightly to disengage the retaining tabs, then pull up on it to completely remove it.

Remove the temperature control knobs and vents by pulling them straight off by hand. Pry up the edges of the dash control panel with a flathead screwdriver to disengage the clips. Remove the dash control panel.

Remove the kick panel trim on both sides with a trim removal tool. Remove the screws holding the kick panel in place with a Phillips screwdriver. Remove the kick panels.

Remove the trim between the windshield and dash with a trim removal tool.

Open the glove compartment. Push in on the glove box and lift to remove the glove box.

Remove the screws holding the dash in place. There are two where each of the kick panels were located, four along the windshield, two inside the glove compartment cavity and three where the center control panel was removed.

If the vehicle has a standard transmission, place the shift control arm in neutral. If it has an automatic transmission, place the shift control arm in the position that is farthest from the dash. Push the button underneath the steering wheel and lower the steering wheel as far as possible.

Lift up caully on the dash, then pull it forward about one and a half feet. Unplug all of the electrical connections from the rear of the dash, including the instrument cluster and temperature controls. Depending on the vehicles features, there may be more.

Slide the dash forward, lift it over the top edge of the steering wheel, then cant it slightly sideways to fit it through the passenger side door. Removing it from the driver side is cramped and could cause damage to the interior, so avoid going that way if possible.

Remove the cable on the negative battery terminal with a socket wrench to prevent the engine from starting while you replace the oil pump. Place a container under the radiator drain and open the radiator drain cock. Allow the coolant to drain into the container and store the coolant for later use. Replace the radiator drain cock.

Raise the vehicle with a jack and support it with jack stands. Place a second container under the drain for the engine oil, then remove the drain plug with a socket wrench. Allow the oil to drain into the container, then fasten the drain plug.

Disconnect the covers for the timing belt with a socket wrench, then remove the timing belt assembly. Remove the bracket for the timing belt tensioner and detach the engine coolant pipe from the water pump. Disconnect the the water pump assembly from the engine. Remove the mounting bolts for the oil pump, then pry the oil pump from the engine block with a small pry tool. Discard the seal and O-ring for the oil pump.

Mount the new seal on the oil pump, then apply a thin layer of sealant to the oil pumps mating surface. Mount the new O-ring to the oil pump and install the oil pump to the engine block. Tighten the mounting bolts for the oil pump to 56 inch-pounds with a torque wrench.

Install the water pump to the engine with a socket wrench and attach the engine coolant pipe to the water pump. Install the timing belt assembly and the covers for the timing belt.

Lower the vehicle. Fill the vehicle with the proper amount of coolant and oil. Attach the cable to the negative battery terminal with a socket wrench.

Relieve the pressure in the fuel system by removing the gas cap, disconnecting the fuel pump relay and running the engine until it stops. Disconnect the negative battery cable. If your vehicle is before 2002 and it has the factory vehicle theft system, follow the instructions in the owners manual to disable it or your radio will not function when you reconnect the battery. Drain the cooling system. Recover the coolant for reuse or recycling.

Remove the spark plugs, timing belt covers, belt, camshaft sprockets, camshafts and disconnect the exhaust manifolds (use penetrating oil to loosen the bolts if necessary). Remove the intake manifold and any other hoses, brackets or accessories that block access to the sides of the engine.

Loosen the cylinder head bolts in the reverse order for tightening. This is generally from the top center to the bottom center then an "X" pattern for the ends. Remove the heads and the old gasket material carefully. Place a clean shop towel in each cylinder to prevent debris contamination.

Use the acetone or lacquer thinner to clean the gasket mating surfaces. Carefully scrape any stuck material from the surfaces. They must be absolutely clean to seal properly. Install the new gasket onto the head locating dowels. Lubricate the head bolts with engine oil and install them finger tight.

Use the torque wrench and torque angle gauge to tighten the head bolts in the exact sequence outlined by the references. Over-tightening will strip the threads and improper sequence can warp the head.

Insert the key into the Bajas ignition. Turn the key halfway to engage the instrument panel. Wait for the instrument panel to light up. If the instrument panel does not light up, you have a problem with your battery. If the instrument panel does light up, check the gas gauge. Fill the gas tank if needed and then try to restart your car.

Pull on the hood-release latch to the left of your feet in the drivers side of the car. Get out of the Baja and open the hood. Look for the battery to the right of the engine block.

Use a pair of channel locks or insulated pliers to tighten the connections of the terminals to the battery prongs. Try to turn the key over to engage the instrument panel. If the instrument panel will not engage, jump-start the Baja.

Connect the red and black leads from your jumper cables to the red and black terminals on the battery. Connect the other end of the jumper cables to the red and black terminals on a friends car. Start your friends car and then start your Baja. Allow the Baja to run for 10 to 15 minutes before you turn off the car. Try to restart the car. If the car will not restart, replace the battery with a new one.

Jack the front of the Baja up and crawl under the car. Locate the starter. This is a small black box next to the engine. Have your friend turn the ignition and listen to the starter. If you hear a "clicking" or a "buzzing" noise coming from the starter, you will need to have a service technician replace the starter.

Check the braking system on your Subaru to ensure that all air has been bled and the hydraulic system is adjusted properly and functioning as designed. Complete any repairs or adjustments to this system before adjusting the parking brake. Apply the parking brake several times while counting the clicks. If the number is more than five or six you will tighten the cable, less and you will loosen it.

Remove the center console by carefully using the trim stick to pry up the console trim cover. Remove the console cover and tray and then the console.

Use a small wrench to loosen the lock nut on the adjuster while holding the adjustment nut with another wrench. Turn the adjuster nut counter-clockwise to loosen the assembly. Snug the nut by hand and apply the brake. If it is still out of adjustment, continue tightening the adjustment nut until you have the proper number of clicks.

Tighten the lock nut against the adjusting nut using two wrenches. Reinstall the console, console tray and console cover. Reinstall the console trim cover.