Subaru IMPREZA 2004 Service Manual
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Subaru IMPREZA 2004 Service Manual

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2004 IMPREZA SERVICE MANUAL
CHASSIS SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
QUICK REFERENCE INDEX
FRONT SUSPENSION
REAR SUSPENSION
WHEEL AND TIRE SYSTEM
DIFFERENTIALS
TRANSFER CASE
DRIVE SHAFT SYSTEM
ABS
ABS (DIAGNOSTICS)
BRAKE
PARKING BRAKE
POWER ASSISTED SYSTEM
(POWER STEERING)
FS
RS
WT
DI
TC
DS
ABS
ABS(diag)
BR
PB
PS
G1870GE5

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Summary of Contents for Subaru IMPREZA 2004

  • Page 1 FRONT SUSPENSION REAR SUSPENSION WHEEL AND TIRE SYSTEM DIFFERENTIALS This service manual has been prepared to provide SUBARU service personnel TRANSFER CASE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. DRIVE SHAFT SYSTEM...

  • Page 2: Table Of Contents

    FRONT SUSPENSION Page General Description ..................2 Wheel Alignment ..................6 Front Transverse Link ................15 Front Ball Joint ..................18 Front Strut ....................19 Front Stabilizer ..................23 Front Crossmember ..................24 Sub Frame ....................25 Front Support Arm..................27 General Diagnostic Table................28...

  • Page 3: General Description

    General Description FRONT SUSPENSION 1. General Description A: SPECIFICATIONS Sedan Wagon Model OUTBACK Non-turbo Turbo Non-turbo Turbo Camber (tolerance: ±0°45′) −0°15′ −0°25′ −0°10′ −0°20′ −0°05′ Caster 3°25′ 3°30′ 3°25′ 3°30′ 3°25′ 0±3 (0±0.12) Each toe angle: ±0°07′30″ Toe-in mm (in) Kingpin angle 14°20′...
  • Page 4 General Description FRONT SUSPENSION B: COMPONENT (17) (28) (28) (18) (19) (28) (20) (33) (16) (21) (22) (11) (34) (27) (28) (23) (10) (11) (28) (28) (24) (31) (14) (15) (28) (12) (13) (15) (27) (28) (25) (12) (28) (10) (29) (26) (28)
  • Page 5 • Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary re- moval, installation, disassembly, and replacement. • Use SUBARU genuine grease etc. or the equiv- alent. Do not mix grease etc. with that of another grade or from other manufacturers.

  • Page 6: Special Tools

    General Description FRONT SUSPENSION D: PREPARATION TOOL 1. SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 927380002 ADAPTER Used as an adapter for camber & caster gauge when measuring camber and caster. (1) 28199AC000 PLATE (2) 28199AC010 BOLT ST-927380002 927680000 INSTALLER & Used for replacing transverse link bushing.

  • Page 7: Wheel Alignment

    Wheel Alignment FRONT SUSPENSION 2. Wheel Alignment A: INSPECTION Check the following items before taking wheel alignment measurement. Check items before taking wheel alignment measurement: • tire air pressure • unbalanced right and left tire wear, size difference • tire run-out •...
  • Page 8 Wheel Alignment FRONT SUSPENSION 1. WHEEL ARCH HEIGHT 1) Set the vehicle on a level surface. 2) Set the vehicle to “curb weight” conditions. (Empty luggage compartment, install spare tire, jack, service tools, and top up fuel tank.) 3) Set the steering wheel in a straight line, then remove the vehicle straight ahead more than 5 m (16 ft) to settle the suspension.
  • Page 9 Wheel Alignment FRONT SUSPENSION 2. CAMBER NOTE: Moving the adjusting bolt by one scale graduation • Inspection changes camber by approx. 0°15′. 1) Place the front wheel on turning radius gauge. Make sure ground contacting surfaces of front and rear wheels are set at the same height. 2) Set the ST into the center of wheel, and then in- stall the wheel alignment gauge.
  • Page 10 Wheel Alignment FRONT SUSPENSION Camber is increased. Rotate camber adjusting bolt LH counterclockwise. Rotate camber adjusting bolt RH clockwise. FS-00009 FS-00010 Camber is decreased. Rotate camber adjusting bolt LH clockwise. Rotate camber adjusting bolt RH counterclockwise. FS-00009 FS-00010 4) Tighten the new two self-locking nuts. ST 927380002 ADAPTER Tightening torque:...
  • Page 11 Wheel Alignment FRONT SUSPENSION 4. STEERING ANGLE 4) Measure the distance “B” between right and left marks. Toe-in can then be obtained by the follow- • Inspection ing equation: 1) Place the vehicle on a turning radius gauge. A − − − − B = Toe-in 2) While depressing the brake pedal, turn the steer- ing wheel fully to the right and left.
  • Page 12 Wheel Alignment FRONT SUSPENSION 6. REAR WHEEL TOE-IN • Inspection Toe-in: 0 ± ± ± ± 3 mm (0 ± ± ± ± 0.12 in) For rear toe-in inspection procedure, refer to FRONT WHEEL TOE-IN procedure. <Ref. to FS-10, FRONT WHEEL TOE-IN, INSPEC- TION, Wheel Alignment.>...
  • Page 13 Wheel Alignment FRONT SUSPENSION Toe-in is increased. Rotate camber adjusting bolt LH clockwise. Rotate camber adjusting bolt RH counterclockwise. FS-00018 FS-00019 Toe-in is decreased. Rotate camber adjusting bolt LH counterclockwise. Rotate camber adjusting bolt RH clockwise. FS-00018 FS-00019 3) Tighten a new self-locking nut. Tightening torque: 100 N·m (10.2 kgf-m, 74 ft-lb) FS-12...
  • Page 14 Wheel Alignment FRONT SUSPENSION 7. THRUST ANGLE Thrust angle: 0 °± °± °± °± 20 ′ ′ ′ ′ • Inspection Less than 20 ′ ′ ′ ′ when “L” is less than 15 mm 1) Position the vehicle on a level surface. (0.6 in).
  • Page 15 Wheel Alignment FRONT SUSPENSION Here, use only positive toe-in values from each wheel to substitute for α and β in the equation. FS-00976 (1) Front (2) Body center line FS-14...

  • Page 16: Front Transverse Link

    Front Transverse Link FRONT SUSPENSION 3. Front Transverse Link 9) Remove the bolt securing transverse link to crossmember, and then extract the transverse link A: REMOVAL from crossmember. 1) Set the vehicle on a lift. 2) Lift-up the vehicle and remove the wheel. 3) Remove the sub frame.
  • Page 17 Front Transverse Link FRONT SUSPENSION 5) Tighten the following points in the order shown 2. REAR BUSHING below when tires are in full contact with the ground 1) Scribe an aligning mark on the transverse link and vehicle is curb weight. and rear bushing.
  • Page 18 Front Transverse Link FRONT SUSPENSION E: INSPECTION 1) Check the transverse link for wear, damage and cracks, and correct or replace if defective. 2) Check the bushings for cracks, fatigue or dam- age. 3) Check the rear bushing for oil leaks. FS-17...

  • Page 19: Front Ball Joint

    Front Ball Joint FRONT SUSPENSION 4. Front Ball Joint C: INSPECTION 1) Measure the play of ball joint by the following A: REMOVAL procedures. Replace with a new one when the play 1) Remove the wheel. exceeds specified value. 2) Pull out the cotter pin from ball stud, remove the (1) With 686 N (70 kgf, 154 lb) loaded in direc- castle nut, and extract the ball stud from transverse tion shown in the figure, measure the dimension...

  • Page 20: Front Strut

    Front Strut FRONT SUSPENSION 5. Front Strut 6) Remove the three nuts securing the strut mount to body. A: REMOVAL 1) Remove the wheel. 2) Remove the bolt securing the brake hose from strut. FS-00037 3) Scribe an alignment mark on the camber adjust- ing bolt which secures the strut to housing.
  • Page 21 Front Strut FRONT SUSPENSION C: DISASSEMBLY (4) Fully contract the piston rod. (5) Repeat three or four times from first step. 1) Using a coil spring compressor, compress the coil spring. NOTE: After completely purging air from strut, be sure to place the strut with piston rod facing up.
  • Page 22 Front Strut FRONT SUSPENSION (2 kgf, 4 lb) in the opposite direction of “W”, then NOTE: read dial gauge indication: P Ensure that the upper spring seat is positioned as shown in the figure. FS-00046 FS-00044 Limit of play (P 0.8 mm (0.031 in) (1) Outside of body If the play is greater than limit, replace the strut.
  • Page 23 Front Strut FRONT SUSPENSION 2) Using a 2 to 3 mm (0.08 to 0.12 in) dia. drill, make holes in areas shown in the figure. FS-00047 (1) 40 mm (1.57 in) 2. STi MODEL CAUTION: • Before handling gas filled struts, be sure to wear goggles to protect eyes from gas, oil and filings.

  • Page 24: Front Stabilizer

    Front Stabilizer FRONT SUSPENSION 6. Front Stabilizer B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL NOTE: 1) Jack-up the front part of the vehicle and support • Install the bushing (on front crossmember side) it with rigid racks. while aligning it with paint mark on stabilizer.

  • Page 25: Front Crossmember

    Front Crossmember FRONT SUSPENSION 7. Front Crossmember B: INSTALLATION 1) Install in the reverse order of removal. A: REMOVAL NOTE: 1) Disconnect the ground cable from battery. Always tighten the bushing when tires are in full 2) Lift-up the vehicle, and then remove the front contact with the ground and vehicle is curb weight.

  • Page 26: Sub Frame

    Sub Frame FRONT SUSPENSION 8. Sub Frame B: INSTALLATION Install in the reverse order of removal. A: REMOVAL NOTE: 1) Lift-up the vehicle. Replace the M12 bolt with a new one. 2) Remove the under cover. 3) Remove the bolt cover. Tightening torque: T1: 34 N·m (3.5 kgf-m, 25 ft-lb) T2: 55 N·m (5.6 kgf-m, 41 ft-lb)
  • Page 27 Sub Frame FRONT SUSPENSION C: INSPECTION 1) Check that there is no damage and distortion at the sub frame. 2) Check that the bolts are tightened with the spec- ified torque. If there is looseness, tighten to the specified torque. Tightening torque: T1: 34 N·m (3.5 kgf-m, 25 ft-lb) T2: 55 N·m (5.6 kgf-m, 41 ft-lb)

  • Page 28: Front Support Arm

    Front Support Arm FRONT SUSPENSION 9. Front Support Arm A: REMOVAL 1) Set the vehicle on a lift. 2) Lift-up the vehicle. 3) Remove the under cover. 4) Remove the four bolts and jack-up plate. FS-00075 5) Remove the two nuts at both ends of arm re- spectively.

  • Page 29: General Diagnostic Table

    General Diagnostic Table FRONT SUSPENSION 10.General Diagnostic Table A: INSPECTION 1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT Possible causes Countermeasures (1) Permanent distortion or breakage of coil spring Replace. (2) Unsmooth operation of damper strut and/or shock absorber Replace.

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