Subaru 2004 IMPREZA Service Manual
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Subaru 2004 IMPREZA Service Manual

Chassis section
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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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  • Page 1 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX CHASSIS SECTION 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.

  • Page 2: Table Of Contents

    POWER ASSISTED SYSTEM (POWER STEERING) Page General Description ..................2 Steering Wheel..................23 Universal Joint...................24 Tilt Steering Column..................26 Steering Gearbox [LHD MODEL] ..............29 Steering Gearbox [RHD MODEL] .............47 Pipe Assembly [LHD MODEL] ..............64 Pipe Assembly [RHD MODEL]..............72 Oil Pump ....................80 Reservoir Tank..................85 Power Steering Fluid.................86 General Diagnostic Table................87...

  • Page 3: Steering Gearbox [Rhd Model]

    Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 6. Steering Gearbox [RHD MOD- 10) Remove the one pipe joint at center of gearbox, and connect vinyl hose to pipe and joint. Discharge fluid by turning the steering wheel fully clockwise and counterclockwise.

  • Page 4: Steering Wheel

    Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) B: INSTALLATION 6) After tightening the castle nut to the specified tightening torque, tighten it further within 60° until 1) Insert the gearbox into crossmember, being cotter pin hole is aligned with slot in the nut. Fit the careful not to damage the gearbox boot.
  • Page 5 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 21) After adjusting the toe-in and steering angle, 3) Remove the clip on outside of boot using pliers, tighten the lock nut on tie-rod end. and then slide the boot to tie-rod end side. Tightening torque: 83 N·m (8.5 kgf-m, 61.5 ft-lb) NOTE:...
  • Page 6 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 6) Tighten the adjusting screw until it no longer 10) Clean the dirt of input shaft. Remove the dust tightens. cover taking care not to scratch the housing or in- put shaft and allow foreign matter to enter gear box interior.
  • Page 7 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 12) Remove the valve assembly taking care not to 14) Install the ST on valve side of rack and press scratch seal ring and valve housing inner surface. outer side oil seal out taking care not to contact rack with steering body inner surface.
  • Page 8 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 15) Insert the ST from valve side and press back- 17) If the cylinder edge is deformed in a convex up ring and oil seal out. shape, repair using an oil stone. ST 927580000 REMOVER PS-00067...
  • Page 9 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 20) Set the stopper to gear box, and then insert the 22) While fixing the 2-surface width, pull out the oil tip of ST to gear box. seal by rotating nut. CAUTION: Take care not to scratch the gear box inner sur- face.
  • Page 10 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 3) Attach the steering body to ST as shown in the 5) Insert the ST·A with oil seal assembled, through figure. Apply a coat of grease to needle bearing. gear side of rack. Remove the oil seal from ST·A ST 926200000 STAND near piston, and then remove the ST·A from rack.
  • Page 11 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 7) Install the ST on rack and equally apply a thin 9) Make the ST2 pass through rack, and then push coat of grease to the rack and ST, then install the oil in the rack and ST2 using a press until ST1 comes seal.
  • Page 12 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 11) Using the ST, clinch steering body cylinder at a 13) Apply a coat of grease on the gear teeth of point less than 3 mm (0.12 in) from holder. valve assembly, and then attach the valve assem- bly taking care not to scratch oil seal and seal ring.
  • Page 13 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 15) Using the ST, install plug. 18) Apply a coat of grease to the sliding surface of seat pad, sleeve and seating surface of spring, and ST 34199AE090 PLUG WRENCH then insert sleeve into steering body. Tightening torque: Charge the adjusting screw with grease, and then 64 N·m (6.5 kgf-m, 47.0 ft-lb)
  • Page 14 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 24) Tighten the adjusting screw. 33) Caulk the boot so the space inside boot band caulking portion becomes 2 mm (0.08 in) or less. Tightening torque: NOTE: 9.8 N·m (10.0 kgf-m, 7.2 ft-lb) Use a new boot band.
  • Page 15 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 36) If the tie-rod end was removed, screw in the lock nut and tie-rod end to screwed portion of tie- rod, and then tighten the lock nut temporarily in a position as shown in the figure. Installed tie-rod length: L Sedan: 25 mm (0.98 in)

  • Page 16: Basic Inspection

    Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) E: INSPECTION 1. BASIC INSPECTION 1) Clean all disassembled parts, and check for wear, damage, or any other faults, then repair or replace as necessary. 2) When disassembling, check the inside of gearbox for water. If any water is found, carefully check the boot for damage, input shaft dust seal, adjusting screw and boot clips for poor sealing.
  • Page 17 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 2. SERVICE LIMIT Right-turn steering: Make a measurement as follows. If it exceeds the Service limit specified service limit, adjust or replace. Direction 0.3 mm (0.012 in) or less NOTE: Direction When making a measurement, vise gearbox by us- 0.19 mm (0.0075 in) or less ing ST.
  • Page 18 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 5. TURNING RESISTANCE OF GEARBOX Using the ST, measure gearbox turning resistance. ST 34099PA100 SPANNER Service limit Maximum allowable resistance 10.5 N (1.1 kgf, 2.4 lb) or less Difference between right and left turning resis- tance: Less than 20% PS-00105...
  • Page 19 Steering Gearbox [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 1) Lift up the vehicle. 3) If the steering wheel spokes are not horizontal when wheels are set in the straight ahead position, 2) Even if the location of leak can be easily found by observing leaking condition, it is necessary to and error is more than 5°...

  • Page 20: Pipe Assembly [Lhd Model]

    Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 7. Pipe Assembly [LHD MODEL] 4) Remove the clamp E from pipes C and D. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and then remove the jack-up plate.
  • Page 21 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 6) NON-TURBO MODEL 7) TURBO MODEL (1) Remove the air intake duct. <Ref. to (1) Remove the air cleaner. IN(H4SO)-6, REMOVAL, Air Intake Duct.> <Ref. to IN(H4DOTC)-7, REMOVAL, Air Clean- (2) Remove the bolt A. er.>...
  • Page 22 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) B: INSTALLATION 2) Install the coolant filler tank. (Turbo model) 1) Temporarily tighten the two bolts fixing pipe C Tightening torque: and D. (bolt A) T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb) T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb) NOTE: Visually check that the hose between tank and pipe...
  • Page 23 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 3) Temporarily connect the pipe C and D to gear 5) Tighten the clamp E firmly. box. Tightening torque: 7.4 N·m (0.75 kgf-m, 5.4 ft-lb) 6) Tighten the joint nut. Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) 7) Connect the pipes A and B to four pipe joints of gearbox.
  • Page 24 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 13) Finally check clearance between pipes and/or hoses, as shown above. If cruise control actuator-to-power steering hose clearance is less than 10 mm (0.39 in), move the portion (A) secured by clamp to other portion, or bend portion (B) to adjust. PS-00179 (1) High pressure hose (2) No interference is allowed...
  • Page 25 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) C: INSPECTION Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as re- quired. Part name Inspection Remedy • O-ring fitting surface for damage Pipe •...
  • Page 26 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) NOTE: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after main- tenance.
  • Page 27 Pipe Assembly [LHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) Fluid leaking area Possible cause Corrective action Insufficient tightening of flare nut, catching Loosen and retighten, if ineffective, dirt or the like, damage to flare or flare nut or replace. eye bolt Leakage from connecting portions of pipes and hoses, numbered with (1) Poor insertion of hose, poor clamping...

  • Page 28: Pipe Assembly [Rhd Model]

    Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 8. Pipe Assembly [RHD MODEL] 4) Remove the clamp E from pipes C and D. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Lift-up the vehicle, and then remove the jack-up plate.
  • Page 29 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 6) Non-turbo model 7) Turbo model (1) Remove the air cleaner. (1) Remove the air cleaner. (2) Remove the bolt A. <Ref. to IN(H4DOTC)-7, REMOVAL, Air Clean- er.> (3) Disconnect the pipe C from oil pump. Dis- connect the pipe D from return hose.
  • Page 30 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) B: INSTALLATION 2) Install the coolant filler tank. (Turbo model) 1) Temporarily tighten the two bolts fixing pipe C Tightening torque: and D. (bolt A for Non-turbo model.) T1: 19 N·m (1.9 kgf-m, 13.7 ft-lb) T2: 21 N·m (2.1 kgf-m, 15.2 ft-lb) NOTE: Visually check that the hose between tank and pipe...
  • Page 31 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 3) Temporarily connect the pipe C and D to gear 6) Tighten the joint nut. box. Tightening torque: 15 N·m (1.5 kgf-m, 10.8 ft-lb) 7) Connect the pipes A and B to four pipe joints of gearbox.
  • Page 32 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) 12) Finally check clearance between pipes and/or hoses, as shown in the figure. PS-00122 (1) Clearance between blow-by hose (3) Clearance between side frame and (5) Steering gearbox and pipe: 3 — 5 mm (0.12 — 0.20 in) hose: 15 mm (0.59 in) or more (2) No interference is allowed between (4) Clearance between crossmember...
  • Page 33 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) C: INSPECTION Check all disassembled parts for wear, damage or other abnormalities. Repair or replace faulty parts as re- quired. Part name Inspection Remedy • O-ring fitting surface for damage Pipe •...
  • Page 34 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) NOTE: It is likely that although one judges fluid leakage, there is actually no leakage. This is because the fluid spilt during the last maintenance was not completely wiped off. Be sure to wipe off spilt fluid thoroughly after main- tenance.
  • Page 35 Pipe Assembly [RHD MODEL] POWER ASSISTED SYSTEM (POWER STEERING) Fluid leaking area Possible cause Corrective action Insufficient tightening of flare nut, catching Loosen and retighten, if ineffective, dirt or the like, damage to flare or flare nut or replace. eye bolt Leakage from connecting portions of pipes and hoses, numbered with (1) Poor insertion of hose, poor clamping...

  • Page 36: Oil Pump

    Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) 9. Oil Pump 6) Remove the bolts which install the power steer- ing pump bracket. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the pulley belt cover. 3) Loosen the belt tension adjusting bolt and gen- erator securing bolt, and then remove the power steering pump V-belt.
  • Page 37 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) B: INSTALLATION Tightening torque: 37.3 N·m (3.8 kgf-m, 27.5 ft-lb) 1) Install the oil pump to bracket. (1) Place the oil pump bracket in a vise. Tighten the bushing using a 12.7 mm (1/2″) type 14 mm and 21 mm box wrench until it is in contact with the oil pump mounting surface.
  • Page 38 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) 7) Tighten the bolt of belt tension. Tightening torque: 25 N·m (2.5 kgf-m, 18.1 ft-lb) 8) Install the pulley belt cover. 9) Connect the battery ground cable to battery. 10) Feed the specified power steering fluid. <Ref. to PS-86, Power Steering Fluid.>...
  • Page 39 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) Axial play (Direction • Measure the load during rotation and make a judgment. 0.9 mm (0.035 in) or less PS-00148 PS-00146 (1) Dial indicator (1) Spring balance 2) Ditch deflection of pulley 3. HYDRAULIC PRESSURE Service limit: NOTE: 1.0 mm (0.039 in) or less...
  • Page 40 Oil Pump POWER ASSISTED SYSTEM (POWER STEERING) (5) Install the ST3 to end of pipe C removed (4) If it is not within the specified value, replace from pump. the oil pump. (6) Replenish power steering fluid up to the 3) Measure the working pressure.

  • Page 41: Reservoir Tank

    Reservoir Tank POWER ASSISTED SYSTEM (POWER STEERING) 10.Reservoir Tank C: INSPECTION Check the reservoir tank for cracks, breakage, or A: REMOVAL damage. If any cracks, breakage, or damage is 1) Remove the air intake duct. <Ref. to IN(H4SO)- found, replace the reservoir tank. 6, REMOVAL, Air Intake Duct.>...

  • Page 42: Power Steering Fluid

    Power Steering Fluid POWER ASSISTED SYSTEM (POWER STEERING) 11.Power Steering Fluid C: REPLACEMENT 1) Lift up the vehicle. A: SPECIFICATION 2) Remove the jack up plate. 3) Remove the pipe joint in center of gear box, and Recommended power steering fluid Manufacturer then install the vinyl hose to pipe and joint.

  • Page 43: General Diagnostic Table

    General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) 12.General Diagnostic Table A: INSPECTION Trouble Possible cause Corrective action • Heavy steering effort in all 1. Pulley belt ranges • Unequal length of pulley belts • Heavy steering effort at • Adhesion of oil and grease stand still •...

  • Page 44: Noise And Vibration

    General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) 1. NOISE AND VIBRATION CAUTION: Don’t keep the relief valve operated over 5 seconds at any time or inner parts of the oil pump may be damaged due to rapid increase of fluid temperature. NOTE: •...
  • Page 45 General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) Trouble Possible cause Corrective action Fix the wrong part causing aera- Fluid aeration tion. Replace the fluid and vent air. Damaged pipe of gearbox Replace the pipe. Sizzling noise (continuous) While engine is running. Abnormal inside of hose or pipe Rectify or replace.
  • Page 46 General Diagnostic Table POWER ASSISTED SYSTEM (POWER STEERING) 2. MEASUREMENT OF STEERING EFFORT Step Check CHECK STEERING EFFORT. Is the steering effort less than Go to step 2. Adjust the back- 1)Stop the vehicle on a concrete road. 29.4 N (3.0 kgf, 6.6 lb)? lash.

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