Subaru impreza 2004 Quick Reference Manual
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Subaru impreza 2004 Quick Reference Manual

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2004 IMPREZA SERVICE MANUAL

BODY 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
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTICS)
AIRBAG SYSTEM
AIRBAG SYSTEM (DIAGNOSTICS)
SEAT BELT SYSTEM
LIGHTING SYSTEM
WIPER AND WASHER SYSTEMS
ENTERTAINMENT
COMMUNICATION SYSTEM
GLASS/WINDOWS/MIRRORS
BODY STRUCTURE
INSTRUMENTATION/DRIVER INFO
SEATS
SECURITY AND LOCKS
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
EXTERIOR/INTERIOR TRIM
EXTERIOR BODY PANELS
AC
AC(diag)
AB
AB(diag)
SB
LI
WW
ET
COM
GW
BS
IDI
SE
SL
SR
EI
EB
G1870GE6

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Summary of Contents for Subaru impreza 2004

  • Page 1: Body Section

    AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) This service manual has been prepared to provide SUBARU service personnel SEAT BELT SYSTEM with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. LIGHTING SYSTEM This manual includes the procedures...
  • Page 2 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CC(diag) (DIAGNOSTICS) IMMOBILIZER (DIAGNOSTICS) IM(diag) G1870GE6...

  • Page 3: Table Of Contents

    SECURITY AND LOCKS Page General Description ..................2 Door Lock Control System ................10 Keyless Entry System ................15 Front Inner Remote ...................22 Front Outer Handle ...................23 Front Door Latch Assembly...............24 Front Door Lock Actuator ................25 Rear Inner Remote..................26 Rear Outer Handle ..................27 Rear Door Latch Assembly ...............28 Rear Door Lock Actuator................29 Rear Gate Outer Handle ................30...

  • Page 4: General Description

    General Description SECURITY AND LOCKS 1. General Description A: COMPONENT 1. DOOR LOCK ASSEMBLY • Without double lock SL-00171 Front Rear Inner remote ASSY Door latch Tightening torque: N·m (kgf-m, ft-lb) Inner remote cover Striker T1: 6.4 (0.65, 4.7) Bell crank Door outer handle T2: 7.4 (0.75, 5.5) Auto-door lock actuator...
  • Page 5 General Description SECURITY AND LOCKS • With double lock SL-00172 Front Rear Inner remote ASSY Striker Tightening torque: N·m (kgf-m, ft-lb) Inner remote cover Door outer handle T1: 6.4 (0.65, 4.7) Bell crank Outer handle cover T2: 7.4 (0.75, 5.5) Auto-door lock actuator Key cylinder (switch) T3: 17.6 (1.8, 13.0)
  • Page 6 General Description SECURITY AND LOCKS 2. TRUNK LID AND REAR GATE LOCK • Without double lock SL-00319 Trunk Rear gate Key cylinder Rear gate outer handle Tightening torque: N·m (kgf-m, ft-lb) Cable Rear gate actuator T1: 4.5 (0.45, 3.3) Striker Rear gate latch T2: 25 (2.5, 18.4) Trunk lid lock ASSY...
  • Page 7 General Description SECURITY AND LOCKS • With double lock (10) SL-00306 Trunk Rear gate Key cylinder Striker Tightening torque: N·m (kgf-m, ft-lb) Bracket Rear gate outer handle T1: 4.5 (0.45, 3.3) Key cylinder stopper Rear gate actuator T2: 25 (2.5, 18.4) Trunk lid lock ASSY Rear gate latch Cable...
  • Page 8 General Description SECURITY AND LOCKS 3. HOOD LOCK AND REMOTE OPENERS HOOD SL-00174 Sedan Wagon Hood lock ASSY Cover Tightening torque: N·m (kgf-m, ft-lb) Lever ASSY Pull handle ASSY T1: 6.4 (0.65, 4.7) Cable T2: 32 (3.3, 23.9) SL-6...
  • Page 9 General Description SECURITY AND LOCKS 4. IMMOBILIZER SYSTEM SL-00175 Antenna Immobilizer control module (IMM Transponder ECM) Immobilizer indicator light (LED bulb) NOTE: IMM ECM location for RHD model is symmetrically opposite. SL-7...
  • Page 10 General Description SECURITY AND LOCKS 5. KEYLESS ENTRY SYSTEM SL-00176 Double lock module (with double Rear gate latch Keyless entry control module lock) (LHD model) Door switch Keyless entry control module (RHD model) SL-8...

  • Page 11: General Description

    General Description SECURITY AND LOCKS B: CAUTION • Adjust parts to specifications contained in this manual if so designated. • Before disassembling or reassembling parts, • Connect the connectors securely during always disconnect the ground cable from reassembly. battery. When repairing radio, control module, •...

  • Page 12: Door Lock Control System

    Door Lock Control System SECURITY AND LOCKS 2. Door Lock Control System A: WIRING DIAGRAM 1. DOOR LOCK CONTROL <Ref. to WI-188, WIRING DIAGRAM, Keyless Entry System.> B: INSPECTION 1. SYMPTOM CHART Symptom Repair order Reference <Ref. to SL-11, CHECK FUSE, 1.
  • Page 13 Door Lock Control System SECURITY AND LOCKS 2. CHECK FUSE Step Check CHECK FUSE. Is the fuse blown out? Replace the fuse Check the power Remove and visually check the fuse No. 2 (in with a new one. supply and ground the main fuse box) and No.
  • Page 14 Door Lock Control System SECURITY AND LOCKS 4. CHECK DOOR LOCK SWITCH AND CIRCUIT Step Check CHECK DOOR LOCK SWITCH CIRCUIT. Is the resistance less than 10 Go to step 2. Go to step 3. Ω? 1)Disconnect the keyless entry control module or double lock module harness connector.
  • Page 15 Door Lock Control System SECURITY AND LOCKS 5. CHECK DOOR LOCK ACTUATOR AND CIRCUIT Step Check CHECK OUTPUT SIGNAL. Is the voltage more than 10 V? Go to step 2. Replace the key- Measure the voltage between the harness con- less entry control nector terminal of keyless entry control module module or double...
  • Page 16 Door Lock Control System SECURITY AND LOCKS 6. CHECK KEY CYLINDER LOCK SWITCH AND CIRCUIT Step Check CHECK KEY CYLINDER LOCK SWITCH CIR- Is the resistance less than 10 Go to step 2. Go to step 3. Ω? CUIT. 1)Disconnect the double lock module harness connector.

  • Page 17: Keyless Entry System

    Keyless Entry System SECURITY AND LOCKS 3. Keyless Entry System A: WIRING DIAGRAM <Ref. to WI-188, WIRING DIAGRAM, Keyless Entry System.> B: ELECTRICAL SPECIFICATION SL-00036 Content Terminal No. Measuring condition Key warning switch 1 (INPUT) Battery voltage is present when inserting the key into ignition switch. Registration connector 2 (INPUT) 0 V is present when connecting the registration connector.
  • Page 18 Keyless Entry System SECURITY AND LOCKS C: INSPECTION 1. SYMPTOM CHART Symptom Repair order Reference <Ref. to SL-17, CHECK TRANSMIT- 1. Check the transmitter battery. TER BATTERY, INSPECTION, Key- less Entry System.> <Ref. to SL-17, CHECK FUSE, 2. Check the fuse. INSPECTION, Keyless Entry Sys- tem.>...
  • Page 19 Keyless Entry System SECURITY AND LOCKS 2. CHECK TRANSMITTER BATTERY Step Check CHECK TRANSMITTER BATTERY. Is the voltage more than 2 V? Further inspection Replace the trans- 1)Remove the battery from transmitter. <Ref. is necessary, refer mitter battery. to SL-43, REMOVAL, Keyless Transmitter.> to “SYMPTOM 2)Check the battery voltage.
  • Page 20 Keyless Entry System SECURITY AND LOCKS 5. CHECK REGISTRATION CONNECTOR CIRCUIT Step Check REGISTRATION CONNECTOR INPUT VOLT- Is the voltage more than 10 V? Go to step 2. Repair the har- AGE INSPECTION ness, and/or con- 1)Disconnect the registration connector. nector.
  • Page 21 Keyless Entry System SECURITY AND LOCKS Step Check Is the resistance less than 1 Ω CHECK DOOR SWITCH. Check the followng: Replace the door • Without double Measure the resistance between door switch when door switch is released? switch. lock: Check the terminals.
  • Page 22 Keyless Entry System SECURITY AND LOCKS Step Check CHECK KEY WARNING SWITCH. Is the resistance more than 1 Check the followng: Replace the key • Harness for 1)Remove the key from ignition switch. MΩ? warning switch. open circuits or 2)Measure the resistance between key warn- shorts between ing switch terminals.
  • Page 23 Keyless Entry System SECURITY AND LOCKS 10.CHECK IGNITION SWITCH ILLUMINATION CIRCUIT Step Check CHECK IGNITION SWITCH ILLUMINATION Is the voltage more than 10 V? Go to step 2. Check the harness POWER SUPPLY. for open circuit or 1)Disconnect the ignition switch illumination shorts between harness connector.

  • Page 24: Front Inner Remote

    Front Inner Remote SECURITY AND LOCKS 4. Front Inner Remote A: REMOVAL 1) Remove the door trim. <Ref. to EI-37, REMOV- AL, Front Door Trim.> 2) Remove the sealing cover. <Ref. to EB-17, RE- MOVAL, Front Sealing Cover.> 3) Remove a screw and two rod joints. 4) Remove the front inner remote.

  • Page 25: Front Outer Handle

    Front Outer Handle SECURITY AND LOCKS 5. Front Outer Handle A: REMOVAL 1. MODEL WITHOUT DOUBLE LOCK 1) Remove the door trim. <Ref. to EI-37, REMOV- AL, Front Door Trim.> 2) Remove the sealing cover. <Ref. to EB-17, RE- MOVAL, Front Sealing Cover.> 3) Remove the bolt (A).

  • Page 26: Front Door Latch Assembly

    Front Door Latch Assembly SECURITY AND LOCKS 6. Front Door Latch Assembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the front door trim. <Ref. to EI-37, RE- MOVAL, Front Door Trim.> 3) Remove the sealing cover. <Ref. to EB-17, RE- MOVAL, Front Sealing Cover.>...

  • Page 27: Front Door Lock Actuator

    Front Door Lock Actuator SECURITY AND LOCKS 7. Front Door Lock Actuator 2. With double lock A: REMOVAL 1) Remove the front door latch assembly. <Ref. to SL-24, REMOVAL, Front Door Latch Assembly.> 2) Remove two screws to remove the front door lock actuator.

  • Page 28: Rear Inner Remote

    Rear Inner Remote SECURITY AND LOCKS 8. Rear Inner Remote A: REMOVAL 1) Remove the rear door trim. <Ref. to EI-38, RE- MOVAL, Rear Door Trim.> 2) Remove the sealing cover. <Ref. to EB-19, RE- MOVAL, Rear Sealing Cover.> 3) Remove a screw and two rod joints. 4) Remove the inner remote.

  • Page 29: Rear Outer Handle

    Rear Outer Handle SECURITY AND LOCKS 9. Rear Outer Handle A: REMOVAL 1) Remove the rear door trim. <Ref. to EI-38, RE- MOVAL, Rear Door Trim.> 2) Remove the sealing cover. <Ref. to EB-19, RE- MOVAL, Rear Sealing Cover.> 3) Remove the rear inner remote. <Ref. to SL-26, REMOVAL, Rear Inner Remote.>...

  • Page 30: Rear Door Latch Assembly

    Rear Door Latch Assembly SECURITY AND LOCKS 10.Rear Door Latch Assembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear door trim. <Ref. to EI-38, RE- MOVAL, Rear Door Trim.> 3) Remove the sealing cover. <Ref. to EB-19, RE- MOVAL, Rear Sealing Cover.>...

  • Page 31: Rear Door Lock Actuator

    Rear Door Lock Actuator SECURITY AND LOCKS 11.Rear Door Lock Actuator 2. With double lock A: REMOVAL 1) Remove the rear door latch assembly. <Ref. to SL-28, REMOVAL, Rear Door Latch Assembly.> 2) Remove two screws to remove rear door lock actuator.

  • Page 32: Rear Gate Outer Handle

    Rear Gate Outer Handle SECURITY AND LOCKS 12.Rear Gate Outer Handle A: REMOVAL 1) Remove the rear gate trim. <Ref. to EI-52, RE- MOVAL, Rear Gate Trim.> 2) Remove the rear gate latch assembly. <Ref. to SL-31, REMOVAL, Rear Gate Latch Assembly.> 3) Remove two nuts to remove the rear gate outer handle.

  • Page 33: Rear Gate Latch Assembly

    Rear Gate Latch Assembly SECURITY AND LOCKS 13.Rear Gate Latch Assembly A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the rear gate trim. <Ref. to EI-52, RE- MOVAL, Rear Gate Trim.> 3) Remove three bolts. SL-00186 4) Disconnect the connectors, and then remove the rear gate latch assembly.

  • Page 34: Rear Gate Latch Lock Actuator

    Rear Gate Latch Lock Actuator SECURITY AND LOCKS 14.Rear Gate Latch Lock Actua- A: REMOVAL 1) Remove the rear gate latch assembly. <Ref. to SL-31, REMOVAL, Rear Gate Latch Assembly.> 2) Remove two screws to remove the rear gate lock actuator.

  • Page 35: Trunk Lid Lock Assembly

    Trunk Lid Lock Assembly SECURITY AND LOCKS 15.Trunk Lid Lock Assembly A: REMOVAL 1) Remove the trunk lid key cylinder rod clamp. 2) Remove two bolts to remove the trunk lid lock assembly. SL-00189 B: INSTALLATION Install in the reverse order of removal. NOTE: •...

  • Page 36: Front Hood Lock Assembly

    Front Hood Lock Assembly SECURITY AND LOCKS 16.Front Hood Lock Assembly A: REMOVAL 1) Open the hood. 2) Remove the bolts. Remove the hood lock as- sembly. 3) Remove the release cable from lock assembly. SL-00190 B: INSTALLATION Install in the reverse order of removal. NOTE: •...

  • Page 37: Remote Openers

    Remote Openers SECURITY AND LOCKS 17.Remote Openers 6) Remove the cable from striker. A: REMOVAL 1. HOOD OPENER 1) Remove the release cable from hood lock. 2) Remove the bolt. Remove the opener lever. SL-00120 (1) Striker (2) Cable 3. FUEL FLAP OPENER SL-00089 1) Remove the rear seat.
  • Page 38 Remote Openers SECURITY AND LOCKS 6) Rotate the fuel lock inside the quarter panel to left and remove. SL-00023 B: INSTALLATION 1. HOOD OPENER Install in the reverse order of removal. 2. TRUNK LID OPENER Install in the reverse order of removal. 3.

  • Page 39: Ignition Key Lock

    Ignition Key Lock SECURITY AND LOCKS 18.Ignition Key Lock A: REPLACEMENT 1) Remove the ground cable from battery. 2) Remove the steering column. <Ref. to PS-26, REMOVAL, Tilt Steering Column.> 3) Secure the steering column in a vise. Remove the bolt with a drill. SL-00024 4) Remove the ignition key lock.

  • Page 40: Key Lock Cylinders

    Key Lock Cylinders SECURITY AND LOCKS 19.Key Lock Cylinders 6) Remove the hooks (two), and then remove the key cylinder lock switch (A) to replace the key cyl- A: REPLACEMENT inder. 1. FRONT DOOR • Without double lock 1) Remove the door trim. <Ref. to EI-37, REMOV- AL, Front Door Trim.>...

  • Page 41: Immobilizer Control Module

    Immobilizer Control Module SECURITY AND LOCKS 20.Immobilizer Control Module A: REMOVAL NOTE: The following positions for removal and installation are for LHD models. The positions for RHD models are symmetrically opposite. 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. <Ref. to EI-43, REMOVAL, Instrument Panel Assembly.>...

  • Page 42: Immobilizer Antenna

    Immobilizer Antenna SECURITY AND LOCKS 21.Immobilizer Antenna A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. <Ref. to EI-43, REMOVAL, Instrument Panel Assembly.> 3) Remove the screws, separate upper column cover and lower column cover. SL-00062 4) Disconnect the immobilizer antenna connector (A) from immobilizer control module.

  • Page 43: Keyless Entry Control Module

    Keyless Entry Control Module SECURITY AND LOCKS 22.Keyless Entry Control Mod- A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. <Ref. to EI-43, REMOVAL, Instrument Panel Assembly.> 3) Remove the nut, and then remove the keyless entry control module while disconnecting connec- tor.

  • Page 44: Double Lock Module

    Double Lock Module SECURITY AND LOCKS 23.Double Lock Module A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the instrument panel lower cover. <Ref. to EI-43, REMOVAL, Instrument Panel Assembly.> 3) Remove the nut, then remove the double lock module while disconnecting the connector.

  • Page 45: Keyless Transmitter

    Keyless Transmitter SECURITY AND LOCKS 24.Keyless Transmitter Tester connection Standard (–) A: REMOVAL Battery (+) termi- Battery (–) termi- 2.5 — 3.0 V 1. TRANSMITTER BATTERY Remove the screw (A) from transmitter, and then If NG, replace the battery. (Use CR1620 or equiva- remove the battery.
  • Page 46 Keyless Transmitter SECURITY AND LOCKS SL-44...

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