Subaru IMPREZA 2004 Service Manual
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Subaru IMPREZA 2004 Service Manual

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2004 Model Year
PDF Service Manual
GENERAL INFORMATION SECTION (Pub.No.G1870GE1)
ENGINE SECTION 1 (Pub.No.G1870GE2)
ENGINE SECTION 2 (Pub.No.G1870GE3)
TRANSMISSION SECTION (Pub.No.G1870GE4)
CHASSIS SECTION (Pub.No.G1870GE5)
BODY SECTION (Pub.No.G1870GE6)
WIRING SYSTEM SECTION (Pub.No.G1870GE7)

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  • Page 1 2004 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G1870GE1) ENGINE SECTION 1 (Pub.No.G1870GE2) ENGINE SECTION 2 (Pub.No.G1870GE3) TRANSMISSION SECTION (Pub.No.G1870GE4) CHASSIS SECTION (Pub.No.G1870GE5) BODY SECTION (Pub.No.G1870GE6) WIRING SYSTEM SECTION (Pub.No.G1870GE7)
  • Page 3 SECTION FOREWORD HOW TO USE THIS MANUAL SPECIFICATIONS PRECAUTION This service manual has been prepared to provide SUBARU service personnel NOTE with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. IDENTIFICATION This manual includes the procedures...
  • Page 5 FOREWORD Page Foreword .....................2...
  • Page 6 FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing mainte- nance, repair, or diagnosis of the Subaru IMPRE- Applied model: GD*****, GG***** from 2004MY The manuals contain the latest information at the time of publication. Changes in specifications, methods, etc.

  • Page 7: How To Use This Manual

    HOW TO USE THIS MANUAL Page How to Use This Manual ................2...
  • Page 8 How to Use This Manual HOW TO USE THIS MANUAL 1. How to Use This Manual A: HOW TO USE THIS MANUAL 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com- ponent.
  • Page 9 How to Use This Manual HOW TO USE THIS MANUAL Example: (20) (21) (12) (23) (22) (16) (14) (18) (10) (11) (11) (13) (10) (15) (17) (19) (10) (15) (22) (12) (35) (34) (27) (10) (26) (23) (24) (25) (14) (24) (36) (25)
  • Page 10 How to Use This Manual HOW TO USE THIS MANUAL 4. SPECIFICATIONS If necessary, specifications are also included. 5. INSPECTION Inspections are included to be carried out before and after maintenance. 6. MAINTENANCE • Maintenance instructions for serviceable parts describes work area and detailed steps with illustration. It also describes the use of special tool, tightening torque, cautions for each procedure.
  • Page 11 How to Use This Manual HOW TO USE THIS MANUAL 7. DIAGNOSIS Tables showing a step-by-step process make it easy to conduct diagnosis. 8. SI UNITS Measurements in these manuals are according to the SI units. Metric and yard/pound measurements are also included.
  • Page 12 : Electronic Gasoline Injection SOHC : Single Overhead Camshaft : Engine : Supplemental Restraint System : Exhaust Gas Recirculation : Subaru Select Monitor : Emergency Locking Retractor : Special Tool : Fuse & Joint Box : Switch : Fusible Link...

  • Page 13: Specifications

    SPECIFICATIONS Page Impreza .......................2...
  • Page 14 Impreza SPECIFICATIONS 1. Impreza A: DIMENSIONS Model Sedan Wagon OUTBACK Overall length mm (in) 4,415 (173.8) Overall width mm (in) 1,740 (68.4) 1,695 (66.7) 1,710 (67.3) 1,740 (68.1) Overall height (at C.W.) mm (in) 1,465 (57.7), 1,475 (58.1), 1,440 (56.7) 1,440 (56.7) 1,485 (58.5) 1,495 (58.9)
  • Page 15 Impreza SPECIFICATIONS B: ENGINE Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Valve arrangement Overhead camshaft type Bore Stroke mm (in) 87.9 65.8 99.5 (3.461 2.591) (3.62 2.95) (3.92 3.11)
  • Page 16 Impreza SPECIFICATIONS D: TRANSMISSION Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L Transmission type Clutch type DSPD DSPD DSPD DSPD DSPD Gear ratio 3.454, 3.454 2.785 3.454 2.785 2.785 3.454 2.785 3.636 3.166 1.947, 2.062 1.545 2.062 1.545 1.545 2.062...
  • Page 17 Impreza SPECIFICATIONS G: BRAKE Model 1.6 L Non-turbo 2.0 L, 2.5 L Turbo 2.0 L, STi Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Drum brake Disc brake Ventilated disc brake Parking brake Mechanical on rear brakes H: TIRE Model...
  • Page 18 Impreza SPECIFICATIONS J: WEIGHT 1. LHD MODEL Sedan Option code Model 1.6 L Base Curb weight (C.W.) Front kgf (lb) (1,587) (1,687) (1,698) (1,620) (1,664) (1,654) (1,654) (1,631) Rear kgf (lb) (1,036) (1,036) (1,036) (1,146) (1,146) (1,146) (1,146) (1,179) Total kgf (lb) 1,190 1,235...
  • Page 19 Impreza SPECIFICATIONS Option code Model 1.6 L 2.0 L Curb weight (C.W.) Front kgf (lb) (1,644) (1,709) (1,698) (1,698) (1,676) (1,654) (1,698) (1,687) Rear kgf (lb) (1,146) (1,146) (1,146) (1,146) (1,168) (1,179) (1,179) (1,179) Total kgf (lb) 1,275 1,295 1,290 1,290 1,295 1,285...
  • Page 20 Impreza SPECIFICATIONS Option code Model 2.0 L Curb weight (C.W.) Front kgf (lb) (1,698) (1,687) (1,698) (1,687) (1,676) (1,687) (1,709) (1,753) Rear kgf (lb) (1,179) (1,179) (1,179) (1,168) (1,157) (1,235) (1,168) (1,168) Total kgf (lb) 1,305 1,300 1,305 1,295 1,285 1,325 1,305 1,325...
  • Page 21 Impreza SPECIFICATIONS Option code Model 2.0 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,742) (1,742) (1,742) (1,753) (1,742) (1,753) (1,753) (1,841) Rear kgf (lb) (1,168) (1,168) (1,168) (1,168) (1,157) (1,168) (1,224) (1,235) Total kgf (lb) 1,320 1,325 1,320 1,325 1,315...
  • Page 22 Impreza SPECIFICATIONS Option code Model 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,808) (1,841) (1,841) (1,852) (1,840) (1,852) (1,852) (1,852) Rear kgf (lb) (1,213) (1,224) (1,235) (1,257) (1,246) (1,257) (1,257) (1,268) Total kgf (lb) 1,370 1,390 1,395 1,410 1,400 1,410 1,410...
  • Page 23 Impreza SPECIFICATIONS Option code Model 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,840) (1,852) (1,852) (1,951) (1,907) (1,951) (1,951) (1,907) Rear kgf (lb) (1,235) (1,268) (1,268) (1,290) (1,290) (1,290) (1,290) (1,290) Total kgf (lb) 1,395 1,415 1,415 1,470 1,450 1,470 1,470...
  • Page 24 Impreza SPECIFICATIONS Wagon Option code Model 1.6 L 5MT D/R Curb weight (C.W.) Front kgf (lb) (1,631) (1,631) (1,676) (1,664) (1,664) (1,643) (1,664) (1,664) Rear kgf (lb) (1,202) (1,213) (1,202) (1,202) (1,202) (1,235) (1,202) (1,213) Total kgf (lb) 1,285 1,290 1,305 1,300 1,300...
  • Page 25 Impreza SPECIFICATIONS Option code Model 1.6 L 2.0 L 5MT D/R Curb weight (C.W.) Front kgf (lb) (1,709) (1,698) (1,698) (1,676) (1,676) (1,731) (1,720) (1,709) Rear kgf (lb) (1,202) (1,202) (1,202) (1,235) (1,257) (1,290) (1,257) (1,257) Total kgf (lb) 1,320 1,315 1,315 1,320...
  • Page 26 Impreza SPECIFICATIONS Option code Model 2.0 L 5MT D/R Curb weight (C.W.) Front kgf (lb) (1,720) (1,720) (1,709) (1,698) (1,709 (1,764) (1,753) (1,742) Rear kgf (lb) (1,257) (1,257) (1,246) (1,300) (1,246) (1,279) (1,246) (1,246) Total kgf (lb) 1,350 1,350 1,340 1,360 1,340 1,380...
  • Page 27 Impreza SPECIFICATIONS Option code Model 2.0 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,753) (1,753) (1,742) (1,742) (1,775) (1,819) (1,830) (1,830) Rear kgf (lb) (1,246) (1,246) (1,235) (1,279) (1,290) (1,290) (1,322) (1,322) Total kgf (lb) 1,360 1,360 1,350 1,370 1,390...
  • Page 28 Impreza SPECIFICATIONS Option code Model 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,830) (1,830) Rear kgf (lb) (1,322) (1,311) Total kgf (lb) 1,430 1,425 (3,153) (3,142) Maximum permissible Front kgf (lb) axle weight (M.P.A.W.) (2,183) (2,183) Rear kgf (lb) (2,094) (2,094) Maximum permissible...
  • Page 29 Impreza SPECIFICATIONS 2. RHD MODEL Sedan Option code Model 1.6 L 2.0 L Curb weight (C.W.) Front kgf (lb) (1,631) (1,676) (1,676) (1,654) (1,698) (1,698) (1,753) (1,698) Rear kgf (lb) (1,146) (1,146) (1,146) (1,146) (1,146) (1,179) (1,168) (1,179) Total kgf (lb) 1,260 1,280 1,280...
  • Page 30 Impreza SPECIFICATIONS Option code Model 2.0 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,753) (1,841) (1,841) (1,852) (1,852) (1,952) (1,952) Rear kgf (lb) (1,168) (1,246) (1,246) (1,257) (1,268) (1,290) (1,290) Total kgf (lb) 1,325 1,400 1,395 1,410 1,415 1,470 1,470...
  • Page 31 Impreza SPECIFICATIONS Option code Model 2.0 L 2.5 L 2.0 L Turbo Unladen weight (U.W.) Front kg (lb) (1,654) (1,687) (1,709) (1,742) (1,720) (1,775) (1,852) (1,841) Rear kg (lb) (1,179) (1,179) (1,168) (1,168) (1,191) (1,179) (1,268) (1,235) Total kg (lb) 1,285 1,300 1,305...
  • Page 32 Impreza SPECIFICATIONS Option code Model 2.0 L Turbo Unladen weight (U.W.) Front kg (lb) (1,852) (1,896) (1,907) (1,907) (1,952) (1,952) Rear kg (lb) (1,257) (1,234) (1,246) (1,257) (1,290) (1,290) Total kg (lb) 1,410 1,415 1,430 1,435 1,470 1,470 (3,109) (3,120) (3,153) (3,164) (3,241)
  • Page 33 Impreza SPECIFICATIONS Wagon Option code Model 1.6 L 2.0 L 5MT D/R 5MT D/R 5MT D/R 5MT D/R Curb weight (C.W.) Front kgf (lb) (1,642) (1,687) (1,676) (1,664) (1,698) (1,720) (1,753) (1,720) Rear kgf (lb) (1,202) (1,202) (1,202) (1,202) (1,202) (1,257) (1,246) (1,257)
  • Page 34 Impreza SPECIFICATIONS Option code Model 2.0 L 2.0 L Turbo Curb weight (C.W.) Front kgf (lb) (1,753) (1,819) (1,819) (1,830) (1,830) Rear kgf (lb) (1,246) (1,830) (1,301) (1,323) (1,323) Total kgf (lb) 1,360 1,410 1,415 1,430 1,430 (2,999) (3,109) (3,120) (3,153) (3,153) Maximum permissible...
  • Page 35 Impreza SPECIFICATIONS Option code Model 2.0 L 2.0 L Turbo OUTBACK 5MT D/ 5MT D/R Unladen weight (U.W.) Front kg (lb) (1,676) (1,709) (1,709) (1,742) (1,698) (1,731) (1,819) (1,874) Rear kg (lb) (1,257) (1,257) (1,246) (1,246) (1,257) (1,257) (1,830) (1,830) Total kg (lb) 1,330...
  • Page 36 Impreza SPECIFICATIONS SPC-24...
  • Page 37 PRECAUTION Page Precaution ....................2...
  • Page 38 Precaution PRECAUTION 1. Precaution 7. AIRBAG MODULE Adhere to the following when handling and storing A: PRECAUTION the airbag module to prevent bodily injury from un- Please clearly understand and adhere to the follow- expected deployment: ing general precautions. They must be strictly fol- •...
  • Page 39 NOTE Page Note......................2...
  • Page 40 4. SERVICE PARTS Use authentic service parts for maximum perfor- mance and maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor perfor- mance resulting from the use of parts not specified by a genuine dealer. 5. PROTECTING VEHICLE UNDER MAIN-...
  • Page 41 Note NOTE 7. LIFTS AND JACKS When using a lift or jack to raise a vehicle, always follow instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful to make sure the vehicle is balanced before raising it.
  • Page 42 Note NOTE NT-00062 Front Rear Front crossmember Rear differential 8. TIE-DOWNS Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only to the specified points on the vehicle. • Tie-down point NT-00063 Hook for tie-down Hook for towing and tie-down NT-4...
  • Page 43 Note NOTE • Chain direction at tie-down condition NT-00038 • Chain pulling range at tie-down condition 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 45˚ 45˚ 45˚ 45˚ : (1) NT-00064 (1) Chain pulling range at tie-down condition • Vehicle sinking volume at tie-down condition Measure the distance L between tire highest point to arch highest point before tie-down and after tie- down.
  • Page 44 Note NOTE 9. TOWING Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD, AT, or VTD, use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damaging the hook or vehicle: •...
  • Page 45 Note NOTE • NOTES Towing Notes ❍ ❍ Lifting up four wheels (On a trailer) Towing the vehicle after lifting up all four wheels is a basic rule for AWD model. NT-00023 ❍ Rope • Check if both front and rear wheels are rotated nor- mally.
  • Page 46 Note NOTE CAUTION: • Check ATF, gear oil and rear differential oil before driving. • Place the shift lever in “N” position during towing. • Do not lift up the rear wheels to avoid unsteady rotation. • Turn the ignition key to “ACC”, then check the steering wheel moves freely. •...
  • Page 47 12.GENERAL SCAN TOOL Using general scan tools will greatly improve effi- ciency of repairing engine electronic controls. The Subaru Select Monitor can be used to diagnose the engine and also the ABS, the air conditioner, and other parts. NT-9...
  • Page 48 Note NOTE NT-10...
  • Page 49 IDENTIFICATION Page Identification ....................2...
  • Page 50 Identification IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The VIN (Vehicle Identification Numbers) is used to classify the vehicle. • POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION ID-00052 ID plate (Europe model) Model number plate Tire inflation pressure label (Driver ADR compliance plate (Australia side) (Australia model) Vehicle identification number...
  • Page 51 Identification IDENTIFICATION • MANUAL TRANSMISSION • REAR DIFFERENTIAL • T-type ID-00055 ID-00056 (1) Transmission serial number (1) Type (white paint) • VA-type DI-00396 (1) Type (label) • MODEL NUMBER PLATE ID-00075 ID-3...
  • Page 52 Identification IDENTIFICATION 2. MEANING OF V.I.N. The meaning of the VIN is as follows: • Europe, Australia and General (Except GCC) ]JF1GD4LG94G002001[ The starting and ending brackets ( ][ ) are stop marks. Digits Code Meaning Details 1 to 3 Manufacturer body area JF1: Passenger car, FHI made Car line IMPREZA...
  • Page 53 Identification IDENTIFICATION 3. MODEL NUMBER PLATE The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts. GD9DL5R Digits Code...
  • Page 54 Identification IDENTIFICATION • Transmission TM754RY5AA Digits Code Meaning Details Transmission T: Transmission Transmission type Y: Full-time AWD MT center differential V: Full-time AWD AT center differential Z: Full-time AWD AT MPT M: FWD MT A: FWD AT 3 and 4 Classification 75: 5MT 85: 6MT...
  • Page 55 Identification IDENTIFICATION • Option code E2BL Digits Code Meaning Details 1 — 2 Destination EC: Europe model (LHD model) EK: Europe model (RHD model) EH: China model KS: Middle East model K4: Central and South America model KA: Australia model E2: Israel model K0: General model (LHD model) K1: General model (RHD model)
  • Page 56 Identification IDENTIFICATION Digits Code Meaning Details Option equipment B: A/C, Airbag, Spoiler package C: A/C, Airbag, Rear spoiler F: A/C, Airbag, Sunroof G: A/C, Airbag, Side airbag I: A/C, Airbag, Audio, Rear spoiler J: A/C, Airbag, Spoiler package, Rear spoiler K: Airbag, Side airbag, Audio L: A/C, Airbag M: Airbag...
  • Page 57 RECOMMENDED MATERIALS Page Recommended Materials ................2...
  • Page 58 Recommended Materials RECOMMENDED MATERIALS 1. Recommended Materials A: RECOMMENDED MATERIALS 1. GENERAL To insure the best performance, always use the specified oil, gasoline, adhesive, sealant, etc. or a substitute of equivalent quality. 2. FUEL Always use a gasoline of the same or higher octane value than specified in the owner’s manual.
  • Page 59 Recommended Materials RECOMMENDED MATERIALS 3. LUBRICANTS Use either the lubricants in the table below or equivalent lubricants. See the table below to choose the correct SAE viscosity. Lubricant Recommended Alternative API Spec. CCMC Spec. ACEA Spec. API Spec. Engine oil SL, SJ Grade “Energy conserving”, or SH G4 or G5 A1, A2 or A3...
  • Page 60 Recommended Materials RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Engine oil SOHC model (˚C) –30 –20 –10 (˚F) –22 –4 10W-30 or 10W-40 5W-30 0W-20 Recommend RM-00007 DOHC turbo model (˚C) –30 –20 –10 –4 (˚F) –22 10W-30 or 10W-40 5W-30 Recommend RM-00003 RM-4...
  • Page 61 Distilled water — Tap water (Soft water) 6. REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant. Do not mix it with other refrigerants. Also, do not use any compressor oil except for DH-PR. Air conditioner Recommended Item number...
  • Page 62 Recommended Materials RECOMMENDED MATERIALS 7. GREASE Use the grease and supplementary lubricants shown in the table below. Grease Application point Recommended Item number Alternative Supplementary lubricants • O sensor Spray type lubricant — — • Bolts, etc. Grease MT main shaft Clutch grease K0879Y0501 —...
  • Page 63 Recommended Materials RECOMMENDED MATERIALS 9. SEAL MATERIAL Use seal material shown in the table below, or equivalent. Seal material Application point Recommended Item number Alternative Seal material • Cylinder block Three Bond 1215B 004403007 Dow Corning’s No. 7038 • Torque converter clutch case •...
  • Page 64 Recommended Materials RECOMMENDED MATERIALS RM-8...
  • Page 65 PRE-DELIVERY INSPECTION Page Pre-delivery Inspection................2...
  • Page 66 • Check if the vehicle after repair is in a normal state. • Make sure to provide a complete vehicle to the customer. For the above reasons, all SUBARU dealers (dealerships) carry out the PDIs before delivering a vehicle. B: PRE-DELIVERY INSPECTION (PDI) PROCEDURE...
  • Page 67 Pre-delivery Inspection PRE-DELIVERY INSPECTION PROCEDURE Check point 17. AT front differential oil Check that the AT front differential oil level is normal. 18. Engine coolant Check that the engine coolant level is normal. 19. Clutch fluid Check that the clutch fluid level is normal. 20.
  • Page 68 Pre-delivery Inspection PRE-DELIVERY INSPECTION 1. APPEARANCE CHECK 5. CHECK THE DOORS FOR LOCK/UN- LOCK AND OPEN/CLOSE OPERATIONS • If the vehicle is covered with protective coating, visually check the vehicle body for damage and 1) Using the key, lock and unlock the door several dents.
  • Page 69 Pre-delivery Inspection PRE-DELIVERY INSPECTION 4) Press the driver’s side power door lock switch to 4) Next, pull the outside door handles of the rear unlock side. Check that all doors including rear doors to ensure that the doors will open. gate are unlocked.
  • Page 70 Pre-delivery Inspection PRE-DELIVERY INSPECTION 9. CHECK THE REAR GATE FOR LOCK/ 11.ACCESSORY CHECK UNLOCK AND OPEN/CLOSE OPERATIONS Check that the following accessories are provided in the luggage compartment or cargo area. 1) Open and close the rear gate several times for •...
  • Page 71 Pre-delivery Inspection PRE-DELIVERY INSPECTION Operate the lever (A) and check that the hood is 15.ENGINE OIL opened normally. Then support the hood with hood Check the engine oil amount. If the amount is insuf- stay. ficient, check that no leaks are found. Then, add the necessary amount of the specified engine oil.
  • Page 72 Pre-delivery Inspection PRE-DELIVERY INSPECTION 17.AT FRONT DIFFERENTIAL OIL 21.HOOD LATCH CHECK Check the AT front differential oil amount. If the Retract the hood stay and close the hood. Check amount is insufficient, check that no leaks are that the hood is securely latched. found.
  • Page 73 Pre-delivery Inspection PRE-DELIVERY INSPECTION 25.WHEEL ALIGNMENT 28.STARTING CONDITION Check the wheel alignments. <Ref. to FS-6, Wheel Start the engine and check that the engine starts Alignment.> and <Ref. to RS-10, Wheel Align- smoothly. If any battery voltage problems are ment.> found, recharge or replace the battery.
  • Page 74 Pre-delivery Inspection PRE-DELIVERY INSPECTION Rear injection position: 42.AT SHIFT CONTROL A: 39 mm (2.36 in) Set the AT select lever to each gear position and B: 72 check the shifting while driving the vehicle. PI-00104 PI-00112 36.WIPER (1) RHD model Check the front and rear wipers for normal opera- (2) LHD model tions.
  • Page 75 Pre-delivery Inspection PRE-DELIVERY INSPECTION 46.ATF LEVEL 49.WATER LEAK TEST Check that the ATF level is normal when the engine Spray the vehicle with water and check that no wa- at idle. If insufficient, check that no leaks are found. ter enters the passenger compartment. Then add the necessary amount of the specified •...
  • Page 76 Pre-delivery Inspection PRE-DELIVERY INSPECTION • If the coated surface is swollen out due to seams or moisture, expose the vehicle to the sun light for a few hours. Otherwise, heat the portion with seams or moisture using a dryer, etc. •...

  • Page 77: Table Of Contents

    PERIODIC MAINTENANCE SERVICES Page General Description ..................2 Schedule .....................3 Engine Oil....................7 Engine Oil Filter...................9 Spark Plugs....................10 V-belt......................11 Timing Belt ....................13 Fuel Line ....................16 Fuel Filter ....................17 Air Cleaner Element ..................18 Cooling System ..................19 Coolant......................21 Idle Mixture....................23 Clutch System ...................24 Transmission Gear Oil ................26 Hill-holder System ..................27 ATF ......................28 Front &...

  • Page 78: General Description

    General Description PERIODIC MAINTENANCE SERVICES 1. General Description A: GENERAL Be sure to perform periodic maintenance in order to maintain vehicle performance and find problems before they become serious. PM-2...
  • Page 79 Schedule PERIODIC MAINTENANCE SERVICES 2. Schedule A: MAINTENANCE SCHEDULE 1 1. FOR EUROPE AREA For periodic maintenance of over 120,000 km (75,000 miles) or 96 months, carry out inspection by referring to the following table. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 120,000 km (75,000 miles) or 96 months.
  • Page 80 Schedule PERIODIC MAINTENANCE SERVICES 2. EXCEPT FOR EUROPE AREA For periodic maintenance of over 50,000 km (30,000 miles) or 48 months, carry out inspections by referring to the following tables. For a maintenance period gone beyond these tables, apply them repeatedly as a set of 50,000 km (30,000 miles) or 48 months.
  • Page 81 Schedule PERIODIC MAINTENANCE SERVICES NOTE: (1) When the vehicle is used in extremely dusty conditions, the air cleaner element should be replaced more often. (2) ATF filter is a maintenance free part. ATF filter needs replacement, when it is physically damaged or ATF leaked. B: MAINTENANCE SCHEDULE 2 1.
  • Page 82 Schedule PERIODIC MAINTENANCE SERVICES 2. EXCEPT FOR EUROPE AREA Salt or other Repeat Extremely High humid- Repeat short corrosive Repeat tow- Item Every rough/muddy cold weather ity or moun- distance drive used or ing trailer road drive area tain area coastal area Engine oil Replace...

  • Page 83: Engine Oil

    Engine Oil PERIODIC MAINTENANCE SERVICES 3. Engine Oil • SOHC MODEL A: REPLACEMENT 1) Open the engine oil filler cap for quick draining of the engine oil. LU-00193 4) Replace the drain plug gasket. 5) Tighten the engine oil drain plug after draining engine oil.
  • Page 84 Use engine oil of proper quality and viscosity, gine; however, use oil having the API classification selected in accordance with the table in figure. and SAE viscosity No. designated by SUBARU. • If vehicle is used in desert areas with very high Recommended oil...

  • Page 85: Engine Oil Filter

    Engine Oil Filter PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter A: REPLACEMENT 1) Remove the under cover. 2) Remove the oil filter with ST. ST 498547000 OIL FILTER WRENCH (Outer diameter 80 mm (3.15 in)) ST 18332AA000 OIL FILTER WRENCH (Outer diameter 68 mm (2.68 in)) ST 18332AA010 OIL FILTER WRENCH (Outer diameter 65 mm (2.56 in))

  • Page 86: Spark Plugs

    Spark Plugs PERIODIC MAINTENANCE SERVICES 5. Spark Plugs 5) Remove the ignition coil. A: REPLACEMENT 1. SOHC MODEL 1) Remove the intake duct and intake chamber. 2) Remove the washer tank and put it aside. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a plug-wrench.
  • Page 87 V-belt PERIODIC MAINTENANCE SERVICES 6. V-belt Belt tension (with belt tension gauge) A: INSPECTION When installing new one: 640 — 785 N 1) Replace the belts, if cracks, fraying or wear is (65.3 — 80.0 kgf, 144 — 176 lb) found.
  • Page 88 V-belt PERIODIC MAINTENANCE SERVICES TURBO MODEL Tightening torque: 23 N·m (2.3 kgf-m, 17.0 ft-lb) SC-00096 PM-00005 2) Loosen the lock bolt (A). 3) Loosen the slider bolt (B). 4) Remove the front side belt (C). 5) Install a new belt, and tighten the slider bolt so as to obtain the specified belt tension.

  • Page 89: Timing Belt

    Timing Belt PERIODIC MAINTENANCE SERVICES 7. Timing Belt 10) Remove the timing belt guide. (MT model) A: REPLACEMENT 1. NON-TURBO MODEL 1) Remove the radiator fan and air conditioner fan. <Ref. to CO(H4SO)-23, Radiator Main Fan and Fan Motor.>, <Ref. to CO(H4SO)-24, Radiator Sub Fan and Fan Motor.>...
  • Page 90 Timing Belt PERIODIC MAINTENANCE SERVICES 15) Remove the automatic belt tension adjuster as- 11) Remove the timing belt guide. (MT model) sembly. PM-00008 PM-00011 16) Install in the reverse order of removal. <Ref. to ME(H4SO)-49, INSTALLATION, Timing Belt As- sembly.> 2.
  • Page 91 Timing Belt PERIODIC MAINTENANCE SERVICES ST 499987500 CRANKSHAFT SOCKET CAUTION: When installing the timing belt, be sure to align all alignment marks on the belt with corre- sponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur. B: INSPECTION 1.

  • Page 92: Fuel Line

    Fuel Line PERIODIC MAINTENANCE SERVICES 8. Fuel Line A: INSPECTION The fuel line is located mostly internally, so check pipes, areas near pipes, and engine compartment piping for rust, hose damage, loose bands, etc. If faulty parts are found, repair or replace them. SOHC model <Ref.

  • Page 93: Fuel Filter

    Fuel Filter PERIODIC MAINTENANCE SERVICES 9. Fuel Filter A: REPLACEMENT For fuel filter replacement procedures, refer to “FU” section. SOHC model <Ref. to FU(H4SO)-60, Fuel Filter.> DOHC Turbo model <Ref. to FU(H4DOTC)-66, Fuel Filter.> B: INSPECTION 1) If it is clogged, or if replacement interval has been reached, replace it.

  • Page 94: Air Cleaner Element

    Air Cleaner Element PERIODIC MAINTENANCE SERVICES 10.Air Cleaner Element 2) Remove the air cleaner. A: REPLACEMENT 1. NON-TURBO MODEL 1) Remove the air intake duct from air cleaner case. 2) Remove the bolt (A) which installs air cleaner case to stays. 3) Remove the clip (B) above the air cleaner case.

  • Page 95: Cooling System

    Cooling System PERIODIC MAINTENANCE SERVICES 11.Cooling System NOTE: Rust or dirt on the cap may prevent the valve from A: INSPECTION functioning normally: be sure to clean the cap be- 1) Check the radiator for leakage, filling it with cool- fore testing.
  • Page 96 <Ref. to CO(H4DOTC)-22, Thermostat.> <Ref. to CO(H4DOTC)-23, Radiator.> <Ref. to CO(H4DOTC)-27, Radiator Cap.> 4) Check the electric fan operates using Subaru Select Monitor, when the coolant temperature ex- ceeds 95 C (203 F). If not operate, check the elec- tric fan system.
  • Page 97 NOTE: The SUBARU Genuine Coolant containing anti- A: REPLACEMENT freeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank- 1. REPLACEMENT OF COOLANT case. Always use SUBARU Genuine Coolant, WARNING: since other coolant may cause corrosion.
  • Page 98 The concentration and safe operating temperature tion in the above diagram and replace the of the SUBARU coolant is shown in the diagram. necessary amount of coolant with an undiluted so- Measuring the temperature and specific gravity of lution of SUBARU genuine coolant (concentration the coolant will provide this information.

  • Page 99: Idle Mixture

    Idle Mixture PERIODIC MAINTENANCE SERVICES 13.Idle Mixture A: INSPECTION AND ADJUSTMENT 1. IDLE MIXTURE Before measuring the idle mixture, make sure that the ignition timing and the engine idle speed are within specifications. 1) Set the gear position at “Neutral” for MT, or “N” or “P”...

  • Page 100: Clutch System

    Clutch System PERIODIC MAINTENANCE SERVICES 14.Clutch System Standard: 80 mm (3.15 in) or more A: INSPECTION AND ADJUSTMENT 3) Pedal height Check that the clutch pedal pad surface is level 1. MECHANICAL CLUTCH TYPE with or higher than brake pedal pad surface. 1) Inspect the free play of clutch pedal by operating 2.
  • Page 101 Clutch System PERIODIC MAINTENANCE SERVICES Recommended clutch fluid: FMVSS No. 116, fresh DOT3 brake fluid CAUTION: Prevent the clutch fluid from being splashed over vehicle body. If the clutch fluid is splashed over vehicle body, flush it, and then wipe it up. NOTE: •...

  • Page 102: Transmission Gear Oil

    Transmission Gear Oil PERIODIC MAINTENANCE SERVICES 15.Transmission Gear Oil Gear oil capacity: FWD model A: REPLACEMENT 3.3 L (3.5 US qt, 2.5 Imp qt) AWD model (5MT single range model): 1. MANUAL TRANSMISSION 3.5 L (3.7 US qt, 3.1 Imp qt) 1) Drain the gear oil by removing drain plug.

  • Page 103: Hill-Holder System

    Hill-holder System PERIODIC MAINTENANCE SERVICES 16.Hill-holder System A: INSPECTION AND ADJUSTMENT 1) Confirm the stopping and starting performance by activating the hill-holder on an uphill road of 3 or higher inclination. (1) When the vehicle does not stop; Tighten the adjusting nut of PHV cable. (2) When the vehicle does not start properly;...
  • Page 104 4AT-32, CONDITION CHECK, Automatic Trans- gine to raise ATF temperature to 70 — 80 C (158 mission Fluid.> — 176 F) on Subaru Select Monitor. <Ref. to 4AT(diag)-21, READ CURRENT DATA, OPERA- TION, Subaru Select Monitor.> 2) Make sure the vehicle is level.
  • Page 105 PERIODIC MAINTENANCE SERVICES 4) Check the ATF level. <Ref. to PM-28, INSPEC- TION, ATF.> PM-00191 (A) Level gauge (B) ATF level range at “HOT” [70 — 80 C (158 — 176 F)] (C) Upper level (D) Lower level (E) ATF level range at “COLD” [20 — 30 C (68 — 86 F)] 2.
  • Page 106 Front & Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES 18.Front & Rear Differential Gear Differential gear oil capacity: 1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 lmp qt) A: REPLACEMENT 1. FRONT DIFFERENTIAL (MT MODEL) Differential oil works as manual transmission oil to lubricate differential.
  • Page 107 Front & Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES VA TYPE PM-00102 (A) Filler plug (B) Drain plug Recommended gear oil: Except for STi model with driver’s control center differential GL-5 (75W-90) or equivalent STi model with driver’s control center differ- ential GL-5 [LSD oil (90)] or equivalent Oil capacity:...
  • Page 108 Brake Line PERIODIC MAINTENANCE SERVICES 19.Brake Line Brake pedal free play: 0.5 — 2.0 mm (0.02 — 0.08 in) A: INSPECTION 1. BRAKE LINE 1) Check scratches, swelling, corrosion, traces of fluid leakage on the brake hoses or pipe joints. 2) Check the possibility of adjacent parts interfering with brake pipes/hoses during driving, and loose connections/clamps.
  • Page 109 Brake Line PERIODIC MAINTENANCE SERVICES 3) Check the pedal stroke. Replace both check valve and vacuum hose if the check valve is faulty. Engine side of vacuum hose While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lb) load and measure the is indicated by marking “ENG”...

  • Page 110: Brake Fluid

    Brake Fluid PERIODIC MAINTENANCE SERVICES 20.Brake Fluid • During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate en- A: REPLACEMENT try of air. 1) Either jack-up the vehicle and place a safety • The brake pedal operating must be very slow. stand under it, or lift-up the vehicle.

  • Page 111: Disc Brake Pads And Discs

    Disc Brake Pads and Discs PERIODIC MAINTENANCE SERVICES 21.Disc Brake Pads and Discs A: INSPECTION 1. DISC BRAKE PAD AND DISC 1) Jack-up the vehicle and support with rigid racks. Then remove the wheels. 2) Visually check the pad thickness through inspec- tion hole of disc brake assembly.
  • Page 112 Brake Linings and Drums PERIODIC MAINTENANCE SERVICES 22.Brake Linings and Drums If deformation or wear of back plate, shoe, etc. is noticeable, replace the affected parts. A: INSPECTION 1. REAR DRUM BRAKE 1) Remove the brake drum, and check that there is no fluid leakage from wheel cylinder.
  • Page 113 Brake Linings and Drums PERIODIC MAINTENANCE SERVICES Brake drum inside diameter 3) Turn back (downward) the adjuster 3 to 4 notch- Except for STi model 4) Install the cover (rubber) at original position cor- Standard value: 170 mm (6.69 in) rectly.
  • Page 114 Suspension PERIODIC MAINTENANCE SERVICES 23.Suspension NOTE: When the transverse link ball joint has been re- A: INSPECTION moved or replaced, check the toe-in of front wheel. If the front wheel toe-in is not at specified value, ad- 1. SUSPENSION BALL JOINT just the toe-in.
  • Page 115 Suspension PERIODIC MAINTENANCE SERVICES 4. WHEEL ALIGNMENT OF FRONT SUS- 8. DAMAGE TO SUSPENSION PARTS PENSION 1) Check the following parts and the fastening por- tion of the vehicle body for deformation or exces- 1) Check the alignment of front suspension to en- sive rusting which impairs the suspension.

  • Page 116: Wheel Bearing

    Wheel Bearing PERIODIC MAINTENANCE SERVICES 24.Wheel Bearing 4) If the bearing free play exists in step 2) above, attach a dial gauge to the hub COMPL and mea- A: INSPECTION sure axial displacement in axial direction. Service limit: 1. FRONT WHEEL BEARING Straight-ahead position within 0.05 mm NOTE: (0.0020 in)
  • Page 117 Wheel Bearing PERIODIC MAINTENANCE SERVICES 5) Turn the hub unit COMPL with hand to check for noise or binding. If the hub unit COMPL is noisy or binds, replace the hub unit COMPL. PM-00153 (A) Rear housing (B) Tone wheel (C) Hub bolt (D) Hub unit COMPL (E) Socket bolt...

  • Page 118: Axle Boots & Joints

    Axle Boots & Joints PERIODIC MAINTENANCE SERVICES 25.Axle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect the front axle boots (A) and rear axle boots (B) for deformation, damage or failure. If faulty, re- place them with new ones. <Ref. to DS-36, Front Drive Shaft.>...
  • Page 119 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 26.Steering System (Power 2. STEERING SHAFT JOINT Steering) When the steering wheel free play is excessive, disconnect the universal joint of steering shaft and A: INSPECTION check it for any play and yawing torque (at the point of the crossing direction).
  • Page 120 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES (2) Retighten the adjusting screw to 7.4 N·m 3) Check the lock nut on tie-rod end for tightness. If (0.75 kgf-m, 5.4 ft-lb) and back off 25 . it is loose, retighten it to the specified torque. (3) Loosen the adjusting screw and apply liquid Tightening torque: packing to at least 1/3 of entire perimeter of its...
  • Page 121 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES NOTE: Prevent the hoses from revolving and/or turning when installing hoses. PM-00071 8. POWER STEERING PIPES FOR DAM- Check the power steering pipes for corrosion and damage. Replace the pipes with a new one if necessary. 9.
  • Page 122 Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES PM-46...

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