Subaru 2004 Impreza Service Manual
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Subaru 2004 Impreza Service 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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  • Page 1: Body Section

    2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION HVAC SYSTEM (HEATER, VENTILATOR AND A/C) HVAC SYSTEM (AUTO A/C) AC(diag) (DIAGNOSTICS) AIRBAG SYSTEM AIRBAG SYSTEM (DIAGNOSTICS) AB(diag) This service manual has been prepared to provide SUBARU service personnel SEAT BELT SYSTEM...
  • 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

    EXTERIOR/INTERIOR TRIM Page General Description ..................2 Front Grille ....................18 Hood Grille ....................19 Front Under Cover ..................21 Front Bumper ....................22 Rear Bumper.....................28 Mud Guard ....................31 Cowl Panel ....................32 Roof Spoiler ....................33 Rear Spoiler ....................35 Side Sill Spoiler ..................36 Front Door Trim ..................37 Rear Door Trim ..................38 Glove Box....................39 Roof Rail ....................40...

  • Page 4: General Description

    General Description EXTERIOR/INTERIOR TRIM 1. General Description A: COMPONENT 1. FRONT GRILLE EI-00413 Front grille Front grille emblem Clip 2. UNDER COVER EI-00414 Under cover Clip (side) Tightening torque: N·m (kgf-m, ft-lb) T: 14 (1.42, 10.3) EI-2...
  • Page 5 General Description EXTERIOR/INTERIOR TRIM 3. HOOD GRILLE EI-00842 Hood grille Grille duct lower Tightening torque: N·m (kgf-m, ft-lb) Packing Intercooler water spray (STi T: 4.5 (0.46, 3.32) model) Grille duct upper EI-3...

  • Page 6: Front Bumper

    General Description EXTERIOR/INTERIOR TRIM 4. FRONT BUMPER (10) EI-00848 Bumper face Air spoiler side bracket Tightening torque: N·m (kgf-m, ft-lb) Fog light cover Air spoiler upper bracket T1: 32 (3.3, 24) Fog light cover (STi model) Bumper bracket side lower T2: 69 (7.0, 51) Air dam skirt ASSY Energy absorber form...
  • Page 7 General Description EXTERIOR/INTERIOR TRIM 5. REAR BUMPER EI-00849 Bumper face Energy absorber form (model with Tightening torque: N·m (kgf-m, ft-lb) bumper beam) Bumper upper beam T1: 33 (3.4, 24) Bumper corner bracket Back beam ASSY (model with T2: 34 (3.5, 25) bumper beam) Bumper side bracket T3: 95 (9.7, 70)

  • Page 8: Cowl Panel

    General Description EXTERIOR/INTERIOR TRIM 6. MUD GUARD EI-00419 Mud guard Sub frame cover Mud guard plate Clip Front air flap plate Rear air flap plate 7. COWL PANEL EI-00420 Cowl panel Protector Seal Cowl side panel EI-6...

  • Page 9: Rear Spoiler

    General Description EXTERIOR/INTERIOR TRIM 8. ROOF SPOILER EI-00421 Roof spoiler Clip Tightening torque: N·m (kgf-m, ft-lb) T: 7.4 (0.75, 5.46) 9. REAR SPOILER EI-00422 Rear spoiler Grommet Tightening torque: N·m (kgf-m, ft-lb) Protector Seal (RH) T: 7.4 (0.75, 5.46) Clip High mount stop lamp EI-7...
  • Page 10 General Description EXTERIOR/INTERIOR TRIM 10.SIDE SILL SPOILER EI-00423 Side sill spoiler Protector Clip (Side sill spoiler) End cover Rivet clip Clip 11.ROOF RAIL EI-00424 Roof rail Tightening torque: N·m (kgf-m, ft-lb) T: 7.4 (0.75, 5.46) EI-8...
  • Page 11 General Description EXTERIOR/INTERIOR TRIM 12.ROOF MOLDING EI-00443 For sedan model For wagon model For wagon model (with roof rail) Roof molding Clip B Clip D Clip A Clip C EI-9...
  • Page 12 General Description EXTERIOR/INTERIOR TRIM 13.DOOR TRIM EI-00425 Front door trim Rear door trim Rear gate trim Gusset cover Clip Power window switch cover Bracket Trim panel Lower trim Weather strip upper EI-10...
  • Page 13 General Description EXTERIOR/INTERIOR TRIM 14.CONSOLE BOX (12) (14) (15) (13) (10) (11) EI-00533 Console cover Lid hinge (11) Lower bracket Cup holder Rear lid (12) Lock Bracket Console box (13) Front cover (AT model) Strip Console pocket (14) Front cover (MT model) Upper lid (10) Upper bracket...

  • Page 14: Instrument Panel

    General Description EXTERIOR/INTERIOR TRIM 15.INSTRUMENT PANEL (10) (19) (11) (17) (18) (15) (12) (13) (16) (14) EI-00427 Pad & frame Air vent grille (side) (16) Glove box lid Center upper panel (10) Instrument panel lower cover (17) Glove box panel Air vent grille (defroster) (11) Console cover...
  • Page 15 General Description EXTERIOR/INTERIOR TRIM 16.INNER TRIM (SEDAN MODEL) (13) (10) (12) (11) EI-00429 Front pillar upper trim Trunk rear trim (10) Center pillar lower trim Center pillar upper trim Trunk side trim (11) Side sill front cover Rear pillar upper trim Rear pillar lower trim (12) Front garnish...
  • Page 16 General Description EXTERIOR/INTERIOR TRIM 17.INNER TRIM (WAGON MODEL) (13) (10) (12) (11) EI-00430 Front pillar upper trim Rear quarter lower trim (11) Side sill front cover Center pillar upper trim Hook (12) Front garnish Rear pillar upper trim Rear skirt trim (13) Rear garnish Rear rail trim...
  • Page 17 General Description EXTERIOR/INTERIOR TRIM 18.ROOF TRIM (SEDAN MODEL) EI-00431 Roof trim 19.ROOF TRIM (WAGON MODEL) EI-00432 Roof trim Roof trim (Model with sun roof) Sun roof garnish EI-15...

  • Page 18: Luggage Floor Mat

    General Description EXTERIOR/INTERIOR TRIM 20.LUGGAGE FLOOR MAT EI-00433 Front floor mat Side floor mat (RH) Side floor mat (LH) Floor box Center floor mat 21.HEAT SHIELD COVER EI-00089 Front heat shield cover Center heat shield cover Rear heat shield cover EI-16...

  • Page 19: General Description

    General Description EXTERIOR/INTERIOR TRIM 22.INNER ACCESSORIES EI-00434 Hook Assist grip Center visor Sun visor B: PREPARATION TOOL TOOL NAME REMARKS Clip remover Used for removal of trim. Clip clamp pliers Used for removal of various clips and clamps. EI-17...

  • Page 20: Front Grille

    Front Grille EXTERIOR/INTERIOR TRIM 2. Front Grille A: REMOVAL 1) Open the front hood. 2) Remove the four clips (A). : (A) EI-00407 3) Remove the right and left hooks on the lower side. EI-00476 B: INSTALLATION Install in the reverse order of removal. EI-18...

  • Page 21: Hood Grille

    Hood Grille EXTERIOR/INTERIOR TRIM 3. Hood Grille 2) Engage the four clips of hood grille to front hood panel. A: REMOVAL CAUTION: 1) Remove the hood insulator. Make sure that the anchor portion of each clip 2) Remove the seven tapping screws and clip (A) is firmly engaged.
  • Page 22 Hood Grille EXTERIOR/INTERIOR TRIM 5) Install the hood duct with clip (A) and seven tap- ping screws. EI-00444 6) Install the hood insulator with new clips. C: INSPECTION Make sure that the clip is firmly engaged. Make sure that there is no abnormal gap at whole periphery of hood grille.

  • Page 23: Front Under Cover

    Front Under Cover EXTERIOR/INTERIOR TRIM 4. Front Under Cover A: REMOVAL 1) Lift-up the vehicle. 2) Loosen the bolts and clips to remove the under cover. EI-00408 B: INSTALLATION Install in the reverse order of removal. Tightening torque: 14 N·m (1.42 kgf-m, 10.3 ft-lb) EI-21...

  • Page 24: Front Bumper

    Front Bumper EXTERIOR/INTERIOR TRIM 5. Front Bumper 5) Remove the two clips (A), turn over the mud guard, and then remove the clip (B). (Same proce- A: REMOVAL dure on the right side.) 1) Disconnect the ground cable from battery. 2) Remove the front grille.
  • Page 25 Front Bumper EXTERIOR/INTERIOR TRIM 10) Loosen the bolt and nut, and then remove the B: INSTALLATION bumper beam from body. 1) Install in the reverse order of removal. 2) Secure the slider (A) to guide plate (B). EI-00439 EI-00521 Tightening torque: Refer to COMPONENT in General Descrip- tion.
  • Page 26 Front Bumper EXTERIOR/INTERIOR TRIM Pro- cess Process name Job contents Solid color Metallic color Use section (block) paint for top coat. Use section (block) paint for top coat. • Paint in use (for each color): • Paint in use (for each color): Solid paint Metallic paint Hardener PB...
  • Page 27 Front Bumper EXTERIOR/INTERIOR TRIM 2) Deep damage caused by scratching fences, etc. A dent cannot be repaired but a whitened or swelled part can be removed. Pro- cess Process name Job contents Cleaning Clean the damaged area with water. Removal of dam- Cut off protruding area, if any, due to collision, using a putty knife.
  • Page 28 Front Bumper EXTERIOR/INTERIOR TRIM Pro- cess Process name Job contents Grind the side just opposite the beveled area with sand paper (#40 to #60) and clean using a sol- vent. Temporarily spot-weld the side, using a PP welding rod and heater gun. Temporary welding EI-00236 (1) Welded spot (Use heater gun and PP welding rod)
  • Page 29 Front Bumper EXTERIOR/INTERIOR TRIM Pro- cess Process name Job contents Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer is half-dry. NOTE: Leave unattended. If dirt or dust comes in contact with the coated area, wipe it off with a cloth impregnated with alco- hol.

  • Page 30: Rear Bumper

    Rear Bumper EXTERIOR/INTERIOR TRIM 6. Rear Bumper 5) Remove the screw and two clips (both sides). A: REMOVAL 1. WAGON MODEL 1) Disconnect the ground cable from battery. 2) Remove the bolt of license plate bracket. (model without bumper beam) EI-00410 6) Remove the floor box.
  • Page 31 Rear Bumper EXTERIOR/INTERIOR TRIM 11) Remove the bolt. (model with bumper beam) 15) Remove the six clips, and then remove the bumper side cover. EI-00352 EI-00532 12) Remove the three bolts, then remove the bumper beam. (model with bumper beam) 16) Remove the corner bracket from body.
  • Page 32 Rear Bumper EXTERIOR/INTERIOR TRIM 2. SEDAN MODEL Refer to description about removal of rear bumper of wagon model. <Ref. to EI-28, WAGON MODEL, REMOVAL, Rear Bumper.> B: INSTALLATION 1. WAGON MODEL Install in the reverse order of removal. Tightening torque: Refer to COMPONENT in General Descrip- tion.

  • Page 33: Mud Guard

    Mud Guard EXTERIOR/INTERIOR TRIM 7. Mud Guard A: REMOVAL 1) Jack-up the vehicle. 2) Remove the screws and clips to remove mud guard. EI-00847 B: INSTALLATION Insert the hook into body, and tighten it with screw and clip. EI-31...

  • Page 34: Cowl Panel

    Cowl Panel EXTERIOR/INTERIOR TRIM 8. Cowl Panel A: REMOVAL 1) Open the front hood. 2) Remove the wiper arm. <Ref. to WW-12, RE- MOVAL, Front Wiper Arm.> 3) Remove the front panel seal. EI-00450 4) Disengage the clips (A) to remove the cowl pan- : (A) EI-00451 B: INSTALLATION...

  • Page 35: Roof Spoiler

    Roof Spoiler EXTERIOR/INTERIOR TRIM 9. Roof Spoiler A: REMOVAL 1. LARGE-SIZED ROOF SPOILER 1) Remove the bolt cap, and then remove the two bolts. 2) Remove the roof spoiler. EI-00478 (A) Panel (B) Spoiler (C) Double-sided tape 2) Adhere the masking tape around the double-sid- ed tape remaining on surface of body and spoiler.
  • Page 36 Roof Spoiler EXTERIOR/INTERIOR TRIM CAUTION: CAUTION: Do not heat the double-sided tape until the sur- To keep the adhesion, do not wash the vehicle face becomes white and excessively dried. within 24 hours. 5) Remove the double-sided tape using a plastic spatula.

  • Page 37: Rear Spoiler

    Rear Spoiler EXTERIOR/INTERIOR TRIM 10.Rear Spoiler A: REMOVAL 1) Disconnect the ground cable from battery. 2) Open the trunk lid. 3) Remove the electrical connector (A) of high mount stop light. 4) Loosen the mounting nut of rear spoiler to re- move rear spoiler.

  • Page 38: Side Sill Spoiler

    Side Sill Spoiler EXTERIOR/INTERIOR TRIM 11.Side Sill Spoiler A: REMOVAL Remove the clips (one on front fender arch, six on bottom of side sill spoiler), then remove the side spoiler. EI-00454 NOTE: Some vehicle have a clip to retain the splash board together with side sill spoiler (forward of rear tire) at rearmost end.

  • Page 39: Front Door Trim

    Front Door Trim EXTERIOR/INTERIOR TRIM 12.Front Door Trim B: INSTALLATION Install in the reverse order of removal. A: REMOVAL CAUTION: Do not apply excessive force to the clip. Other- wise the clip may be broken. 1) Disconnect the ground cable from battery. 2) Pull the inner remote cover toward you to re- move upper hook.

  • Page 40: Rear Door Trim

    Rear Door Trim EXTERIOR/INTERIOR TRIM 13.Rear Door Trim 5) Disconnect the power window harness connec- tor. (for models with power window) A: REMOVAL CAUTION: Do not apply excessive force to the clip. Other- wise the clip may be broken. 1) Disconnect the ground cable from battery. 2) Pull the inner remote cover toward you to re- move upper hook.

  • Page 41: Glove Box

    Glove Box EXTERIOR/INTERIOR TRIM 14.Glove Box A: REMOVAL 1) Open the glove box. 2) Loosen the screws to remove the glove box. EI-00465 B: INSTALLATION Install in the reverse order of removal. EI-39...

  • Page 42: Roof Rail

    Roof Rail EXTERIOR/INTERIOR TRIM 15.Roof Rail A: REMOVAL 1) Remove the roof trim. <Ref. to EI-50, REMOVAL, Roof Trim.> 2) Remove the four mounting nuts, and then detach the roof rail carefully. EI-00467 B: INSTALLATION Install in the reverse order of removal. CAUTION: Be careful not to scratch the body panels with roof rail stud bolts when removing and installing them.

  • Page 43: Roof Molding

    Roof Molding EXTERIOR/INTERIOR TRIM 16.Roof Molding B: INSTALLATION 1) Remove the clip of roof and rear pillar (sedan A: REMOVAL model) from roof molding, and then install it to body 1) Turn over the edge of roof molding, and then re- side.

  • Page 44: Console Box

    Console Box EXTERIOR/INTERIOR TRIM 17.Console Box 4) Loosen the screws to remove the console box. A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the console cover. : (A) : (B) EI-00468 (A) Hook pawl (B) Clip 3) Remove the shift knob (MT model) and front cover.

  • Page 45: Instrument Panel Assembly

    Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 18.Instrument Panel Assembly 6) Remove the ash tray, and then remove the three screws. A: REMOVAL CAUTION: • All airbag system wiring harness and con- nectors are colored yellow. Do not use electri- cal equipment on these circuits. •...
  • Page 46 Instrument Panel Assembly EXTERIOR/INTERIOR TRIM 11) Remove the instrument panel installation bolts. EI-00493 12) Check that all the harness is disconnected, and • When storing the removed instrument panel, then remove the instrument panel from vehicle. place it standing up on the floor. NOTE: •...
  • Page 47 Instrument Panel Assembly EXTERIOR/INTERIOR TRIM B: INSTALLATION CAUTION: • Be careful not to snag the harness. • Carry out installation checking that the har- ness is connected correctly. • When setting the instrument panel into vehi- cle, do not damage trim panels. Install in the reverse order of removal.

  • Page 48: Upper Inner Trim

    Upper Inner Trim EXTERIOR/INTERIOR TRIM 19.Upper Inner Trim A: REMOVAL 1) Remove the lower inner trim. <Ref. to EI-47, RE- MOVAL, Lower Inner Trim.> 2) Remove the front molding (A). 3) Remove the front pillar upper trim (B). 4) Detach the front seat belt shoulder anchor, and then remove the center pillar upper trim (C).

  • Page 49: Lower Inner Trim

    Lower Inner Trim EXTERIOR/INTERIOR TRIM 20.Lower Inner Trim A: REMOVAL 1) Remove the side sill front cover (A). 2) Remove the rear seat cushion <Ref. to SE-13, REMOVAL, Rear Seat.>, and then remove side sill rear cover (B). 3) Remove the center pillar lower trim (C). : (D) EI-00072 (D) Clip...

  • Page 50: Rear Quarter Trim

    Rear Quarter Trim EXTERIOR/INTERIOR TRIM 21.Rear Quarter Trim 6) Loosen the bolts and clips to remove the rear quarter lower trim (D). A: REMOVAL 1. SEDAN MODEL 1) Remove the rear seat. <Ref. to SE-13, REMOV- AL, Rear Seat.> 2) Remove the side sill rear cover. <Ref. to EI-47, REMOVAL, Lower Inner Trim.>...

  • Page 51: Sun Visor

    Sun Visor EXTERIOR/INTERIOR TRIM 22.Sun Visor A: REMOVAL Remove the mounting screws, and then detach the sun visor (A), hook (B) and center visor (C). EI-00499 B: INSTALLATION Install in the reverse order of removal. EI-49...

  • Page 52: Roof Trim

    Roof Trim EXTERIOR/INTERIOR TRIM 23.Roof Trim 10) Remove the clips, and then remove the roof trim. A: REMOVAL CAUTION: When removing the clip, use great care not to damage the roof trim. 1. SEDAN MODEL 1) Disconnect the ground cable from battery. 2) Remove the sunroof switch.
  • Page 53 Roof Trim EXTERIOR/INTERIOR TRIM 10) Remove the rear quarter upper trim (B) of both sides. : (E) EI-00498 (E) Clip 11) Remove the clips, and then remove the roof trim. EI-00502 B: INSTALLATION Install in the reverse order of removal. EI-51...

  • Page 54: Rear Gate Trim

    Rear Gate Trim EXTERIOR/INTERIOR TRIM 24.Rear Gate Trim A: REMOVAL CAUTION: Be careful not to damage the clips or their holes. Remove the clips, and then detach the rear gate trim. EI-00503 B: INSTALLATION Install in the reverse order of removal. EI-52...

  • Page 55: Rear Shelf Trim

    Rear Shelf Trim EXTERIOR/INTERIOR TRIM 25.Rear Shelf Trim A: REMOVAL 1) Disconnect the ground cable from battery. 2) Remove the high mount stop light. EI-00504 3) Remove the rear quarter upper trim. <Ref. to EI- 48, REMOVAL, Rear Quarter Trim.> 4) Remove the seat belt center anchor lower bolt.

  • Page 56: Trunk Trim

    Trunk Trim EXTERIOR/INTERIOR TRIM 26.Trunk Trim A: REMOVAL 1) Remove the rear seat backrest. <Ref. to SE-13, SEDAN MODEL, REMOVAL, Rear Seat.> 2) Remove the clip (A). 3) Loosen the clips, and then detach the trunk rear trim (B). 4) Loosen the clips to remove the trunk side trim (C).

  • Page 57: Floor Mat

    Floor Mat EXTERIOR/INTERIOR TRIM 27.Floor Mat A: REMOVAL 1) Remove the front seats. <Ref. to SE-6, REMOV- AL, Front Seat.> 2) Remove the rear seat cushion. <Ref. to SE-13, REMOVAL, Rear Seat.> 3) Remove the console box. <Ref. to EI-42, Con- sole Box.>...

  • Page 58: Luggage Floor Mat

    Luggage Floor Mat EXTERIOR/INTERIOR TRIM 28.Luggage Floor Mat A: REMOVAL Remove the clips, and then detach the rear floor mats and boxes. EI-00508 B: INSTALLATION Install in the reverse order of removal. EI-56...

  • Page 59: Trunk Room Mat

    Trunk Room Mat EXTERIOR/INTERIOR TRIM 29.Trunk Room Mat A: REMOVAL Draw out the trunk room mat. EI-00507 B: INSTALLATION Install in the reverse order of removal. EI-57...

  • Page 60: Heat Shield Cover

    Heat Shield Cover EXTERIOR/INTERIOR TRIM 30.Heat Shield Cover B: INSTALLATION Install in the reverse order of removal. A: REMOVAL 1. FRONT HEAT SHIELD COVER Loosen the four bolts to remove the front heat shield cover. DI-00211 (A) Transmission mount 2. CENTER HEAT SHIELD COVER Loosen the four bolts to remove the center heat shield cover.

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