Home

2001 IMPREZA SERVICE MANUAL QUICK

1. CSS GI0103 D 457745 45 45 Tie down range GIO123 7 TOWING Avoid towing vehicles except when the vehicle can not be driven For vehicles with AWD AT or VTD use a loader instead of towing When towing other vehicles to prevent excessive weight from damag ing the hook or vehicle Do not tow other vehicles with a front towing hook Make sure the vehicle towing is heavier that the vehicle being towed 8 TRAINING For information about training contact a dealer or agent 9 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 6 IDENTIFICATION 1 ai ee 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 Emisson control label Vacuum hose piping label 10 plate Europe model ADR compliance plate Australia model Tire inflation pressure label Driver side Australia model Tire pressure label Driver side Except Australia model Vehicle identification number Sa
2. 6 praeler 8 jocis E D m c D 9 10 Camshaft Drive Belt 12 Malve Glearance ix eeu c eite eL Pael LNE ehem te tec tone me d Air Cleaner Element Cooling Syslerm oa E elei Ee ERE ERREUR ale MIXTUEG er e EE e E EE Hill holder System Transmission OU E Front amp Rear Differential Oil e QI LL E ERI aei Disc Brake Pads Disce iaire iaa a Aa a 33 Brake Linings and DrumS ene He m a ee dee 34 e NEE 36 555 38 Axle Boots amp Joints 12 1 4 4 4 4 nnnm nnne 39 Steering System Power Steering 40 Supplemental Restraint System 43 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 SCHEDULE PERIODIC MAINTENANCE SERVICES 2 Schedule A MAINTENANCE SCHEDULE 1 1 MAINTENANCE SCHEDULE 1 1 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 bey
3. Lower level 10088 PRE DELIVERY INSPECTION 16 AT FRONT DIFFERENTIAL OIL Check the AT front differential oil amount If the amount is insufficient check that no leaks are found Then add the necessary amount of the specified AT front differential oil Oil level gauge Upper level Lower level GI0089A 17 COOLANT Check the coolant amount on the reservoir If the amount is insufficient check that no leaks are found Then add the necessary amount of coolant with the specified concentration 18 CLUTCH FLUID Check the clutch fluid amount If the amount is in sufficient check that no leaks are found Then add the necessary amount of the specified fluid 19 WINDOW WASHER FLUID Check the window washer fluid amount If the amount is insufficient check that no leaks are found Then add the necessary amount of washer fluid commercially available 20 HOOD LATCH CHECK Retract the hood stay and close the hood Check that the hood is securely latched 7 PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION 21 KEYLESS ENTRY SYSTEM Check the keyless entry system operations as fol lows Remove the key from the ignition switch and close all the doors including rear gate wagon Press the LOCK button on the transmitter mo mentarily once and check if all the doors are locked and the hazard light flashes once B5M1182 Press the OPEN button
4. NOTE Apply fluid packing to drain plug threads before installation in Except Non TURBO AT model Non TURBO AT model uses a new aluminum gasket Fluid packing Three Bond 1105 Tightening torque Except Non TURBO AT model 49 0 5 0 kgf m 36 2 ft Ib Non TURBO AT model 34 N m 3 5 kgf m 25 3 ft Ib 4 After installing drain plug onto rear differential gear case firmly fill oil up fully to the mouth of filler plug Non TURBO AT model Filler bolt 10130 Except Non TURBO model Filler plu PA J m o 48 Drain plug 910131 Oil capacity 0 8 0 0 8 US qt 0 7 Imp qt NOTE Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands PM 28 FRONT amp REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 5 Install filler plug onto rear differential gear case firmly NOTE Apply fluid packing to filler plug before installa tion in Except Non TURBO AT model Non TURBO AT model uses a new aluminum gasket Fluid packing Three Bond 1105 Tightening torque Except Non TURBO AT model 49 0 N m 5 0 kgf m 36 2 ft Ib Non TURBO AT model 34 N m 3 5 kgf m 25 3 ft Ib PM 29 BRAKE LINE PERIODIC MAINTENANCE SERVICES 20 Brake Line A INSPECTION 1 BRAKE LINE 1 Check scratches swelling corrosion and or trac es of fluid leakage on brake hoses or pipe joints 2
5. Sit in the driver seat close the driver s door com pletely and place the door lock knob A to the lock position Then pull the all inside door handles B to ensure that the all doors will not open For other doors place the lock levers to the lock po sitions and then pull the inside door handles to en sure that the doors will not open 10148 GI0079A 5 POWER WINDOW OPERATION CHECK Manipulate the power window switches one by one to check that each of the power windows goes up and down with no abnormal noises 6 OPERATION CHECK OF TRUNK LOCK RELEASE LEVER Operate the trunk lock release lever and verify that the trunk lid opens PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION 7 OPERATION CHECK OF REAR GATE LOCK RELEASE LEVER Operate the rear gate lock release lever and verify that the rear gate is unlocked and opened smooth ly 8 OPERATION CHECK OF FUEL LID OPENER LOCK RELEASE LEVER Operate the fuel lid opener and verify that the fuel lid opens normally Check that the filler cap is se curely closed 9 ACCESSORY CHECK Check that the following accessories are provided in the luggage compartment or cargo area Owner s manual Warranty booklet Service booklet Spare key Jack Tool set Spare tire Jack handle 910149 Jack handle 22 610150 10 OPERATION CHECK HOOD LOCK RELEASE SYSTEM Unlatch and op
6. Hold the adjusting screw with a wrench to pre vent it from turning while tightening the lock nut 4 TIE ROD 1 Check tie rod and tie rod ends for bends scratches or other damage Knuckle arm GI0105A 2 Check connections of knuckle ball joints for play inspect for damage on dust seals and check free play of ball studs If castle nut is loose retighten it to the specified torque then tighten further up to 60 until cotter pin hole is aligned Tightening torque 27 2 75 kgf m 19 9 ft lb 3 Check lock nut on the tie rod end for tightness If it is loose retighten it to the specified torque Tightening torque 83 8 5 kgf m 61 5 ft lb PERIODIC MAINTENANCE SERVICES 5 POWER STEERING FLUID LEVEL NOTE The fluid level must be checked when the temper ature of the reservoir tank surface is approximately 20 C 68 F 1 Place vehicle with engine off on the flat and lev el surface 2 Check the fluid level using the scale on the out side of the reservoir tank A If the level is below MIN B add fluid to bring it up to MAX C GI0014A NOTE If fluid level is at MAX level or above drain fluid to keep the level in the specified range of indicator by using a syringe or the like Recommended fluid Dexron or Ill Fluid capacity 0 7 2 0 7 US qt 0 6 Imp qt 6 POWER STEERING FLUID FOR LEAKS Inspect the underside of oil pump and gearbox for p
7. 1 730 3 814 1 800 3 968 1 800 3 968 Model AWD 2 01 LHD RHD RHD GX OUTBACK 4ATx2 4AT 6 Dual rangex5 4 5 Curb weight C W Front kaf Ib 770 1 698 790 1 742 750 1 653 765 1 687 Rear kgf Ib 565 1 246 565 1 246 570 1 257 570 1 257 Total kgf Ib 1 335 2 943 1 355 2 987 1 320 2 910 1 335 2 943 Maximum permissible Front kgf Ib 920 2 028 920 2 028 920 2 028 920 2 028 axle weight M PA W Rear kgf Ib 960 2 116 960 2 116 960 2 116 960 2 116 Maximum permissible Total kgf Ib weight MPW gf Ib 1 800 3 968 1 800 3 968 1 800 3 968 1 800 3 968 xi Includes weight of roof rail Includes weight of ABS roof rail Includes weight of ABS air conditioner roof rail Includes weight of cruise control ABS roof rail Includes weight of ABS roof rail air conditioner rear spoiler Includes weight of air conditioner SPC 7 IMPREZA SPECIFICATIONS LHD RHD 5MTx3 5 4 Curb weight C W 805 1 775 765 1 687 585 1 290 570 1 257 1 390 3 064 1 335 2 943 Maximum permissible 970 2 138 970 2 138 axle weight M P A W 950 2 094 950 2 094 Maximum permissible 1 860 4 100 1 860 4 100 weight M P W 3 Includes weight of ABS roof rail 4 Includes weight of ABS air conditioner roof rail SPC 8 IMPREZA SPECIFICATIONS 2 AUSTRALIA SPEC VEHICLE S
8. 4AT 1 5MT 1 4AT 1 Curb weight C W Maximum permissible axle weight M P A W 715 1 576 760 1 676 715 1 576 760 1 676 470 1 036 470 1 036 470 1 036 470 1 036 1 185 2 612 890 1 962 1 230 2 712 890 1 962 1 185 2 612 890 1 962 1 230 2 712 890 1 962 890 1 962 890 1 962 890 1 962 890 1 962 Maximum permissible weight M P W 1 660 3 660 1 660 3 660 1 660 3 660 1 660 3 660 5MT 5MTx2 5 2 5 Curb weight C W 730 1 609 735 1 620 810 1 786 830 1 830 520 1 146 1 250 2 756 520 1 146 1 255 2 767 555 1 224 1 365 3 009 555 1 224 1 385 3 053 Maximum permissible axle weight M P A W 890 1 962 890 1 962 890 1 962 890 1 962 960 2 116 920 2 028 960 2 116 920 2 028 Maximum permissible weight M P W 1 690 3 726 1 690 3 726 1 820 4 012 1 820 4 012 5MT 4AT 5 4 4ATX4 Curb weight C W Maximum permissible axle weight M P A W 745 1 642 770 1 698 535 1 179 790 1 742 535 1 179 530 1 168 765 1 687 530 1 168 1 280 2 822 920 2 028 1 300 2 866 920 2 028 1 300 2 866 920 2 028 1 320 2 910 920 2 028 910 2 006 910 2 006 910 2 006 910 2 006 M
9. 4 Remove pulley bolt To lock crankshaft use ST ST 499977300 CRANKSHAFT PULLEY WRENCH GI0138 5 Remove crankshaft pulley 6 Remove air conditioning compressor drive belt tensioner 7 Remove left side belt cover 8 Remove right side belt cover 9 Remove front belt cover PERIODIC MAINTENANCE SERVICES 10 Turn crankshaft and align alignment marks on crankshaft and left and right camshaft sprockets with notches of belt cover and cylinder block To turn crankshaft use ST ST 499987500 CRANKSHAFT SOCKET Notch Notch Alignment p Alignment mark 19 090 Alignment mark SI Cal 3 mark Q d Alignment 1 Ali t mark A Alignment Alignment BO0139 11 12 Remove timing belt 13 Remove automatic belt tension adjuster as sembly PM 13 CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES B INSTALLATION 1 SOHC MODEL To install reverse order of removal procedures Ref to ME SOHC 46 Timing Belt Assembly 2 DOHC MODEL To install reverse order of removal procedures Ref to ME DOHC TURBO 47 Timing Belt As sembly gt 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 C INSPECTION 1
10. Check the possibility of adjacent parts interfering with brake pipes hoses during driving and loose connections clamps 3 Check any trace of fluid leakage scratches etc on master cylinder wheel cylinder and pressure control valve NOTE When the brake fluid level in the reservoir tank is lower than the specified limit the brake fluid warn ing light on the combination meter will come on Visually check brake hose using a mirror where it is difficult to see for any damage SE NS SA HINC 0100148 qul B CHECKING 1 SERVICE BRAKE 1 Check the free play of brake pedal with a force of less than 10 N 1 kgf 2 Ib Brake pedal free play 1 3 mm 0 04 0 12 in Lock nut Brake lodi operating rod Pedal play 1 3mm 0 04 0 12 in Play at Y GI0050A 2 If the free play is out of specifications above ad just the brake pedal as follows 1 Be sure engine is off No vacuum is applied to brake booster 2 There should be play between brake boost er clevis and pin at brake pedal installing por tion Depress brake pedal pad with a force of less than 10 1 kgf 2 Ib to a stroke of 1 to mm 0 04 to 0 12 in 3 Depress the surface of brake pad by hand 4 If there is no free play between clevis pin and clevis turn brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes
11. Full time AWD Single range 4 Full time AWD Dual range 5 AWD AT 9 FWD 1 2001MY 2 2002MY Drive type Model year Factory location 12 to 17 002001 Serial number GCC countries Saudi Arabia etc JF1GD33MX1G002001 The starting and ending brackets are stop marks Meaning G FHI Gunma Details Manufacturer body area JF1 Passenger car FHI made Car line IMPREZA Body type D 4 Door Sedan G Wagon Displacement 3 1 6 L FWD 4 1 6 L AWD 8 2 0 L AWD 3 BASE 5 TS 7 GX Restraint Check digit M Manual belts dual airbag Model year Transmission type 1 2001MY 2 2002MY 3 2003MY B FWD5MT K FWD 4 AT G Full time AWD 5 speed MT single range H Full time AWD 4 speed AT J Full time AWD 5 speed MT dual range 12 to 17 002001 Serial number ID 4 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 GD9AL7R Meaning Details Series IMPREZA Body style D 4 Door Sedan G Wagon Engine displacement 4 1 6 L FWD Drive system 5 1 6 AWD Suspension system 9 2 0 L AWD Minor change 2001MY Destination K Right hand drive for general market L Left hand drive for general market Y Left ha
12. 2 When camber angle does not conform to stan dard value visually inspect parts listed below If de formation is observed replace damaged parts Suspension components Shock absorber link F link R link UPR arm R sub frame etc Body parts to which suspensions are installed 3 When toe in and thrust angle are out of standard value adjust them so that they conform to respec tive service standard 6 OIL LEAKAGE OF STRUT AND SHOCK ABSORBER Visually inspect front strut and rear shock absorber for oil leakage as instructed Replace front strut and rear shock absorber if oil leaks excessively 7 TIGHTNESS OF BOLTS AND NUTS Check bolts and nuts shown in the figure for loose ness Retighten bolts and nuts to specified torque If self lock nuts and bolts are removed replace them with new ones Front suspension Ref to FS 2 General Descrip tion Rear suspension Ref to RS 2 General Descrip tion PERIODIC MAINTENANCE SERVICES 8 DAMAGE TO SUSPENSION PARTS 1 Check the following parts and the fastening por tion of the vehicle body for deformation or exces sive rusting which impairs the suspension lf necessary replace damaged parts with new ones If minor rust formation pitting etc are noted re move rust and apply remedial anti corrosion mea sures Front suspension Transverse link Crossmember Strut Rear suspension Crossmember Lateral links Trailing link Strut
13. 485 1 069 485 1 069 535 1 179 545 1 202 540 1 191 1 190 2 624 1 235 2 723 1 275 2 811 1 295 2 855 1 320 2 910 Maximum permissible 890 1 962 890 1 962 890 1 962 920 2 028 920 2 028 axle weight M P A W 890 1 962 890 1 962 890 1 962 910 2 006 910 2 006 Maximum permissible weight M P W Wagon 1 660 3 660 1 660 3 660 1 690 3 726 1 760 3 880 1 760 3 880 BASE GX 5MT Dual rangex2 Dual rangex2 4 Curb weight C W 700 1 543 505 1 113 745 1 642 560 1 235 750 1 653 580 1 279 780 1 720 575 1 268 Maximum permissible 1 205 2 657 890 1 962 1 305 2 877 900 1 984 1 330 2 932 920 2 028 1 355 2 987 920 2 028 axle weight M P A W 900 1 984 910 2 006 960 2 116 960 2 116 Maximum permissible weight M P W 1 Includes weight of ABS 2 Includes weight of roof rail 3 Includes weight of ABS roof rail 1 690 3 726 1 730 3 814 1 800 3 968 SPC 10 1 800 3 968 PRECAUTION PRECAUTION PRECAUTION 1 Precaution A PRECAUTION Please clearly understand and adhere to the follow ing general precautions They must be strictly fol lowed to avoid minor or serious injury to the person doing the work or people in the area 1 ABS Handle t
14. 7 5 8 5 mm 0 295 0 335 in reused 9 0 10 0 mm 0 354 0 394 in There is no belt B on models without an air con ditioner GI0019A C P Crankshaft pulley GEN Generator P S Power steering oil pump pulley A C Air conditioning compressor pulley Idler pulley B REPLACEMENT 1 V BELT COVER 1 Remove V belt cover 2 FRONT SIDE BELT DRIVING POWER STEERING OIL PUMP AND GENERATOR NOTE Wipe off any oil or water on the belt and pulley 1 Loosen the lock bolt A 2 Loosen the slider bolt B 3 Remove the front side belt C 4 Install a new belt and tighten the slider bolt so as to obtain the specified belt tension 5 Tighten the slider bolt B 6 Tighten the lock bolt A Tightening torque Lock bolt through bolt 25 2 5 kgf m 18 ft lb Slider bolt 8 0 8 kgf m 5 8 ft lb GI0021A PM 10 DRIVE BELT S 3 REAR SIDE BELT DRIVING AIR CONDI TIONER NOTE Wipe off any oil or water on the belt and pulley Before removing the rear side belt remove the front side belt 1 Loosen the lock nut A 2 Loosen the slider bolt B 3 Remove the rear side belt 4 Install a new belt and tighten the slider bolt so as to obtain the specified belt tension 5 Tighten the slider bolt B 6 Tighten the lock nut A Tightening torque 22 6 2 3 kgf m 16 6 ft Ib PM 11 PERIODIC MAINTENANCE SERV
15. Application point Windshield and body thane E Recommended Essex Chemical Crop s Ure Item number 004404002 Alternative Sunstar 580 Weatherstrip rubber parts Soft vinyl Cemedine 540 Cemedine 5430L Spray type 3M s EC 1770 EC 1368 3M s EC 776 EC 847 or EC 1022 Momentary sealant 9 SEAL MATERIAL Use seal material shown in the table below or equivalent Seal material Application point Cemedine 3000 Recommended Item number Armstrong s Eastman 910 Alternative Engine case Three Bond 1215 004403007 Dow Corning s No 7038 Transmission Three Bond 1217B 0877 020 Rear differential Three Bond 1324 004403042 Rear differential Three Bond 1105 004403010 Dow Corning s No 7038 Weatherstrip Starcalking B 33A 000018901 Butyl Rubber sealant Steering adjusting screw Three Bond 1102 004403006 SOHC cam cap Three Bond 1280B RM 5 K0877YA018 RECOMMENDED MATERIALS RECOMMENDED MATERIALS RM 6 PRE DELIVERY INSPECTION 1 Pre delivery Inspection e oh ht Rer EES 2 PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION 1 Pre delivery Inspection A GENERAL The purposes of the pre delivery inspection PDI are as follows Remove the additional parts used for ensuring the vehicle quality during transportation and restore the vehicle to its normal
16. differential oil amount 17 Coolant 18 Clutch fluid 0 Check the clutch fluid amount 1 9 Check the coolant amount 19 Window washer fluid Check the window washer fluid amount 20 Hood latch check Check that the hood is closed and latched securely 21 Keyless entry system Check that the keyless entry system operates normally 22 Seat 23 Seat belt Check the seat installation conditions and functionality Check the seat belt installation conditions and functionality 24 Wheel alignment 1 11 12 13 14 Check the seat surfaces for smears or dirt 15 16 17 Check that the wheel alignments are properly adjusted PI 3 PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION Checks with the Engine Running Step Check point 1 Read memory and test mode connectors 2 Starting condition 1 2 Read memory and test mode connectors Start the engine and check that the engine starts smoothly 3 Exhaust system 3 Check that the exhaust noise is normal and no leaks are found 4 Indicator light 4 Check that all the indicator lights operate normally 5 Clock 5 Check that the clock operate normally 6 Radio 6 Check that the radio system operates normally 7 Cigarette lighter 7 Check that the cigarette lighter operates normally 0 8 Lighting system 8 Check that the lighting systems operate normally 9 Window washer 9 Check that th
17. it in and out to check bearing free play 3 Loosen wheel nuts and remove rear wheel 4 If bearing free play exists in step 2 above attach a dial gauge to hub COMPL and measure axial dis placement in axial direction Service limit Straight ahead position within 0 05 mm 0 0020 in 5 Remove the DOJ of rear drive shaft from rear dif ferential Ref to 05 37 Rear Drive Shaft 6 While supporting rear drive shaft horizontally with one hand turn hub COMPL with the other to check for noise or binding If hub COMPL is noisy or binds disassemble rear axle and check condition of oil seals bearings etc Inner oil seal Rear housing t 2 Tone wheel 9 With ABS only 0 Hub bolt Socket bolt Bearing 0 With ABS only Snap ring Outer oil seal lt gt 0134 38 AXLE BOOTS amp JOINTS PERIODIC MAINTENANCE SERVICES 26 Axle Boots amp Joints A INSPECTION 1 FRONT AND REAR AXLE BOOTS Inspect front axle boots A and rear axle boots B for deformation damage or failure If faulty replace them with new ones Ref to DS 32 Front Drive Shaft Ref to 05 37 Rear Drive Shaft SN 10135 2 PROPELLER SHAFT Inspect propeller shaft for damage or failure If faulty replace with new one Ref to DS 16 Pro peller Shaft PM 39 STEERING SYSTEM POWER STEERING PERIODIC MAINTENANCE SERVICES 27 Steering System Powe
18. n the district where salt is sprayed to melt snow on a road in winter check suspension parts for damage caused by rust every 12 months after lapse of 60 months Take rust prevention measure as required PM 37 WHEEL BEARING PERIODIC MAINTENANCE SERVICES 25 Wheel Bearing A INSPECTION 1 FRONT WHEEL BEARING NOTE Inspect the condition of front wheel bearing grease 1 Jack up the front of vehicle 2 While holding front wheel by hand swing it in and out to check bearing free play 3 Loosen wheel nuts and remove front wheel 4 If bearing free play exists in step 2 above attach a dial gauge to hub and measure axial displace ment in axial direction Service limit Straight ahead position within 0 05 mm 0 0020 in 5 Remove bolts and self locking nuts and extract transverse link from front crossmember 6 While lightly hammering spring pin which se cures S F J to transmission spindle remove it 7 Extract S F J from transmission spindle Ref to DS 19 Front Axle 8 While supporting front drive shaft horizontally with one hand turn hub with the other to check for noise or binding If hub is noisy or binds disassemble front axle and check condition of oil seals bearing etc Inner oil seal Hub bolt 63 A Snap ring 0 7 Bearing S Housing V Outer oil seal 2 Hub GI0133 2 REAR WHEEL BEARING 1 Jack up the rear of vehicle 2 While holding rear wheel by hand swing
19. state e Check if the vehicle before delivery is in a normal state e Check for any damage or missing parts that may have taken place during transportation or storage Make sure to provide a complete vehicle to the customer Because of the above reasons all dealerships must always carry out the PDls before delivering vehicle In addition all franchised shops and PDI centers must check the status of every vehicle received to identify who is responsible for any possible defects 2 PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION B PDI PROCEDURE Follow the procedures shown in the table below Static Checks Just After Vehicle Receipt Step Check point 1 Appearance check 2 Tire check 1 If the vehicle is covered with protective coating visually check the vehicle body for damage and dents If the protective coating has been removed visually check the body paints for small areas of damage or stains 2 Visually check the glass and light lenses for any damage and cracks or excessive gaps to the body sheet metal 3 Visually check the plated parts for any damage 4 Check the tires for damage abnormal conditions and dents on the wheels 5 Check the tire air pressure 3 Fuse installation 6 If the vehicle is about to be delivered to the customer attach a room lamp fuse 4 Check the doors for lock unlock and open close operations 5 Power window operation check 7 Usin
20. that they are within speci fied values 3 When wheel arch height is out of standard visu ally inspect following components and replace de formed parts Suspension components Front strut assembly and rear shock absorber assembly Body parts to which suspensions are installed 4 When no components are deformed adjust wheel arch height by replacing coil spring in the suspension whose wheel arch height is out of stan dard Ref to FS 8 Wheel Alignment Ref to RS 10 Wheel Alignment PM 36 SUSPENSION 4 WHEEL ALIGNMENT OF FRONT SUS PENSION 1 Check alignment of front suspension to ensure that following items conform to standard values Toe in Camber angle Caster angle Steering angle Ref to FS 8 Wheel Alignment 2 When caster angle does not conform to standard value visually inspect following components and replace deformed parts Suspension components Strut assembly cross member transverse link etc Body parts to which suspensions are installed 3 When toe in and camber are out of standard val ue adjust them so that they conform to respective service standard 4 When right and left turning angles of tire are out of standard adjust to standard value 5 WHEEL ALIGNMENT OF REAR SUS PENSION 1 Check alignment of rear suspension to ensure that following items are within standard values Toe in Camber angle Thrust angle Ref to RS 10 Wheel Alignment
21. x 6JJ 16 x 6 5JJ 17 x 7JJ Tire size 175 70R14 84T 185 70R14 88H 195 60R15 88H P205 55R16 89V 215 45R17 87W Type Steel belted radial Tubeless SPC 4 IMPREZA SPECIFICATIONS I CAPACITY FWD Model 1 6L 50 13 2 11 0 4 0 4 2 3 5 3 0 3 2 2 6 Fuel tank 0 US gal Imp gal Engine oil Upper level 0 US qt Imp qt Lower level US qt Imp qt Transmission gear oil US qt Imp qt Automatic transmission fluid US qt Imp qt AWD rear differential gear oil US qt Imp ot Fower steering fluid US qt Imp qt AWD Model 1 61 Non Turbo 2 0 L Turbo 2 0 L 5MT 4 5MT 4 5MT Fuel tank 0 US gal Imp gal 50 13 2 11 0 50 13 2 11 0 60 15 9 13 2 Engine oil Upper level 0 US qt Imp at 4 0 4 2 3 5 Lower level 0 US qt Imp at 3 0 3 2 2 6 3 5 8 7 3 1 Transmission gear oil 0 US qt Imp qt 3 5 8 7 3 1 3 5 4 0 4 2 3 5 1 0 0 0 AT differential gear oil 0 US qt Imp qt 0 Automatic transmission fluid 0 US qt Imp qt AT differential gear oil 0 US qt Imp qt AWD rear differential gear oil 0 US qt Imp qt 0 8 0 8 0 6 0 0 Power steering fluid US qt Imp at 0 7 0 7 0 6 Engine coolant 7 0 7 4 6 2 US qt Imp at 1 Dual range SPC 5 SPECIFICATIONS IMPREZA J WEIGHT 1 EUROPE SPEC VEHICLE Sedan 5 1
22. 0 3 mm 0 012 in Brake switch Brake booster operating rod Play at pin j Pedal play 1 3 0 04 0 12 0051 30 BRAKE LINE 3 Check the pedal stroke While the engine is idling depress the brake pedal with a 490 N 50 kgf 110 Ib load and measure the distance between the brake pedal and steering wheel With the brake pedal released measure the distance between the pedal and steering wheel again The difference between the two measure ments must be less than 95 mm 3 74 in If the dis tance is more than specified there is a possibility air is in the inside of the hydraulic unit Brake pedal reserve distance A more than 95 mm 3 74 in 490 N 50 kgf 110 Ib 41 2 Toe board 4 Check to see if air is in the hydraulic brake line by the feel of pedal operation If air appears to exist in the line bleed it from the system 5 Check for even operation of all brakes using a brake tester or by driving the vehicle for a short dis tance on a straight road 2 BRAKE SERVO SYSTEM 1 With the engine off depress the brake pedal several times applying the same pedal force Make sure the travel distance should not change 2 With the brake pedal depressed start the en gine Make sure the pedal should move slightly to ward the floor 3 With the brake pedal depressed stop the engine and keep the pedal depressed for 30 seconds Make sure t
23. 0 miles 6 months 12 500 km 7 500 miles 6 months 12 500 km 7 500 miles Parking brake 6 months 12 500 km 7 500 miles Suspension 6 months 12 500 km 7 500 miles Axle boots amp joints Steering system Power steering 6 months 12 500 km 7 500 miles 6 months 12 500 km 7 500 miles PM 5 ENGINE OIL PERIODIC MAINTENANCE SERVICES 3 Engine Oil A REPLACEMENT 1 Drain engine oil by loosening engine oil drain plug s Drain plug 2 Open engine oil filler cap for quick draining of the engine oil Upper level About 1 04 US 0 9 Imp at Lower level GI0013A NA Engine oil filler cap gt Oil level gauge Fo oL 3 Replace drain plug gasket 4 Tighten engine oil drain plug after draining en gine oil Tightening torque 44 4 5 kgf m 33 ft Ib GI0012A 5 Fill engine oil through filler pipe up to upper point on level gauge Make sure that vehicle is placed level when checking oil level Use engine oil of proper quality and viscosity selected in accor dance with the table in figure Engine oil capacity Non TURBO model Upper level 4 0 0 4 2 US qt 3 5 Imp qt Lower level 3 0 0 3 2 US qt 2 6 Imp qt Engine oil capacity TURBO model Upper level 4 5 0 4 8 US qt 4 0 Imp qt Lower level 3 5 0 3 7 US qt 3 1 Imp qt SAE Viscosity No a
24. 16218 None Water for dilution Distilled water Tap water 6 REFRIGERANT Standard air conditioners on Subaru vehicles use HFC134a refrigerant Do not mix it with other refrigerants Also do not use any air compressor oil except for ZXL200PG and DENSO OIL 9 erste Refrigerant HFC134a Compressor oil LHD ZXL200PG RHD DENSO OIL 9 RM 4 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 O2 sensor Bolts etc SUBARU CRC 004301003 Grease 8 ADHESIVES MT main shaft Clutch master cylinder push rod FX clutch grease Slicolube G 40M 000040901 004404003 Steering shaft bear ing Gear shift bush SUNLIGHT2 003602010 Steering gear box Valiant grease M 2 003608001 Disc brake Niglube RX 2 003606000 or 725191040 Drum brake Brake pad Brake shoe Molykote No 7439 Molykote AS 880N 72519460 26298 000 Front axle SFJ SSG 6003 28093 000 Front EBJ 2218 28093AA000 Rear axle BJ Molykote No 2 723223010 Rear axle DOJ VU 3A702 23223GA050 Control cable Throttle linkage Water pump Door latch Door striker Slicolube G 30M Use the adhesives shown in the table below or equivalent Adhesive
25. 2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFOMATION SECTION FOREWORD HOW TO USE THIS MANUALS SPECIFICATIONS PRECAUTION 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 IDENTIFICATION This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of RECOMMENDED MATERIALS components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual PRE DELIVERY INSPECTION fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition PERIODIC MAINTENANCE SERVICES PM When replacement of parts during repair work is needed be sure to use SUBARU genuine parts NOTE 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 G1830GE1 Has capo E e ew ti FOREWORD FOREWORD FOREWORD 1 Foreword A FOREWORD These manuals are used when performing mainte nance repair or diagnosis of the Subaru IMPRE ZA Applied model GG and GD from 2001MY The additional manuals below are also available AUTOMATIC TRANSMISSION SERVICE MANU AL Pub No G0853ZE The manuals contain t
26. 8 8 136 0 3 600 292 29 8 215 4 3 600 IMPREZA SPECIFICATIONS C ELECTRICAL Model 1 6L Non Turbo 2 0 L Turbo 2 01 Ignition timing at idling speed BTDC rpm 5 10 700 10 10 700 12 10 750 Spark plug Generator Type and manu facturer Without OBD With OBD BKR6E without catalyst CHAMPION RC10YC4 with catalyst BKR5E 11 with catalyst 10 4 Alternate RC8YC4 BKR6E 1 1 K20PR U1 1 12V 75A PFR6G Battery Type and capac ity BHR For Europe and South MT 12V 48AH 55D23L MT 12V 48AH 55D23L AT 12V 52AH 75D23L AT 12V 52AH 65D23L America Others 12V 27AH 34B19L D TRANSMISSION FWD Model Transmission type 4AT 2 Clutch type TCC Gear ratio 1st 2 785 2nd 1 545 1 000 4th 0 694 5th Reverse 2 272 Reduction gear Front drive 1st reduction Type of gear Helical Gear ratio 1 000 Final reduction Type of gear Gear ratio Hypoid Reduction gear Rear drive Transfer reduction Type of gear Gear ratio Final reduction Type of gear Gear ratio 5 1 5 forward speeds with synchromesh and 1 reverse 4 2 Electronically controlled fully automatic 4 forward speeds and 1 reverse DSPD Dry Single Plate Diaphragm TCC T
27. IC CLUTCH TYPE 1 Push the release lever to retract the push rod of the operating cylinder and check if the fluid level in the clutch reservoir tank rises or not Non TURBO model ko Release lever IN Push rod 1191 9 610129 2 If the fluid level rises pedal free play is correct 3 If the fluid level does not rise or the push rod cannot be retracted adjust the clutch pedal Ref to CL 32 Clutch Pedal 4 Inspect the underside of master cylinder clutch damper and operating cylinder for clutch system hoses piping and their couplings for fluid leaks If fluid leaks are found correct them by retightening their fitting bolt and or replacing their parts 5 Check the fluid level using the scale on the out side of the clutch master cylinder tank A If the lev el is below MIN B add clutch fluid to bring it up to MAX C Recommended clutch fluid FMVSS 116 fresh DOT3 or DOT4 brake fluid NOTE Avoid mixing different brakes of brake fluid to prevent degradation of the fluid PM 23 PERIODIC MAINTENANCE SERVICES Be careful not to allow dirt or dust to get into the reservoir tank CLUTCH SYSTEM 2490 DONA 24 HILL HOLDER SYSTEM 16 Hill holder System A INSPECTION AND ADJUSTMENT 1 Confirm stopping and starting performance by activating hill holder on an uphill road of 3 or high er incl
28. ICES CAMSHAFT DRIVE BELT PERIODIC MAINTENANCE SERVICES 7 Camshaft Drive Belt A REPLACEMENT 1 SOHC MODEL 1 Remove radiator fan Ref to CO 9 Radiator Main Fan System and air conditioner fan Ref to CO 17 Radiator Sub Fan System 2 Remove V belt cover GI0020 3 Remove V belts Ref to ME SOHC 42 V belt gt 4 Remove air conditioning compressor drive belt tensioner 5 Remove pulley bolt To lock crankshaft use ST ST 499977100 CRANKSHAFT PULLEY WRENCH Remove crankshaft pulley Remove left side belt cover Remove front belt cover Remove timing belt guide MT vehicle only 6 7 8 9 10 Turn crankshaft and align alignment marks on crankshaft and left and right camshaft sprockets with notches of belt cover and cylinder block ST 499987500 CRANKSHAFT SOCKET Notch Alignment mark al Var N Alignment mark Notch gS Alignment mark 11 Remove belt idler 12 Remove belt idler No 2 GI0025A 13 Remove timing belt 14 Remove automatic belt tension adjuster as sembly GI0027 PM 12 CAMSHAFT DRIVE BELT 2 DOHC MODEL 1 Remove radiator fan and air conditioner fan Pr SS 17 2 Remove V belts Ref to ME DOHC TURBO 43 V belt gt 3 Remove air conditioning compressor drive belt tensioner
29. OUTBACK 4 405 173 4 Overall width Overall height at CW 1 730 68 1 1 440 56 7 1 695 66 7 1 465 57 7 1 485 58 5 4 1 710 67 3 1 475 58 1 1 495 58 9 4 1 890 74 4 1 845 72 6 1 380 54 3 1 180 46 5 1 200 47 2 1 150 45 3 5 1 200 47 2 1 150 45 3 5 2 525 99 4 1 485 58 5 1 475 58 1 1 480 58 3 3 1 460 57 5 1 1 465 57 7 1 450 57 1 1 1 455 57 3 1 460 57 5 1 455 57 3 Compartment Length Width Height Wheelbase Tread Rear Minimum road Without catalytic clearance converter With catalytic converter 1 1 6L 2 GX 3 WRX x4 With roof rail 5 With sun roof B ENGINE Model 150 5 9 155 6 1 2 150 5 9 155 6 1 3 1 6L 150 5 9 155 6 1 2 150 5 9 155 6 1 3 160 6 3 Non Turbo 2 0 L Turbo 2 01 Engine type Horizontally opposed iquid cooled 4 cylinder 4 stroke gasoline engine Valve arrangement Bore x Stroke mm in 87 9 x 65 8 3 461 x 2 591 Overhead camshaft type 92x75 3 62 x 2 95 Displacement cm cu in 1 597 97 45 1 994 121 67 Compression ratio Firing order Idle speed at Park Neutral position Maximum output kW HP rpm 75 100 5 200 7504100 92 123 5 600 160 215 5 600 Maximum torque kgf m ft Ib rpm 143 14 6 105 5 3 600 SPC 2 184 1
30. RM 2 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 API Spec Recommended Spec ACEA Spec Alternative Engine oil Manual transmission oil SJ Grade Energy conserving G4 or G5 GI0001 GI0002 A1 A2 or A3 API SH or SG Front differential Rear differential SAE viscosity Engine oil 10W 30 or 10W 40 5W 30 Recommend RM 3 GI0003A RECOMMENDED MATERIALS RECOMMENDED MATERIALS SAE viscosity SAE viscosity No and applicable temperature SAE J300 Manual transmission oil 20 10 10 4 14 50 Rear differential GI0004A Front differential GIO005A 4 FLUID Use the fluids specified in the table below Do not mix two different kinds or makes of fluid Fluid Recommended Alternative Remarks Automatic transmission fluid DEXRON III Power steering fluid DEXRON III Brake fluid FMVSS No 116 DOT3 FMVSS No 116 DOT4 Clutch fluid FMVSS No 116 DOT3 FMVSS No 116 DOT4 5 COOLANT Use genuine coolant to protect the engine The table below shows the ratio of coolant to distilled water Coolant Recommended Item number Alternative Coolant SUBARU coolant 0000
31. SOHC MODEL 1 Remove left and right timing belt covers 2 While cranking engine at least four rotations check timing belt back surface for cracks or dam age Replace faulty timing belt as needed 3 Measure timing belt width W If it is less than 27 mm 1 06 in check idlers tensioner water pump pulley and cam sprocket to determine idler align ment squareness Replace worn timing belt GI0142 4 Install left and right timing belt covers 2 DOHC MODEL 1 Remove left and right timing belt covers 2 While cranking engine at least four rotations check timing belt back surface for cracks or dam age Replace faulty timing belt as needed 3 Measure timing belt width W If it is less than 30 mm 1 18 in check idlers tensioner water pump pulley and cam sprocket to determine idler align ment squareness Replace worn timing belt 4 Install left and right timing belt covers 10143 14 VALVE CLEARANCE 8 Valve Clearance A INSPECTION For the inspection procedures of the valve clear ance Ref to ME SOHC 29 Valve Clearance or Ref to ME DOHC TURBO 28 Valve Clear ance PM 15 PERIODIC MAINTENANCE SERVICES FUEL LINE PERIODIC MAINTENANCE SERVICES 9 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 repai
32. ately stop the engine and check and repair the necessary compo nents 27 EXHAUST SYSTEM Listen to the exhaust noise to see if no abnormal noises are observed 28 INDICATOR LIGHT Check that all the indicator lights are off 29 CLOCK Check the clock for normal operations and enough accuracy 30 RADIO Check the radio for full functionality and normal noise level Also check the CD unit operations 31 CIGARETTE LIGHTER Check that the cigarette lighter operations 32 LIGHTING SYSTEM Check the headlight operations Check the brake light operations Check the other lights for normal operations PRE DELIVERY INSPECTION 33 WINDOW WASHER Check that the window washer system injects washer fluid to the specified area of the windshield shown in the figure Front Injection position A 350mm 13 78 B 162mm 5 91 in N m C 300mm 11 81 D 500mm 23 62 A Nozzle Gl0152 Rear Injection position A 39 mm 2 36 in N m B 72 Nozzle 610153 34 WIPER Check the front and rear wipers for normal opera tions 35 BRAKE TEST Check the foot brake for normal operations 36 PARKING BRAKE Check the parking brake for normal operations 9 PRE DELIVERY INSPECTION 37 AT SHIFT CONTROL Set the AT select lever to each gear position while checking that the demanded gear position is cor rectly atta
33. aximum permissible weight M P W 1 Includes weight of air conditioner 2 Includes weight of ABS 3 Includes weight of ABS air conditioner 1 760 3 880 4 Includes weight of ABS air conditioner rear spoiler 1 760 3 880 SPC 6 1 760 3 880 1 760 3 880 IMPREZA Wagon SPECIFICATIONS Model FWD 1 6L LHD RHD BASE 5MT 1 4AT 4 5MT 1 4 1 Curb weight C W Front kgf Ib 710 1 565 765 1 687 710 1 565 760 1 676 Rear kgf Ib 490 1 080 495 1 091 490 1 080 490 1 080 Total kgf Ib 1 200 2 646 1 260 2 778 1 200 2 646 1 250 2 756 Maximum permissible Front kgf Ib 890 1 962 890 1 962 890 1 962 890 1 962 axle weight M PA W Rear kgf Ib 900 1 984 900 1 984 900 1 984 900 1 984 Maximum permissible Total kgf Ib weight M PWO gf Ib 1 690 3 726 1 690 3 726 1 690 3 726 1 690 3 726 LHD RHD LHD RHD Dual rangex2 Dual rangex3 Dual rangex2 Dual Curb weight C W 735 1 620 545 1 202 740 1 631 545 1 202 745 1 642 570 1 257 765 1 687 570 1 257 1 280 2 822 1 285 2 833 1 315 2 899 1 335 2 943 Maximum permissible axle weight M P A W 900 1 984 910 2 006 900 1 984 910 2 006 920 2 028 960 2 116 920 2 028 960 2 116 Maximum permissible weight M P W 1 730 3 814
34. base oil and addi tives Thus do not mix two or more brands 3 Fill transmission gear oil through the oil level gauge hole up to the upper point of level gauge Gear oil capacity FWD model 3 3 0 3 5 US qt 2 9 Imp qt Single range model 3 5 0 3 7 US qt 3 1 Imp qt Dual range model 4 0 0 4 2 US qt 3 5 Imp qt Upper level Lower level 10042 26 18 A REPLACEMENT 1 AUTOMATIC TRANSMISSION FLUID 1 Drain ATF Automatic Transmission Fluid by re moving drain plug after allowing the engine to cool for 3 to 4 hours NOTE Before m Work cool off the engine well AS differential i p plug 2 Eeer E 2 Reinstall drain Pius after draining ATF and tight en it to the specified torque Tightening torque 24 5 N m 2 5 kgf m 18 1 ft Ib 3 Fill ATF up to the middle of the COLD side on level gauge by using the gauge hole Recommended fluid Dexron type automatic transmission fluid Fluid capacity Fill the same amount drained from ATF drain plug hole 4 Run the vehicle until the ATF temperature rises to 60 to 80 C 140 to 176 F and check the ATF level Hot side Upper COLD Level gauge level side Upper Lower Cg 3 Sr 10044 2 ATF FILTER NOTE ATF filter is maintenance free part ATF filter needs replacement when it has physically damaged or ATF leaked For the replacement
35. dering parts See the parts catalog for details Rear differential 1 VA1REJ Meaning For AWD V AED Type A A type Hypoid gear diameter 1 152 dia 2 160 dia Installation position R Rear Reduction gear ratio B 3 900 E 4 111 F 4 444 Specification differ J Case B ences Rear differential 2 T1 Reduction gear ratio 3 900 4 111 No Viscous Viscous strengthened type Viscous strengthened type Viscous ID 6 RECOMMENDED MATERIALS 1 Recommended 2 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 that of equivalent quality 2 FUEL Always use a gasoline of the same or higher octane value than specified in the owner s manual Ignor ing the specifications below will result in damage or poor operation of the engine and fuel injection sys tem Use the specified gasoline to correct perfor mance Unleaded gasoline Use unleaded gasoline and not leaded gasoline on vehicles with catalytic converter installed to reduce air pollution Using leaded gasoline will damage the catalytic converter Leaded gasoline On vehicles without catalytic converter use gaso line with an octane value of 90 RON or higher
36. e PM 22 CLUTCH SYSTEM 15 Clutch System A INSPECTION AND ADJUSTMENT 1 MECHANICAL CLUTCH TYPE 1 Inspect free play of clutch pedal by operating pedal by hand If it is out of the specified value adjust it by turning wing nut on engine side of clutch cable at release fork Tightening torque Adjusting nut on release fork 4 4 7 4 N m 0 45 0 75 kgf m 3 3 5 4 ft Ib Standard free play AT clutch pedal 10 20 mm 0 39 0 79 in Free play 10 20mm 0 39 0 79in 610144 Fork lever free play allowance 2 4 mm 0 08 0 16 in Free play Full stroke 2 4mm 25 5mm 1 in 0 08 0 16in p Release fork 010145 2 Pedal to floor plate gap disengaged position 1 With the engine idling pull parking brake le ver completely 2 Slowly depress clutch pedal while moving shift lever into reverse 3 Stop depressing clutch pedal when gear shifting is complete With clutch pedal in this po sition measure the distance between the upper side of pedal pad and the lower end of front pan el intersection of front panel with floor Check that the measured value is within the specified standard Standard 80 mm 3 15 in or more Lock nut Adjusting nut PERIODIC MAINTENANCE SERVICES 3 Pedal height Check that the clutch pedal pad surface is level with or higher than brake pedal pad surface 2 HYDRAUL
37. e move anything that may obstruct the operation or which must be kept dry Close all of the windows completely and then close all of the doors tightly Close the hood and trunk lid before starting the test Connect a hose to a tap and spray water on the vehicle The rate of water discharge must be ap prox 20 to 25 liters 5 3 to 6 6 US gal 4 4 to 5 5 Imp gal per minute When spraying water on areas adjacent to the floor and wheel house increase the pressure When di recting water on areas other than the floor portion and wheel house decrease the pressure But the force of water must be made strong occasionally by pressing the end of the hose NOTE Be sure to keep the hose at least 10 cm 3 9 in from the vehicle Check the following areas Front window and body framework mating portion Door mating portions Glass mating portions Rear quarter window mating portions Rear window and body framework mating portion Around roof drips f any dampness in the compartments is discov ered after the water has been applied carefully check all areas that may have possibly contributed to the leak 10 PERIODIC MAINTENANCE SERVICES PM ooo UOI Ic PO P PO PP AH A AH AH sch SNAAKSSSSOBNAHROV S Page General Description nitore e eter Hd eL FU e Lu Ene da Rice 2 RTT eene 3 E Deine scatet te eege tu cn
38. e window washer system operates normally 10 Wiper 10 Check that the wiper system operates normally Dynamic Test with the Vehicle Running Check point 1 Brake test 1 Check that the foot brake operates normally 2 Parking brake 2 Check that the parking brake operates normally 3 AT shift control 3 Check the AT shift patterns are correct 4 Heater amp ventilation 4 Check that the heater amp ventilation system operates normally 5 Air conditioner 5 Check that the air conditioner operates normally 6 Cruise control 6 Check that the cruise control system operates normally Checks after Dynamic Test Step Check point 1 ATF level 1 Check that the ATF level is normal 2 Power steering fluid level 2 Check that the power steering fluid level is normal 3 Fluid leak check 3 Check for fluid oil leaks 4 Water leak check 4 Spray the vehicle with water and check for water leaks 5 Appearance check 2 5 Remove the protective coating if any 5 6 Check the body paints for damage and smears 7 Check the plated parts for damage and rust PLA PRE DELIVERY INSPECTION 1 APPEARANCE CHECK f the vehicle is covered with protective coating visually check the vehicle body for damage and dents f there is no protective coating check the body paints for small areas of damage or stains and re pair as necessary Check the window glass door glass and lig
39. edan AWD 2 01 WRX 5 4 5 2 Curb weight C W 750 1 653 775 1 709 830 1 830 535 1 179 530 1 168 560 1 235 1 285 2 833 1 305 2 877 1 390 3 064 Maximum permissible axle weight M P A W 920 2 028 920 2 028 960 2 116 910 2 006 910 2 006 920 2 028 Maximum permissible weight M P W Wagon 1 760 3 880 1 760 3 880 1 820 4 012 GX OUTBACK WRX Dual range 4AT Dual range 4AT 5MT 1 Curb weight C W Maximum permissible axle weight M P A W 750 1 653 775 1 709 570 1 257 565 1 246 750 1 653 570 1 257 765 1 687 570 1 257 825 1 819 585 1 290 1 320 2 910 1 340 2 954 920 2 028 920 2 028 1 320 2 910 920 2 028 1 335 2 943 920 2 028 1 410 3 109 970 2 138 960 2 116 960 2 116 960 2 116 960 2 116 950 2 094 Maximum permissible weight M P W 1 Includes weight of air conditioner 1 800 3 968 1 800 3 968 2 Includes weight of air conditioner rear spoiler SPC 9 1 800 3 968 1 800 3 968 1 860 4 100 SPECIFICATIONS IMPREZA 3 OTHERS Sedan FWD 1 6L BASE TS GX 5MT 4AT 5MT 5MT 4AT 1 Curb weight C W 705 1 554 750 1 653 740 1 631 750 1 653 780 1 720
40. en the hood while checking that no abnormal conditions are found Then support the hood with the hood stay A En 0082 910151 11 OF AIR CONDITIONER HARNESS A vehicle just delivered has its air conditioner har ness disconnected to protect the air conditioner compressor Connect the harness as shown in the figure Gl0085 PRE DELIVERY INSPECTION 12 BATTERY Check the battery terminals to make sure that no rust or corrosions due to fluid leaks are found Check that the battery tent is securely tightened Lower level 13 BRAKE FLUID Check the brake fluid amount If the amount is in sufficient carry out a brake line test to identify brake fluid leaks and check the brake operation Af ter that refill the brake fluid tank with the specified type of fluid 14 ENGINE OIL Check the engine oil amount If the amount is insuf ficient check that no leaks are found Then add the necessary amount of the specified engine oil GI0086A level gauge peA Diarra Engine oil filler cap Upper level d About 1 07 1 1 US at 0 9 Imp qt rj Lower level GI0087A 15 TRANSMISSION FLUID Check the transmission fluid amount If the amount is insufficient check that no leaks are found Then add the necessary amount of the specified fluid a Upper level
41. ere is a risk of static electricity Always use a static electricity prevention cord or touch grounded metal before conducting work 3 IGNITION OFF BATTERY When removing the battery cables always be sure to turn the ignition off to prevent electrical damage to the ECM from rush current 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 NT 2 5 LIFTS AND JACKS When using a lift or jack ridged rack 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 Support locations Pantograph jack Lift Safety stand GI0120 NT 3 Front Front cross member Rear Rear differential Glo121 NT 4 6 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 Hook for tie down Hook for towing and tie down GI0122 NT 5
42. ess mm in Front Rear Standard 24 0 94 10 0 39 Wear limit 22 0 87 8 5 0 335 Turbo Model Brake disc thickness mm in Front Rear 24 0 94 18 0 71 22 0 87 16 0 63 Standard Wear limit 4 Measure the disc rotor runout at a point less than 5 mm 0 20 in from the outer periphery of the rotor Disc rotor runout limit Front 0 075 mm 0 0030 in Rear 0 075 mm 0 0030 in NOTE When replacing a pad always replace the pads for both the left and right wheels at the same time Also replace pad clips if they are twisted or worn GI0147 PM 33 BRAKE LININGS AND DRUMS PERIODIC MAINTENANCE SERVICES 23 Brake Linings and Drums A INSPECTION 1 REAR DRUM BRAKE 1 Remove brake drum and check that there is no fluid leakage from wheel cylinder If there is fluid leakage from wheel cylinder replace it 2 Inspect brake shoes for damage or deformities and check brake linings for wear NOTE Always replace both leading and trailing brake shoes for the left and right wheels at the same time When either the left or the right brake assembly is replaced always replace the leading shoe and trailing shoe of the other The cotter pin once removed cannot be reused Thickness of lining except back metal Standard value 4 1 mm 0 161 in Service limit 1 5 mm 0 059 in 10059 1 2 3 Rotational direction of drum Forward Wheel cy
43. g the key check if the door can be locked and unlocked normally 8 Open and close the all doors to see that there are no abnormal condi tions 9 Check the power window for correct operations 6 Operation check of trunk lock release lever 7 Operation check of rear gate lock release lever 10 Operate the trunk lock release lever to check that the trunk opens nor mally 11 Operate the rear gate lock release lever to check that the rear gate is unlocked normally 8 Operation check of fuel lid opener lock release lever 9 Accessory check 12 Operate the fuel lid opener to check that the fuel lid is unlocked normally Check the following accessories are provided Owner s manual Warranty booklet Service booklet Spare key Jack Tool set Spare tire 10 Operation check of hood lock release system 1 Operate the hood lock release lever to check that the hood opens nor mally 11 Connection of air conditioner harness 12 Battery 2 If the vehicle is about to be delivered to the customer connect the air con ditioner harness 3 Check the battery for any abnormal conditions such as rust and trace of battery fluid leaks 13 Brake fluid 4 Check the fluid amount 14 Engine oil 5 Check the oil amount 15 Transmission fluid 16 AT front differential oil 6 Check the fluid amount 7 For AT check the front differential oil 8 Check the AT front
44. he ABS as a total system Do not disas semble or attempt to repair individual parts Doing so could prevent the ABS system from operating when needed or cause it to operate incorrectly and result in injury 2 BRAKE FLUID If brake fluid gets in your eyes or on your skin do the following Wash out your eyes and seek immediate medical attention Wash your skin with soap and then rinse thor oughly with water 3 ELECTRIC FAN The electric fan may rotate without warning even when the engine is not on Do not place your hand cloth tools or other items near the fan at any time 4 ROAD TESTS Always conduct road tests in accordance with traf fic rules and regulations to avoid bodily injury and interrupting traffic 5 AIRBAG To prevent bodily injury from unexpected deploy ment of airbags and unnecessary maintenance fol low the instructions in this manual when performing maintenance on airbag components or nearby and airbag wiring harnesses or nearby To prevent unexpected deployment perform one of the steps below and then wait at least 20 seconds to discharge electricity before beginning work Step 1 Turn the ignition switch OFF Step 2 Remove the negative battery terminal 6 AIRBAG DISPOSAL To prevent bodily injury from unexpected airbag deployment do not dispose airbag modules in the same way as other refuse Follow the special in structions for disposal in this manual Follow all government regu
45. he latest information at the time of publication Changes in specifications methods etc may be made without notice FW 2 HOW TO USE THIS MANUALS 1 How to Use This Manuals mmm rmn HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 1 How to Use This Manuals A HOW TO USE THIS MANUALS 1 STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com ponent The specification maintenance and other information for the components are included and diagnosis information has also been added where necessary 2 INDEX The first page has an index with tabs And at the end of each section is an alphabetical index 3 COMPONENTS For each component a composition drawing is in cluded 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 are provided for each component When multiple components comprise one process refer to the instructions for that pro cess for each component 7 DIAGNOSIS Tables showing a step by step process make it easy to conduct diagnosis 8 SIUNITS Measurements in these manuals are according to the SI units Metric and yard pound measurements are also included HU 2 SPECIFICATIONS SPECIFICATIONS 1 Impreza A DIMENSIONS Model Overall length IMPREZA Sedan Wagon
46. he pedal height should not change PERIODIC MAINTENANCE SERVICES 4 Check valve is built into vacuum hose Discon nect vacuum hose to inspect function of check valve Blow air into vacuum hose from its brake booster side end Air must flow out of engine side end of hose Next blow air into hose from engine side Air should not flow out of hose Replace both check valve and vacuum hose if check valve is faulty Engine side of vacuum hose is indicated by marking ENGINE as shown Engine side Brake booster side den lt ENG GI0053A 5 Check vacuum hose for cracks or other damage NOTE When installing the vacuum hose on the engine and brake booster do not use soapy water or lubri cating oil on their connections 6 Check vacuum hose to make sure it is tight and secure PM 31 BRAKE FLUID PERIODIC MAINTENANCE SERVICES 21 Brake Fluid A REPLACEMENT 1 Either jack up vehicle and place a safety stand under it or lift up vehicle 2 Remove both front and rear wheels 3 Draw out the brake fluid from master cylinder with syringe 4 Refill reservoir tank with recommended brake fluid Recommended brake fluid FMVSS No 116 fresh DOT3 or 4 brake fluid NOTE Avoid mixing different brands of brake fluid to prevent degrading the quality of the fluid Be careful not to allow dirt or dust to get into the reservoir tank Bleeding sequence 1 2 3 4 1 as 3 Fron
47. he undiluted solution only Necessary concentration of coolant 3 2 2 6 2 2 1 1 8 1 1 1 1 8 e 20 30 40 50 Concentration of coolant in the vehicle cooling system 96 Quantity of coolant to be drained 2 US qt Imp at Concentration of coolant in vehicle and quantity to be drained GI0038A PM 21 PERIODIC MAINTENANCE SERVICES IDLE MIXTURE PERIODIC MAINTENANCE SERVICES 14 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 for AT 2 Warm up engine sufficiently until cooling fan starts to operate 3 Measure the idle mixture with the CO meter Engine idle speed 700 100 rpm 1 0 0 5 4 If out of specification adjust the idle mixture us ing CO adjusting screw of mass air flow sensor 5 After adjusting the CO value check and adjust increment coefficient of CO resistor by using Select Monitor 1 Select Current data display amp Save on the select monitor 2 If out of specified data adjust the increment coefficient of CO resistor while rotating CO ad justing screw Specified data 0 28 4 22V 2 ca e usting screw GI0114A NOTE If driving the vehicle on out of specified data the trouble code 49 is indicated in many cas
48. hts for any cracks or damage and repair or replace the parts as necessary Check the plated parts such as the grilles and door knobs for damage or loss of gloss and repair or replace the parts as necessary 2 TIRE CHECK Check the tire outer faces for any damage Checkthe tire air pressure by referring to the fol lowing table Tire size Tire inflation pressure kPa kg cm psi Front Rear 175 70R14 220 2 2 32 220 2 2 32 185 70R14 220 2 2 32 220 2 2 32 195 60R15 220 2 2 32 220 2 2 32 215 45R17 230 2 3 33 220 2 2 32 3 FUSE INSTALLATION A vehicle just delivered has no fuses for the room lamp circuit to prevent battery discharge Attach a 15 A fuse as shown in the figure LI JC GI0084A PRE DELIVERY INSPECTION 4 CHECK THE DOOR OPERATIONS LOCK UNLOCK AND OPEN CLOSE AS FOLLOWS Using the key lock and unlock the door several times to check for normal operation Open and close the door several times for smooth movement e Vehicles with manual door locks Sit in the driver seat close the door completely and move the lock lever to the lock position Then pull the inside door handle to ensure the door will not open Vehicles with power door locks
49. ination 1 When vehicle does not stop Tighten adjusting nut of PHV cable 2 When vehicle does not start properly A When hill holder is released later than en gagement of clutch engine tends to stall Loos en adjusting nut gradually until smooth starting is enabled B When hill holder is released earlier than en gagement to clutch vehicle slips down slightly Tighten adjusting nut so that hill holder is re leased later than engagement of clutch status in A Then make adjustment the same as in A NOTE Whenever turning adjusting nut hold inner cable with pliers to prevent it from turning Replace pressure hold valve PHV return spring of PHV or PHV cable with new one if they are defective and or damaged Adjusting nut po ai Lock nut C Pressure hold valve GIO115A PM 25 PERIODIC MAINTENANCE SERVICES TRANSMISSION OIL PERIODIC MAINTENANCE SERVICES 17 Transmission Oil A REPLACEMENT 1 MANUAL TRANSMISSION 1 Drain gear oil by removing drain plug after allow ing the engine to cool for 3 to 4 hours NOTE Before starting work cool off the engine well GI0041 2 Reinstall drain plug after draining gear oil and tighten it to the specified torque Tightening torque 44 N m 4 5 kgf m 32 5 ft Ib NOTE Be sure to place a gasket between the transmis sion case and drain plug Replace the gasket with a new one Each oil manufacturer has its
50. ined Selector lever gate pattern GO P En tA R 92 OO Gc v D K 6 LHD GI0113A Selector Gear Position Position 2nd 3rd D Yes Yes 3 Yes Yes 2 Yes 1 38 HEATER amp VENTILATION Operate the heater and ventilation system to check for normal airflow and heating capacity 39 AIR CONDITIONER Operate the air conditioner Check that the A C compressor operates normally and enough cooling is provided 40 CRUISE CONTROL Operate the cruise control system Check that the system is activated and deactivated correctly 41 ATF LEVEL Check that the ATF level is normal If insufficient check that no leaks are found Then add the neces sary amount of the specified ATF el Upper level 9 Lower level GI0098A PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION 42 POWER STEERING FLUID LEVEL 45 APPEARANCE CHECK 2 Check that the power steering fluid level is normal Check the vehicle body paints plated faces glass If insufficient check that no leaks are found Then and lenses for any dirt or damage add the necessary amount of the specified power steering fluid 10099 43 FLUID LEAK CHECK Check the entire areas of the vehicle for any trace of coolant oil fluid leaks 44 WATER LEAK TEST Spray the vehicle with water and check that no wa ter enters the passenger compartment Before performing the water leakage test r
51. ir tank up to FULL level Coolant capacity fill up to FULL level 1 6 2 AT model Approx 7 3 0 7 7 US qt 6 4 Imp qt 1 6 0 MT model Approx 7 4 0 7 8 US qt 6 5 Imp qt Non turbo 2 0 0 AT model Approx 6 9 0 7 3 US qt 6 1 Imp qt Non turbo 2 0 0 MT model Approx 7 0 0 7 4 US qt 6 2 Imp qt Turbo model Approx 7 7 0 8 1 US qt 6 8 Imp qt NOTE The SUBARU Genuine Coolant containing anti freeze and anti rust agents is especially made for SUBARU engine which has an aluminum crank case Always use SUBARU Genuine Coolant since other coolant may cause corrosion 9 Securely install radiator cap 10 Run engine for more than five minutes at 2 000 to 3 000 rpm Run engine until radiator becomes hot in order to purge air trapped in cooling system 11 Stop engine and wait until coolant temperature lowers Then open radiator cap to check coolant level and add coolant up to radiator filler neck Next add coolant into reservoir tank up to FULL level 12 After adding coolant securely install radiator and reservoir tank caps 2 RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEM PERATURE The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram Measuring the temperature and specific gravity of the coolant will provide this information Example If the coolant temperature is 25 C 77 F and its specific gravity is 1 054 the concentration
52. is 3596 point A the safe operating temperature is 14 7 F point B and the freezing temperature is 20 C 4 F point C Safe operating temperature Concentration of coolant 55 1 030 Freezing temperature 1 020r 1 010 10 40 30 2010 0 10 20 30 40 50 40 22 C 4 14 32 50 68 86 104 122 Coolant temperature GI0037A PM 20 3 PROCEDURE TO ADJUST THE CON CENTRATION OF THE COOLANT To adjust the concentration of the coolant accord ing to temperature find the proper fluid concentra tion in the above diagram and replace the necessary amount of coolant with an undiluted so lution of SUBARU genuine coolant concentration 50 The amount of coolant that should be replaced can be determined using the diagram Example Assume that the coolant concentration must be in creased from 25 to 40 Find point A where the 2596 line of coolant concentration intersects with the 4096 curve of the necessary coolant concentra tion and read the scale on the vertical axis of the graph at height A The quantity of coolant to be drained is 2 1 liters 2 2 US qt 1 8 Imp qt Drain 2 1 liters 2 2 US qt 1 8 Imp qt of coolant from the cooling system and add 2 1 liters 2 2 US qt 1 8 Imp qt of the undiluted solution of SUBARU cool ant If a coolant concentration of 5096 is needed drain all the coolant and refill with t
53. it value has been main tained for this period PERIODIC MAINTENANCE SERVICES Radiator cap valve open pressure Standard value 93 123 kPa 0 95 1 25 kg cm 14 18 psi Service limit 83 kPa 0 85 kg cm 12 psi GI0034 Deformation damage rust GI0035A 3 If the coolant temperature exceeds 76 0 to 80 0 C 169 to 176 F while radiator is not so hot check thermostat If thermostat does not open at 76 0 to 80 0 C 169 to 176 F replace it with a new one 4 If electric fan does not operate when coolant temperature exceeds 90 to 94 C 194 to 201 F check thermoswitch or fan motor Crack deformation PM 19 PERIODIC MAINTENANCE SERVICES 13 Coolant A REPLACEMENT 1 REPLACEMENT OF COOLANT WARNING The radiator is of the pressurized type Do not attempt to open the radiator cap immediately after the engine has been stopped 1 Lift up the vehicle 2 Remove under cover 3 Place a container under drain pipe 4 Loosen and remove drain screw A to drain en gine coolant into container fl d SE 7 5 For quick draining open radiator cap CAUTION Be careful not to spill coolant on the floor 6 Drain coolant from reservoir tank 7 Tighten radiator drain screw securely after drain ing coolant 8 Slowly pour prepared coolant from radiator filler port to neck of filler then pour into reservo
54. lations concerning disposal of refuse 7 AIRBAG MODULE Adhere to the following when handing and storing the airbag module to prevent bodily injury from un expected deployment Do not hold harnesses or connectors to carry the module Do not face the bag in the direction that it opens towards yourself or other people Do not face the bag in the direction that it opens towards the floor or walls 8 AIRBAG SPECIAL TOOLS To prevent unexpected deployment only use spe cial tools 9 WINDOW Always wear safety glasses when working around any glass to prevent glass fragments from damag ing your eyes 10 WINDOW ADHESIVE Always use the specified urethane adhesive when attaching glass to prevent it from coming loose and falling resulting in accidents and injury PC 2 DE e 1 Note A NOTE This is information that can improve efficiency of maintenance and assure sound work 1 FASTENER NOTICE Fasteners are used to prevent parts from damage and dislocation due to looseness Fasteners must be tightened to the specified torque Do not apply paint lubricant rust retardant or oth er substances to the surface around bolts fasten ers etc Doing so will make it difficult to obtain the correct torque and result in looseness and other problems 2 STATIC ELECTRICITY DAMAGE Do not touch the ECM connectors logic boards and other such parts when th
55. leed air from each wheel cylinder by following the previous 5 steps 11 Depress brake pedal with a force of approxi mately 294 N 30 kgf 66 Ib and hold it there for ap proximately 20 seconds At this time check pedal to see if it makes any unusual movement Visually in spect bleeder screws and brake pipe joints to make sure that there is no fluid leakage 12 Install wheels and drive vehicle for a short dis tance between 2 to 3 km 1 to 2 miles to make sure that brakes are operating properly PM 32 DISC BRAKE PADS AND DISCS 22 Disc Brake Pads and Discs A INSPECTION 1 DISC BRAKE PAD AND DISC 1 Jack up vehicle and support with rigid racks Then remove wheels 2 Visually check pad thickness through inspection hole of disc brake assembly Replace pad if neces sary Non Turbo Model gt nspection hole GIO056A Pad thickness including back metal mm in Front Rear 17 0 67 14 0 55 Standard 7 5 0 295 6 5 0 256 Turbo Model nie in ne I I hole Exi 010146 Pad thickness including back metal mm Front Rear Standard 14 5 0 570 16 0 629 Service limit 6 0 0 236 6 0 0 236 Thickness of pad Lining d Back gt B metal GI0057A PERIODIC MAINTENANCE SERVICES 3 Check the disc rotor and correct or replace if it is damaged or worn Non Turbo Model Brake disc thickn
56. linder Upper shoe return spring Adjusting lever Trailing shoe Lower shoe return spring Leading shoe 6 1 A TA To replace trailing shoe remove cotter pin Clevis pin should also be replaced if worn 3 Check brake drum for wear dents or other dam age If the inside surface of brake drum is streaked cor rect the surface with emery cloth 200 or more If itis unevenly worn tapered or the outside surface of brake drum is damaged correct or replace it Brake drum inner diameter Standard value 228 6 mm 9 000 in Service limit 230 6 mm 9 079 in If deformation or wear of back plate shoe etc is noticeable replace the affected parts Measuring inside diameter GIOO60A 2 PARKING BRAKE REAR DISC BRAKE Inspect brake linings and drums of both sides of the rear brake at the same time by removing brake drums 1 Inspect brake shoes for damage or deformation and check brake linings for wear NOTE Always replace both primary and secondary brake shoes for the left and right wheels at the same time Brake lining thickness excluding back metal Standard value 3 2 mm 0 126 in Wear limit 1 5 mm 0 059 in Brake shoe Brake shoe Primary Secondary GI0061A PM 34 BRAKE LININGS AND DRUMS 2 Check brake drum for wear dents or other dam age If the inside surface of brake drum is streaked correct the surface with emery cloth 200 o
57. nd Applicable Temperature C 30 20 15 0 15 30 40 22 5 32 59 86 10W 30 10W 40 gt lt 5W 30 PREFERRED GI0015A The proper viscosity helps vehicle get good cold and hot starting by reducing viscous friction and thus increasing cranking speed NOTE When replenishing oil it does not matter if the oil to be added is a different brand from that in the en gine however use oil having the API classification and SAE viscosity No designated by SUBARU If vehicle is used in desert areas with very high temperatures or for other heavy duty applications the following viscosity oils may be used API classification SJ or SH SAE Viscosity No 30 40 10W 50 20W 40 20W 50 6 Close engine oil filler cap 7 Start engine and warm it up for a time 8 After engine stops recheck the oil level If necessary add engine oil up to upper level on level gauge gt r Notch mark Upper level About 1 02 1 1 US qt 0 9 Imp at Lower level GI0016A Oil level gauge 21 zA Engine oil filler cap Fo PM 6 ENGINE OIL B INSPECTION 1 Park vehicle on a level surface 2 Remove oil level gauge and wipe it clean 3 Reinsert the level gauge all the way Be sure that the level gauge is correctly inserted and in the proper orientation 4 Remove it again and note the reading If the en gine oil level is below the L line add oil to bring the level up to
58. nd drive for United States Canada and Taiwan 3 Base 4 TS 5 GX 7 OUTBACK 8 WRX 7 R Transmission fuel feed G SOHC MPI 5 speed MT system K SOHC MPI 5 speed MT R SOHC MPI 4 speed AT P DOHC B MPI 4 speed AT J SOHC MPI 5 speed MT AWD D DOHC B MPI 5 speed MT AWD The engine and transmission type are as follows Engine EJ161RX3AA Meaning Details Engine type EJ 4 cylinders Displacement 16 1 6L 20 2 0 L Fuel feed system 1 D MPI SOHC A 5 MPI Turbo Detailed specifications Used when ordering parts See the parts catalog for details Transmission W MT X AT Detailed specifications Used when ordering parts See the parts catalog for details ID 5 IDENTIFICATION IDENTIFICATION e Transmission TV1B4A1AA Meaning Details Transmission T Transmission Transmission type A FWD AT M FWD MT Y Full time AWD MT center differential V Full time AWD AT center differential Z Full time AWD AT MPT Classification 75 MT 1B AT Series MT 4 5MT AT 4 New AT Transmission specifica R FWD MT tions S Part time AWD 5 speed MT Single range D Part time AWD 5 speed MT Dual range A FWD AT V Full time AWD 5 speed MT with viscous coupling center dif ferential single range X Full time AWD 5 speed MT with viscous coupling center dif ferential dual range Z Full time AWD 4 speed AT with MPT Y Full time AWD 4 speed AT with VTD Detailed specifications Used when or
59. on the transmitter mo mentarily once and check if the all doors is un locked the hazard light flashes twice and the dome light illuminates Close all doors and rear gate press the LOCK button of the transmitter Press the OPEN button of the transmitter and wait for 30 seconds Check that all doors and the rear gate are automatically locked again 22 SEAT Check that each seat provides full functionality in sliding and reclining Check all available functions of the rear seat such as a trunk through center arm rest 23 SEAT BELT Pull out the seat belt and then release it Check that the belt webbing retracts smoothly 24 WHEEL ALIGNMENT Check the wheel alignments Ref to FS 8 Wheel Alignment and Ref to RS 10 Wheel Alignment gt 25 READ MEMORY AND TEST MODE CON NECTORS Turn the ignition switch to ON and check that the check engine light starts blinking If the light blinks return the ignition key to LOCK and disconnect the test mode connector Then turn the ignition key to ON again If the check engine light blinks at that time in spite of the disconnected test mode connec tor carry out an engine diagnosis 8 With OBD model connector Green SA N 10119 26 STARTING CONDITION Start the engine and check that the engine starts smoothly If any battery voltage problems are found recharge or replace the battery If any ab normal noises are observed immedi
60. ond these tables apply them repeatedly as a set of 50 000 km 30 000 miles or 48 months Maintenance Interval Number of months or km miles whichever occurs first Months Remarks x 1 000 km x 1 000 miles Engine oil Engine oil filter 2 MAINTENANCE SCHEDULE 1 2 For periodic maintenance of over 100 000 km 60 000 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 100 000 km 60 000 miles or 48 months Maintenance Interval Number of months or km miles whichever occurs first Months 48 Remarks x 1 000 km 100 x 1 000 miles 60 Spark plugs For Turbo R Others R R Drive belt s Camshaft drive belt Valve clearance Use in Europe coun Inspect every 100 000 km 60 000 tries miles Use in others Inspect every 160 000 km 100 000 miles Fuel line Fuel filter Air cleaner element Cooling system Coolant Idle mixture For models without catalyst con verter Clutch system Hill holder system Transmission oil ATF Front amp rear differen tial oil Brake line Brake fluid Disc brake pads amp discs Brake linings and drums Parking brake SCHEDULE PERIODIC MAINTENANCE SERVICES Maintenance Interval Number of months or km miles whichever occurs first Months Rema
61. onnect spark plug cord 4 Remove spark plug with a plug wrench GI0018A 5 Set new spark plug Recommended spark plug SOHC CHAMPION RC10YC4 CHAMPION 8 4 BKR6E 11 NIPPONDENSO K20PR U11 Spark plug gap 1 0 1 1 mm 0 039 0 043 in SOHC Without OBD NGK BKR6E Without catalytic converter CHAMPION RC10YC4 With catalytic con verter NGK BKRS5E 11 With catalytic converter Spark plug gap 0 7 0 8 mm 0 028 0 031 in Without catalytic converter 1 0 1 1 mm 0 039 0 043 in With cat alytic converter DOHC Turbo NGK PFR6B Spark plug gap 0 7 0 8 mm 0 028 0 031 in 6 Tighten spark plug lightly with hand and then se cure with a plug wrench to the specified torque Tightening torque 20 6 N m 2 10 kgf m 15 19 ft Ib NOTE sure to place the gasket between the cylinder head and spark plug f torque wrench is not available tighten spark plug until gasket contacts cylinder head then tight en further 1 4 to 1 2 turns PM 9 PERIODIC MAINTENANCE SERVICES DRIVE BELT S PERIODIC MAINTENANCE SERVICES 6 Drive Belt s A INSPECTION 1 Replace belts if cracks fraying or wear is found 2 Check drive belt tension and adjust it if neces sary by changing generator installing position and or idler pulley installing position Belt tension A replaced 7 9 mm 0 276 0 354 in reused 9 0 10 0 mm 0 354 0 394 in B replaced
62. orque Converter Clutch SPC 3 IMPREZA SPECIFICATIONS AWD Model Non Turbo 2 0 L Turbo 2 0 L Transmission type 5MTx1 4 2 5 1 Clutch type DSPD TCC DSPD Gear ratio 1st 3 454 2 785 3 454 2nd 2 062 1 545 1 947 1 448 1 000 1 336 4th 1 088 0 694 0 972 0 825 0 738 Reverse 3 333 2 272 3 333 Dual range 1 447 1 447 Reduction gear 1st reduction Type of gear Helical Front drive Gear ratio 1 000 Final reduction Type of gear Hypoid Hypoid Gear ratio 4 111 3 900 3 900 Reduction gear Transfer reduction Type of gear Helical Helical Helical Rear drive Gear ratio 1 000 1 000 1 Final reduction Type of gear Hypoid Hypoid Gear ratio 4 111 3 545 5MT 1 5 forward speeds with synchromesh and 1 reverse 4AT x2 Electronically controlled fully automatic 4 forward speeds and 1 reverse DSPD Dry Single Plate Diaphragm TCC Torque Converter Clutch E STEERING WAX OUTBACK OTHERS Type Rack and Pinion Turns lock to lock 1 6 1 5 1 6 Minimum turning circle m ft Curb to curb Wall to wall F SUSPENSION Macpherson strut type Independent Coil spring Dual link type Independent Coil spring G BRAKE Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Drum brake Disc brake Parking brake Mechanical on rear brakes H TIRE Rim size 14 x 51 2JJ 15
63. ower steering system hoses piping and their couplings for fluid leaks If fluid leaks are found correct them by retightening their fitting bolts or nuts and or replacing their parts NOTE Wipe the leakage fluid off after correcting fluid leaks or a wrong diagnosis is taken later Also pay attention to clearances between hoses or pipings and other parts when inspecting fluid leaks PM 41 STEERING SYSTEM POWER STEERING PERIODIC MAINTENANCE SERVICES 7 HOSES OF OIL PUMP FOR DAMAGES Check pressure hose and return hose of oil pump for crack swell or damage Replace hose with new one if necessary NOTE Prevent hoses from revolving and or turning when installing hoses GI0017 8 POWER STEERING PIPES FOR DAM AGE Check power steering pipes for corrosion and dam age Replace pipes with new one if necessary 9 GEARBOX BOOTS Inspect both sides of gearbox boots as follows and correct the defects if necessary 1 A and B positions of gearbox boot are fitted correspondingly in A and B grooves of gearbox and the rod 2 Clips are fitted outside of A and B positions of boot 3 Boot does not have crack and hole NOTE Rotate B position of gearbox boot against twist of it produced by adjustment of toe in etc Apply grease B GI0023A 10 FITTING BOLTS AND NUTS Inspect fitting bolts and nuts of oil pump and brack et for looseness and
64. procedures of the ATF filter Ref to AT 43 ATF Filter PM 27 PERIODIC MAINTENANCE SERVICES FRONT amp REAR DIFFERENTIAL OIL PERIODIC MAINTENANCE SERVICES 19 Front amp Rear Differential Oil A REPLACEMENT 1 FRONT DIFFERENTIAL MANUAL TRANSMISSION For M T vehicle manual transmission oil works as differential oil to lubricate differential Refer to Transmission Oil Ref to PM 26 Transmission Oil 2 FRONT DIFFERENTIAL AUTOMATIC TRANSMISSION 1 Drain differential gear oil by removing drain plug after allowing the engine to cool for 3 to 4 hours NOTE Before starting work cool off the engine well 610045 2 Reinstall drain plug after draining differential gear oil and tighten it to the specified torque Tightening torque 44 N m 4 5 kgf m 32 5 ft Ib NOTE Be sure to place a gasket between the transmis sion case and drain plug Replace the gasket with a new one Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands 3 Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge Differential gear oil capacity 1 1 1 3 0 1 2 1 4 US qt 1 0 1 1 Imp qt Cil level gauge Upper level CU Lower level GI0046A 3 REAR DIFFERENTIAL 1 Drain oil by removing drain plug 2 Remove filler plug for quick draining oil 3 Reinstall drain plug after draining oil
65. r Steering A INSPECTION 1 STEERING WHEEL 1 Set steering wheel in a straight ahead position and check wheel spokes to make sure they are cor rectly set in their specified positions 2 Lightly turn steering wheel to the left and right to determine the point where front wheels start to move Measure the distance of the movement of steering wheel at the outer periphery of wheel Steering wheel free play 0 17 mm 0 0 67 in 10074 Move steering wheel vertically toward the shaft to ascertain if there is play in the direction Maximum permissible play 0 5 mm 0 020 in 3 Drive vehicle and check the following items dur ing operation 1 Steering force The effort required for steering should be smooth and even at all points and should not vary 2 Pull to one side Steering wheel should not be pulled to either side while driving on a level surface 3 Wheel runout Steering wheel should not show any sign of runout 4 Return factor Steering wheel should return to its original posi tion after it has been turned and then released Maximum permissible play 0 5 mm 0 020 in 2 STEERING SHAFT JOINT 1 When steering wheel free play is excessive dis connect universal joint of steering shaft and check it for any play and yawing torque at the point of the crossing direction Also inspect for any damage to sealing or worn ser
66. r more If itis unevenly worn tapered or the outside surface of brake drum is damaged correct or re place it Brake drum inside diameter Standard value 170 mm 6 69 in Wear limit 171 mm 6 73 in n Disc brake Measuring inside diameter GI0062A 3 If the deformation or wear of back plate shoe etc is noticeable replace them 4 When the shoe return spring tension is exces sively weakened replace it taking care to identify upper and lower springs PERIODIC MAINTENANCE SERVICES ADJUSTMENT 1 REAR DRUM BRAKE The main brake is adjusted automatically and so there is no need to adjust it 2 PARKING BRAKE REAR DISC BRAKE For rear disc brake adjust parking brake after bleeding the air 1 Remove rear cover rubber installed at back plate 2 Turn adjuster toward arrow mark upward until it is locked slightly by using slot type screwdriver as shown in illustration Adjuster Cover rubber Slot type screwdriver GI0063A 3 Turn back downward adjuster 3 to 4 notches 4 Install cover rubber at original position correct ly PM 35 SUSPENSION PERIODIC MAINTENANCE SERVICES 24 Suspension A INSPECTION 1 SUSPENSION BALL JOINT 1 Jack up vehicle until front wheels are off ground 2 Next grasp bottom of tire and move it in and out If relative movement is observed bet
67. r or replace them Ref to FU SOHC 64 Fuel Delivery Return and Evap oration Lines or Ref to FU SOHCw oOBD 60 Fuel Delivery Return and Evaporation Lines or Ref to FU DOHC TURBO 64 Fuel Delivery Re turn and Evaporation Lines PM 16 FUEL FILTER 10 Fuel Filter A REPLACEMENT For fuel filter replacement procedures refer to FU section Ref to FU SOHC 61 Fuel Filter or Ref to FU SOHCw oOBD 57 Fuel Filter or Ref to FU DOHC TURBO 61 Fuel Filter PM 17 PERIODIC MAINTENANCE SERVICES AIR CLEANER ELEMENT PERIODIC MAINTENANCE SERVICES 11 Air Cleaner Element A REPLACEMENT NOTE Do not attempt to clean the air cleaner element The filter paper of the element is wetted with a spe cial non inflammable slow evaporating viscous liq uid It is resistant to cold weather and has a long service life Dirt adhering to this filter paper forms porous laminations with the viscous liquid which function as a filtration layer to reduce dust penetra tion into the filter paper If this filter paper is cleaned the filtration layer thus formed will be lost along with the viscous liquid 1 NON TURBO MODEL 1 Remove bolt A which install air cleaner case to stays 2 Remove the clip B above the air cleaner case 3 Remove air cleaner 4 Install in the reverse order of removal CAUTION Fasten with a clip after inser
68. rations If the joint is loose re tighten the mounting bolts to the specified torque Tightening torque 24 N m 2 4 kgf m 17 4 ft Ib GI0075A 3 GEARBOX 1 With wheels placed on a level surface turn steering wheel 90 in both the left and right direc tions While wheel is being rotated reach under vehicle and check for looseness in gearbox Tightening torque 59 N m 6 0 kgf m 43 4 ft lb E 9 OU XN M te eco GH 7 D scd L Deme eres mounting bolts Rep La GI0076A 2 Check boot for damage cracks or deterioration 3 With vehicle on a level surface quickly turn steering wheel to the left and right While steering wheel is being rotated check the gear backlash If any unusual noise is noticed ad just the gear backlash in the following manner 1 Tighten adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft Ib and then loosen Repeat this op eration twice 2 Retighten adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft Ib and back off 25 PM 40 STEERING SYSTEM POWER STEERING 3 Apply liquid packing to at least 1 3 of entire perimeter of adjusting screw thread M EI Apply liquid packing NS to at least 1 3 of entire perimeter 1 E GI0077A 4 Install lock nut While holding adjusting screw with a wrench tighten lock nut using ST ST 926230000 SPANNER Tightening torque Lock nut 39110 4 01 0 kgf m 29 7 ft lb
69. retighten them if necessary Inspect and or retighten them when engine is cold PM 42 SUPPLEMENTAL RESTRAINT SYSTEM PERIODIC MAINTENANCE SERVICES 28 Supplemental Restraint System A INSPECTION Check the airbag system in accordance with the result of the self diagnosis Ref to AB 2 Basic Diagnostic Procedure 1 Ensure that airbag connectors are connected If not properly connect also double lock the connector When the ignition switch is turned ON with the connector s disconnected the airbag warning light blinks to identify the fault FUEL DOORD 25 Cea pw TEMP GI0136 2 Turn the ignition switch ON and connect the airbag diagnosis terminal of the service connector located below lower cover to the ground terminal 3 The warning light blinks to indicate a trouble code a fault is identified When the airbag system is in good order no trouble codes are stored in the memory the warning light blinks on and off at 0 6 second intervals as long as the diagnosis terminal is connected to the ground terminal 4 When the warning light indicates a trouble code check the airbag system in accordance with the trouble shooting procedure Ref to AB 2 Basic Diagnostic Procedure PM 43 SUPPLEMENTAL RESTRAINT SYSTEM PERIODIC MAINTENANCE SERVICES PM 44
70. rks x 1 000 km x 1 000 miles Suspension Wheel bearing Axle boots amp joints Steering system Power steering Symbols used R Replace I Inspection R or I Recommended service for safe vehicle operation NOTE 1 Periodic inspection and replacement of the camshaft drive chains on the 3 0 liter models are not required 2 When the vehicle is used in extremely dusty conditions the air cleaner element should be replaced more often 3 ATF filter is maintenance free part ATF filter needs replacement when it has physically damaged or ATF leaked PM 4 SCHEDULE PERIODIC MAINTENANCE SERVICES B MAINTENANCE SCHEDULE 2 Repeat short distance drive Repeat rough muddy road drive Extremely cold weather area Salt or other corrosive used or coastal area High humid ity or moun tain area Repeat tow ing trailer Engine oil Replace more fre quently Replace more fre quently Replace more fre quently Engine oil filter Fuel line Transmission oil 6 months 12 500 km 7 500 miles Replace more fre quently Replace more fre quently Replace more fre quently Replace more fre quently Replace more fre quently Front amp rear dif ferential oil Replace more fre quently Brake line 6 months 12 500 km 7 500 miles Brake fluid Brake pads Brake linings and drums 12 months 25 000 km 15 00
71. t right Rear left Front left Rear right Secondary Primary 4 GS 2 Gioos4a 5 Install one end of a vinyl tube onto the air bleeder and insert the other end of the tube into a container to collect the brake fluid 610055 Cover bleeder with waste cloth when loosening it to prevent brake fluid from being splashed over surrounding parts During bleeding operation keep the brake re serve tank filled with brake fluid to eliminate entry of air Brake pedal operation must be very slow For convenience and safety it is advisable to have two men working The amount of brake fluid required is approxi mately 500 m 0 16 9 US fl oz 17 6 Imp fl oz for to tal brake system 6 Instruct your co worker to depress the brake pedal slowly two or three times and then hold it de pressed 7 Loosen bleeder screw approximately 1 4 turn until a small amount of brake fluid drains into con tainer and then quickly tighten screw 8 Repeat steps 6 and 7 above until there are no air bubbles in drained brake fluid and new fluid flows through vinyl tube NOTE Add brake fluid as necessary while performing the air bleed operation in order to prevent the tank from running short of brake fluid 9 After completing the bleeding operation hold brake pedal depressed and tighten screw and in stall bleeder cap Tightening torque 8 0 8 kgf m 5 8 ft Ib 10 B
72. the F line 5 After turning off the engine wait a few minutes for the oil to drain back into the oil pan before checking the level 6 Just after driving or while the engine is warm en gine oil level may show in the range between the line and the notch mark This is caused by ther mal expansion of the engine oil 7 To prevent overfilling the engine oil do not add oil above the F line when the engine is cold PM 7 PERIODIC MAINTENANCE SERVICES ENGINE OIL FILTER PERIODIC MAINTENANCE SERVICES 4 Engine Oil Filter A REPLACEMENT 1 Remove oil filter with ST ST 498547000 OIL FILTER WRENCH CO IR ea Oil filter Drain plug GI0012A 2 Get a new filter and apply a thin coat of engine oil to the seal rubber 3 Install oil filter by turning it by hand being careful not to damage seal rubber 4 Tighten more approximately 2 3 to 3 4 turn af ter the seal rubber contacts the oil pump case Do not tighten excessively or oil may leak 5 After installing oil filter run engine and make sure that no oil is leaking around seal rubber NOTE The filter element and filter case are permanently joined therefore interior cleaning is not necessary 6 Check the engine oil level Ref to 3 PDI PROCEDURE Pre delivery Inspection PM 8 SPARK PLUGS 5 Spark Plugs A REPLACEMENT 1 Remove intake duct and intake chamber 2 Remove washer tank and put it aside 3 Disc
73. ting the lower tab of the case 2 TURBO MODEL pm 2 Remove air cleaner 3 Install in the reverse order of removal CAUTION Before installing air cleaner upper cover align holes with protruding portion of air cleaner low er case then secure upper cover to lower case 0906 18 COOLING SYSTEM 12 Cooling System A INSPECTION 1 Check radiator for leakage filling it with coolant and attach radiator cap tester to the filler neck Then apply a pressure of 157 kPa 1 6 kg cm 23 psi and check the following points Each portion of radiator for leakage Hose joints and other connections for leakage NOTE When attaching or detaching tester and when operating tester use special care not to deform ra diator filler neck Non TURBO model Cap tester When performing this check be sure to keep the engine stationary and fill radiator with coolant Wipe off check points before applying pressure Use care not to spill coolant when detaching tester from radiator 2 Check the radiator cap valve open pressure us ing radiator cap tester NOTE Rust or dirt on cap may prevent valve from func tioning normally be sure to clean cap before test ing Raise the pressure until the needle of gauge stops and see if the pressure can be retained for five to six seconds The radiator cap is normal if a pres sure above the service lim
74. udi Arabia plate Saudi Arabia model Model number plate Built date plate Australia model 10154 Transmission serial number 2 GI0007A GI0008A Transmission serial number 10009 ID 2 IDENTIFICATION IDENTIFICATION VA type J as Ss H D D Label NG N T type Stamp location D MT GI0010A FUJI HEAVY INDUSTRIES LTD E SS 20 011 BAAL 2 262 zoze E LO meon engine ype 2 2 52 RGIAJA A OS TS lexan 2 GI0011A ID 3 IDENTIFICATION IDENTIFICATION 2 MEANING OF The meaning of the VIN is as follows Europe Australia and General Except GCC JF1GD5LJ31G002001 The starting and ending brackets are stop marks Meaning Manufacturer body area Details JF1 Passenger car FHI made Car line Body type IMPREZA D 4 Door Sedan G Wagon Displacement 4 1 6 L FWD 5 1 6 AWD 9 2 0 L AWD A 2 0 L AWD Turbo Steering position Engine amp transmission K RHD Right hand drive L LHD Left hand drive G SOHC MPI 5 speed MT R SOHC MPI 4 speed AT J SOHC MPI Full time AWD 5 speed MT SOHC Full time AWD 5 speed MT Dual range D DOHC Turbo Full time AWD 5 speed MT 3
75. ween brake disc cover and end of transverse link ball joint may be excessively worn 3 Next grasp end of transverse link and move it up and down Relative movement between housing and transverse link boss indicates ball joint may be excessively worn 4 If relative movement is observed in the immedi ately preceding two steps remove and inspect ball joint If free play exceeds standard replace ball joint Ref to FS 18 Front Ball Joint Transverse link Ball joint Housing Transverse link Ball joint GIO065A 5 Damage of dust seal Visually inspect ball joint dust seal If it is damaged remove transverse link lt Ref to FS 16 Front Transverse Link gt And measure free play of ball joint lt Ref to FS 18 Front Ball Joint gt 1 When looseness exceeds standard value replace ball joint 2 If the dust seal is damaged replace with the new ball joint NOTE When transverse link ball joint has been removed or replaced check toe in of front wheel If front GI0066A wheel toe in is not at specified value adjust toe in Ref to FS 8 Wheel Alignment 2 TRANSVERSE LINK S REAR BUSHING Check oil leaks at around liquid filled bushing If oil leaks replace bushing A n GI0067A 3 WHEEL ARCH HEIGHT 1 Unload cargoes and set vehicle in curb weight empty condition 2 Then check wheel arch height of front and rear suspensions to ensure

2001 IMPREZA SERVICE MANUAL QUICK

Contents

Download Pdf Manuals

Related Search

Related Contents