2001 impreza service manual quick reference index body section
Contents
1. Do not damage piston rods and oil seals Never disassemble cylinders They contain gas EB 18 2 Loosen bolts to remove gas stay from rear gate REAR GATE PANEL ST 5 BO0156 B INSTALLATION 1 REAR GATE PANEL 1 Install in the reverse order of removal 2 Install rear gate panel with uniform clearance to body CAUTION Do not damage painted surfaces of body and rear gate 2 GAS STAY Install in the reverse order of removal CAUTION EXTERIOR BODY PANELS 1 Cover with a vinyl case as shown in the figure Gas stay Sce Y Vinyl sack 0264 CAUTION Prevent the vinyl case from being caught by drill cutting edge 2 Lift body side slightly with piston rods fully tended and secure body side on vise stand Drill a hole in 2 to 3 mm 0 08 to 0 12 in diameter at a point 10 to 200 mm 0 39 to 7 87 in from door side and bleed gas stay completely Body side Door side 190mm 10mm 7 48 in 0 39 in Portion to be drilled Piston rod Cylinder BO0263 After supporting rear gate with a jack start eration C DISPOSAL 1 GAS STAY CAUTION Gas is colorless odorless and harmless How ever gas pressure may spray cutting powder or oil Be sure to wear dust resistant goggles EB 19 REAR GATE PANEL EXTERIOR BODY PANELS EB 202. ing surface of torsion bar EB 17 REAR GATE PANEL EXTERIOR BODY PANELS 9 Rear Gate Panel A REMOVAL 1 REAR GATE PANEL 1 Open rear gate 2 Remove rear gate outer handle lt Ref to SL 36 REMOVAL Rear Gate Outer Handle gt 3 Remove rear gate latch assembly lt Ref to SL 37 REMOVAL Rear Gate Latch Assembly gt 4 Remove rear gate key lock cylinders Ref to SL 43 REAR GATE REPLACEMENT Key Lock Cylinders gt 5 Remove rear wiper lt Ref to WW 21 REMOV AL Rear Wiper Motor gt 6 Disconnect connectors of rear wiper rear defog ger and other lighting devices 7 Disconnect washer hose 8 Remove rubber duct A connection and pull out harness and washer hose from rear gate FR B5M0733A 9 Using a support support the rear gate while re moving gas stay mounting bolts CAUTION When the rear gate is released it may hit and damage the body To prevent this place a shop cloth between body and gate 10 Loosen rear gate bolts to remove rear gate s f zt E Zi iR 2 GAS STAY 1 Open rear gate Using a support jack to support the rear gate CAUTION After gas stay is removed rear gate cannot stay open Supporting the rear gate with a jack remove the bolts
3. easily break the cover If cover gets broken replace it with a new one G5M0391 B INSTALLATION 1 Install in the reverse order of removal 2 When replacing sealing cover use CEMEDINE 5430L sealer 3 Press sealer applied area firmly to prevent any floating on surface Sealer CEMEDINE 54301 equivalent CAUTION Apply a uniform bead of sealer Attach sealing cover keeping it from becom ing wrinkled Breaks in the bead will allow water leakage and contamination C INSPECTION If sealing cover is damaged replace it with a new one EB 13 EXTERIOR BODY PANELS REAR DOOR PANEL EXTERIOR BODY PANELS 6 Rear Door Panel A REMOVAL CAUTION During removal and installation of doors do not damage body Doors are heavy Be careful not to drop and damage them 1 Disconnect ground cable from battery 2 Remove rear door trim lt Ref to El 21 REMOV AL Rear Door Trim gt 3 Remove rear door regulator and motor assem bly lt Ref to GW 34 REMOVAL Rear Regulator and Motor Assembly gt 4 Remove rear door latch lt Ref to SL 34 RE MOVAL Rear Door Latch Assembly gt 5 Remove rear outer handle lt Ref to SL 33 RE MOVAL Rear Outer Handle gt 6 Remove center pillar lower trim lt Ref to El 29 REMOVAL Lower Inner Trim gt 7 Disconnect connector of door harness Ae NY NT DA onse 8 Put a wooden block on the jack and place the jack u
4. 10 Remove door side bolts for upper and lower hinges to remove door G5M0385 11 Using special tool remove body side bolts for upper and lower hinges and remove door hinges ST 925610000 DOOR HINGE WRENCH B5M0933A CAUTION During removal and installation of doors do not damage body Doors are heavy Be careful not to drop and damage them B INSTALLATION 1 Install in the reverse order of removal 2 Apply grease to sliding area of door hinges EB 11 FRONT DOOR PANEL EXTERIOR BODY PANELS C ADJUSTMENT 1 Using special tool loosen body side bolts of up per and lower hinges to align the position of front door panel longitudinally vertically ST 925610000 DOOR HINGE WRENCH 2 Loosen door side bolts of upper and lower hing es to align the position of front door panel vertically and laterally at the front end G5M0385 3 Loosen screw A and tap striker B using plas tic hammer to adjust striker CAUTION Do not use impact wrench Welding area on striker nut plate is easily broken 12 FRONT SEALING 5 Front Sealing Cover A REMOVAL 1 Remove front door trim lt Ref to 20 REMOV AL Front Door Trim gt 2 Remove front speaker lt Ref to ET 10 REMOV AL Front Speaker gt 3 Using a spatula remove sealer CAUTION Carefully remove sealer Excessive force will
5. EXTERIOR BODY PANELS 3 Fender Panel A REMOVAL 1 Disconnect ground cable from battery 2 Remove side sill spoilers Ref to El 19 Side Sill Spoiler If fitted 3 Remove front bumper face Ref to 8 RE MOVAL Front Bumper 4 Remove mud guard Ref to El 16 REMOVAL Mud Guard 5 Loosen bolts to remove front fender Se 153 INSTALLATION 1 Install in the reverse order of removal 2 When fender panel is installed clearance be tween fender panel and hood or front fender must be equal EB 10 FRONT DOOR PANEL 4 Front Door Panel A REMOVAL 1 Disconnect ground cable from battery 2 Remove front door trim lt Ref to El 20 REMOV AL Front Door Trim gt 3 Remove outer mirror assembly lt Ref to GW 46 REMOVAL Outer Mirror Assembly gt 4 Remove front door regulator and motor lt Ref to GW 31 REMOVAL Front Regulator and Motor As sembly gt 5 Remove front door latch assembly lt Ref to SL 30 REMOVAL Front Door Latch Assembly gt 6 Remove front outer handle lt Ref to SL 29 RE MOVAL Front Outer Handle gt 7 Remove front pillar lower trim to disconnect con nector from body harness B5M0726 8 Put wooden block on jack and place jack under door Support door with a support jack to protect it from damage BO0261 9 Remove checker bolts E ssp EXTERIOR BODY PANELS
6. kg m ft Ib 2 Seal Front hood 6 T 7 35 0 75 5 4 3 7 Locking piece T1 24 5 2 5 18 1 4 Hood grille EB 3 GENERAL DESCRIPTION EXTERIOR BODY PANELS 2 FRONT DOOR PANEL BO0249 1 Gusset 7 Sealing cover Tightening torque kg m ft Ib 2 Weatherstrip Outer 8 Checker T1 7 35 0 75 5 4 3 Clip Weatherstrip outer 9 Lower hinge T2 18 1 8 13 4 Stabilizer Lifter 10 Upper hinge T3 30 3 1 2 2 5 Stabilizer Outer 11 Door panel 6 Stabilizer Inner EB 4 GENERAL DESCRIPTION EXTERIOR BODY PANELS REAR DOOR PANEL T3 BO0250 1 Weatherstrip Outer 7 Sealing cover Tightening torque N m kg m ft lb 2 Clip Weatherstrip outer 8 Checker T1 7 35 0 75 5 4 3 Stabilizer Outer 9 Lower hinge 2 18 1 8 13 4 Stabilizer Inner 10 Upper hinge T3 30 3 1 2 2 5 Door panel 6 Bracket EB 5 EXTERIOR BODY PANELS 4 TRUNK LID PANEL GENERAL DESCRIPTION 4 N BO0251 1 Torsion bar 2 Trunk lid 3 Weatherstrip 4 Hinge ASSY 5 Cover EB 6 2 7 5 0 76 5 5 14 1 8 13 Tightening torque kg m ft Ib DESCRIPTION EXTERIOR BODY PANELS 5 REAR GATE PANEL BO0252 1 Gas stay Tightening torque kg m ft Ib 2 25 2 5 18 1 3 Rear
7. 2001 IMPREZA SERVICE MANUAL REFERENCE INDEX BODY SECTION HVAC SYSTEM HEATER VENTILATOR AND A C HVAC SYSTEM AUTO A C DIAGNOSTICS AIRBAG SYSTEM AIRBAG SYSTEM DIAGNOSTICS 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 LIGHTING SYSTEM This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of WIPER AND WASHER SYSTEMS components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual ENTERTAINMENT fully to ensure complete repair work for satisfying our customers by keeping their vehicle optimum condition COMMUNICATION SYSTEM When replacement of parts during repair work is needed be sure to use SUBARU genuine parts GLASS WINDOWS MIRRORS GW SEAT BELT SYSTEM BODY STRUCTURE BS INSTRUMENTATION DRIVER INFO IDI SEATS SE SECURITY AND LOCKS SL IMMOBILIZER DIAGNOSTICS IM SUNROOF T TOP CONVERTIBLE TOP cp SUNROOF All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval EXTERIOR INTERIOR TRIM El FUJI HEAVY INDUSTRIES LTD G1830GE6 Kana I s FF e F 2001 IMPREZA SERVICE MANUAL REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CC CRUI
8. SE CONTROL SYSTEM CC DIAGNOSTICS G1830GE6 edi BODY PANELS Page 1 General Description ied te ett toes er EE Remb GANA ad 2 2 EIODLUHOOQ ERE 9 3 Fender GN a aa Qu 10 4 Front Door Panel ir Rete eter ence re eer eed eee eed 11 5 Front Sealing Cover aan a tena RD TM IE 13 mear boor Panel ic Luise iei 14 7 Rear Sealing Cover Ud bett 16 8 zc REM 17 92 Rear Gale eor steht eite feet 18 DESCRIPTION EXTERIOR BODY PANELS 1 General Description A SPECIFICATIONS Front hood Front fender N Front fender Front door SECTION A SECTION B Front door EN Rear door SECTION C Door panel Rear door AL Side sill Rear quarter SECTION D SECTION E F BO0260 Section Part Specification NA 4 0 1 0 0 16 0 04 in Front Nood to Front fender TURBO 3 7 1 0 0 15 0 04 in Front fender to Front door 4 7 1 0 0 19 0 04 in Front door to Rear door 5 1 0 20 in Rear door to Rear quarter 4 6 0 18 in Door panel to Side sill 5 9 0 23 in EB 2 GENERAL DESCRIPTION EXTERIOR BODY PANELS B COMPONENT 1 FRONT HOOD BO0248 1 Front hood 5 Packing Tightening torque
9. gate C CAUTION Exterior body panels are heavy Do not drop and damage the panels During removal and installa tion do not damage the panel painting surface While removing mounting bolts using assistance devices such as a support jack will help support the panel Be careful not to lose small parts EB 7 DESCRIPTION EXTERIOR BODY PANELS D PREPARATION TOOL 1 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 925610000 WRENCH Used for removing and installing door hing B5M1117 927780000 REMOVER Used for removing and installing trunk torsion bar B5M1118 2 GENERAL TOOL TOOL NAME REMARKS Support Jack Used for supporting door panel EB 8 FRONT HOOD EXTERIOR BODY PANELS 2 Front Hood 3 Rotate hood buffer to adjust lateral height A REMOVAL 1 Open front hood to remove washer nozzles 2 Release clips to remove hood insulator Ip S 5 0750 B5M1090 3 Remove bolts to disconnect hood from hinges B5M0747 B INSTALLATION 1 Install in the reverse order of removal 2 Adjust clearance between hood and fender Clearance must be equal at both sides C ADJUSTMENT 1 Use hinge mounting holes to align front hood longitudinally and laterally B5M0747 2 Adjust height at front end of hood Ref to SL 40 ADJUSTMENT Front Hood Lock Assembly EB 9 FENDER PANEL
10. nder the door Support the door with the jack to protect it re BO0261 9 Remove checker bolts E AN 10 Remove door side bolts for upper and lower hinges to remove door G5M0385 11 Using special tool remove body side bolts for upper lower hinges and remove door hinges B INSTALLATION 1 Install in the reverse order of removal 2 Apply grease to sliding area of door hinges EB 14 REAR DOOR PANEL C ADJUSTMENT 1 Using special tool loosen body side bolts of up per and lower hinges to align the position of rear door pana ng Unay and vertically 2 Loosen door side bolts of upper and lower hing es to align the position of rear door panel vertically and laterally at front end G5M0385 3 Loosen screw A and tap striker B using plas tic hammer to adjust striker CAUTION Do not use an impact wrench The welding area on the striker nut plate is easily broken WP EB 15 EXTERIOR BODY PANELS REAR SEALING COVER EXTERIOR BODY PANELS 7 Rear Sealing Cover A REMOVAL 1 Remove rear door trim Ref to El 21 REMOV AL Rear Door Trim 2 Remove rear speaker lt Ref to ET 12 REMOV AL Rear Speaker 3 Using a spatula remove sealer CAUTION Carefully remove sealer Excessive force will easily break the cover If cover gets broken replace i
11. t with a new one G5M0391 B INSTALLATION 1 Install in the reverse order of removal 2 When replacing sealing cover use CEMEDINE 5430L sealer 3 Press sealer applied area firmly to prevent any floating on surface Sealer CEMEDINE 54301 equivalent CAUTION Apply an uniform bead of sealer Attach sealing cover keeping it from becom ing wrinkled Breaks in the bead will allow water leakage and contamination C INSPECTION If sealing cover gets damaged replace it with a new one EB 16 TRUNK LID PANEL 8 Trunk Lid Panel A REMOVAL 1 TRUNK LID 1 Open trunk lid 2 Disconnect trunk lid connector 3 Loosen trunk lid mounting bolts to remove trunk lid from hinges G5M0144 2 TORSION BAR 1 Open trunk lid 2 Using special tool remove torsion bar from hinge link ST 927780000 CAUTION During removal and installation carefully han dle torsion bar It will generate reactive force US REMOVER y NG pa 3 Remove right left torsion bars CAUTION After the torsion bar is removed the trunk lid will slam shut Be careful not to get hit by the trunk lid EXTERIOR BODY PANELS B INSTALLATION 1 TRUNK LID 1 Install in the reverse order of removal 2 Install trunk lid with uniform clearance 2 TORSION BAR 1 Install in the reverse order of removal 2 Apply grease to rotating area of hinges and mat
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