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Subaru 2004 Automobile User Manual

1. Selective part Replacement part 21 sB Sealing point 4 Should be lubricated with oil Should be lubricated with grease Ti T2 Tightening torque HU 00017 HU 3 How to Use This Manual HOW TO USE THIS MANUAL 4 SPECIFICATIONS If necessary specifications are also included 5 INSPECTION Inspections are included to be carried out before and after maintenance 6 MAINTENANCE Maintenance instructions for serviceable parts describes work area and detailed steps with illustration It also describes the use of special tool tightening torque cautions for each procedure f many serviceable parts are included in one service procedure appropriate reference are provided for each part Example 15 Main Shaft Assembly for Sin gle Range A REMOVAL B 1 Remove the manual transmission assembly from vehicie Ref to MT 33 REMOVAL Manual Transmission Assembly 11 Tighten the lock nuts to the specified torque us ing ST1 and ST2 NOTE D Secure the lock nuts in two Places affer tightening ST2 499987003 SOCKET WRENCH ST1 498937000 iB TRANSMISSION HOLDER T Tightening torque 118 N m 12 0 kgf m 86 8 ft lb G m H HU 00002 A
2. 4 FLUID RM 00004 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 Clutch fluid 5 COOLANT FMVSS No 116 DOT3 Use genuine coolant to protect the engine Coolant Recommended FMVSS No 116 DOT4 Item number Alternative Coolant SUBARU coolant 000016218 None Water for dilution 6 REFRIGERANT Distilled water Tap water Soft water Standard air conditioners on Subaru vehicles use HFC 134a refrigerant Do not mix it with other refrigerants Also do not use any compressor oil except for DH PR Air conditioner Recommended Item number Alternative Refrigerant HFC134a None Compressor oil DH PR None RM 5 Recommended Materials RECOMMENDED MATERIALS 7T GREASE Use the grease and supplementary lubricants shown in the table below Grease Application point Recommended Item number Alternative Supplementary lubricants Oo sensor Spray type lubricant Bolts etc Grease MT main shaft Clutch grease K0879Y0501 Clutch master cylinder Silicolube G 40M 004404003 push rod Gear shift lever SUNLIGHT2 003602010 Select lever Clutch operating
3. PM 00048 NOTE Coverthe bleeder with waste cloth when loosen ing it to prevent brake fluid from being splashed over surrounding parts During the bleeding operation keep the brake reservoir tank filled with brake fluid to eliminate en try of air The brake pedal operating must be very slow For convenience and safety two people should do the work The amount of brake fluid required is approx 500 m2 16 9 US fl oz 17 6 Imp fl oz for total 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 the bleeder screw approx 1 4 turn until a small amount of brake fluid drains into container and then quickly tighten the screw 8 Repeat steps 6 and 7 above until there are no air bubbles in the 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 the screw and install bleeder cap Tightening torque 8 0 8 kgf m 5 8 ft lb 10 Bleed air from each wheel cylinder by following the previous 5 steps 11 Depress the brake pedal with a force of approx 294 N 30 kgf 66 Ib and hold it there for approx 20 seconds At this time check the pedal to see if it makes any unusual movement V
4. 00148 10 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 11 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 Immobilizer cover EK model Immobilizer relay EK model 00146 B Jack handle 12 OPERATION CHECK OF HOOD LOCK RELEASE SYSTEM Operate the hood release knob A and check that the hood is unlocked normally 9 ME fe e Pre delivery Inspection PRE DELIVERY INSPECTION Operate the lever A and check that the hood is opened normally Then support the hood with hood stay 00151 13 BATTERY Check the battery terminals to make sure that no rust or corrosions due to fluid leaks are found Check that the battery caps are securely tightened 00012 B Upper level C Lower level 14 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 15 ENG
5. Maximum permissible Total kgf Ib 1 860 1 860 weight M P W 4 101 Option Air conditioner ABS O Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Spoiler pack 1 For option code refer to ID section Ref to ID 7 Option code D R Dual range SPC 15 SPECIFICATIONS Option code Impreza Model 2 0 L Turbo AWD WRX 5MT Curb weight C W Front kgf Ib 830 1 830 830 1 830 Rear kgf Ib 600 1 322 595 1 311 Total kgf Ib 1 430 3 153 1 425 3 142 Maximum permissible axle weight M P A W Front kgf Ib 990 2 183 990 2 183 Rear kgf Ib 950 2 094 950 2 094 Maximum permissible weight M P W Total kgf Ib 1 860 4 101 1 860 4 101 Option D R Dual range Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Spoiler pack 1 For option code refer to ID section Ref to ID 7 Option code SPC 16 Impreza SPECIFICATIONS 2 RHD MODEL Sedan Option code Model Curb weight C W Front kgf Ib Rear kgf Ib Total kgf Ib Maximum permissible axle weight M P A W Front kgf Ib Rear kgf Ib Maximum permissible weight M P W Total kg
6. D D i jak o For models without catalyst con verter Adjust the clutch pedal free play every 1 600 km 1 000 miles Clutch system Hill holder system Transmission oil ATF Front amp rear differential oil Brake line Brake fluid Disc brake pads amp discs Brake linings and drums Parking brake Suspension Wheel bearing Axle boots amp joints Steering system Power steering Clutch cable xy 2 m m x m mm Symbols used R Replace I Inspection R or I Recommended service for safe vehicle operation PM 4 Schedule PERIODIC MAINTENANCE SERVICES NOTE 1 When the vehicle is used in extremely dusty conditions the air cleaner element should be replaced more often 2 ATF filter is a maintenance free part ATF filter needs replacement when it is physically damaged or ATF leaked B MAINTENANCE SCHEDULE 2 1 EUROPE AREA Item 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 Replace more fre quently Replace more fre quently Replace more fre quently Fuel line 12 months
7. 15 000 km 9 000 miles Transmission oil Replace more fre quently Replace more fre quently Front amp rear dif ferential oil Replace more fre quently Brake line 12 months 15 000 km 9 000 miles Brake fluid 12 months 15 000 km 9 000 miles Brake pads 12 months 15 000 km 9 000 miles Brake linings and drums 12 months 15 000 km 9 000 miles Parking brake 12 months 15 000 km 9 000 miles Suspension 12 months 15 000 km 9 000 miles Axle boots amp joints 12 months 15 000 km 9 000 miles Steering system Power steering 12 months 15 000 km 9 000 miles PM 5 PERIODIC MAINTENANCE SERVICES 2 EXCEPT FOR EUROPE AREA Item Repeat short distance drive Schedule 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 Replace more fre quently Replace more fre quently Replace more fre quently Fuel line 6 months 12 500 km 7 500 miles Transmission oil Replace more fre quently Replace more fre quently Front amp rear dif
8. Since the servo brake does not work be careful that the brake is not applied effectively When en gine is stopped In case of the malfunction of internal transmission or drive system lift up four wheels on a trailer for towing 10 FRONT HOOD STAY INSTALLATION At the check and general maintenance EN When wider hood opening is necessary Set stay into the hole of hood inner as shown in the figure below NT 00069 11 TRAINING For information about training contact a dealer or agent 12 GENERAL SCAN TOOL Using general scan tools will greatly improve effi ciency of repairing engine electronic controls The Subaru Select Monitor can be used to diagnose the engine and also the ABS the air conditioner and other parts Note NT 9 NOTE Note NOTE NT 10 IDENTIFICATION 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 4 SS eit JU d EL 2 6 RE Ls 5 7 Y ID 00052 ID plate Europe model 4 Tire inflation pressure label Driver 6 Model number plate ADR compliance plate Australia side Australia model Vehicle identification number 7 model Tire inflation pressure label Driver VIN Europe RHD model and 2 Vehi
9. 1 For option code refer to ID section Ref to ID 7 Option code D R Dual range SPC 22 Impreza SPECIFICATIONS Option code KA Model 2 0 L Turbo AWD OUTBACK WRX 5MT D R MY D BMT 4AT Unladen weight U W Front kg Ib 760 775 770 785 825 850 1 676 1 709 1 698 1 731 1 819 1 874 Rear kg Ib 570 570 570 570 585 585 1 257 1 257 1 257 1 257 1 830 1 830 Total kg Ib 1 330 1 345 1 340 1 355 1 410 1 435 2 932 2 965 2 955 2 987 3 109 3 164 Gross vehicle mass Front kg Ib 950 950 950 950 990 990 G V M 2 094 2 094 2 094 2 094 2 183 2 183 Rear kg lb 960 960 960 960 950 950 2 116 2 116 2 116 2 116 2 094 2 094 Total kg Ib 1 800 1 800 1 800 1 800 1 860 1 860 3 969 3 969 3 969 Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Spoiler pack Cruise control 1 For option code refer to ID section Ref to ID 7 Option code D R Dual range SPC 23 Impreza SPECIFICATIONS SPC 24 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 inju
10. 3 969 1 800 3 969 1 800 3 969 Option D R Dual range Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Spoiler pack 1 For option code refer to ID section Ref to ID 7 Option code SPC 13 Impreza SPECIFICATIONS Option code Model 5MT D R Curb weight C W Front kgf Ib 780 775 1 720 1 709 Rear kgf Ib 570 565 1 257 1 246 Total kgf Ib 1 350 1 340 2 977 2 955 Maximum permissible Front kgf Ib 950 950 axle weight M P A W 2 094 2 094 Rear kgf Ib 960 960 2 116 2 116 Maximum permissible Total kgf Ib 1 800 1 800 weight M P W 3 969 3 969 Option Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Spoiler pack 1 For option code refer to ID section Ref to ID 7 Option code D R Dual range SPC 14 Impreza SPECIFICATIONS Option code EC Model 2 0 L Turbo WRX 5MT Curb weight C W Front kgf Ib 825 830 1 819 1 830 Rear kgf Ib 585 600 1 290 1 322 Total kgf lb 1 410 1 430 3 109 3 153 Maximum permissible Front kgf Ib 990 990 axle weight M P A W 2 183 2 183 Rear kgf Ib 950 950 2 094 2 094
11. ment 26 TEST MODE CONNECTOR Turn the ignition switch to ON and check that the malfunction indicator light starts blinking If the light blinks return the ignition key to LOCK and discon nect the test mode connector Then turn the igni tion key to ON again If the malfunction indicator light blinks at that time in spite of the disconnected test mode connector carry out an engine diagno sis e With OBD MODEL A Test mode connector Green Without OBD MODEL SN PI 00120 A Read memory connector Black B Test mode connector Green 27 IMMOBILIZER SYSTEM 1 Check that the engine starts with all keys that are equipped on vehicle 2 60 seconds after turning the ignition switch from ON to ACC or OFF or immediately after removing the key check that the security indicator light blink ing NOTE If malfunctions occur refer to IMMOBILIZER DI AGNOSIS PRE DELIVERY INSPECTION 28 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 immediately stop the engine and check and repair the necessary compo nents 29 EXHAUST SYSTEM Listen to the exhaust noise to see if no abnormal noises are observed 30 INDICATOR LIGHT Check that all the indicator lights are off 31 CLOCK Check the clock for normal operations and enou
12. NT 00060 1 Support locations 3 Lift 5 Without side sill cover 2 Pantograph jack 4 Rigid rack 6 With side sill cover NT 3 Note NOTE A B NT 00062 A Front B Rear 1 Front crossmember 2 Rear differential 8 TIE DOWNS Tie downs are used when transporting vehicles and when using the chassis dynamo Attach tie downs only to the specified points on the vehicle Tie down point Axx po S a 2 S o D NT 00063 1 for tie down 2 Hook for towing and tie down NT 4 Note NOTE Chain direction at tie down condition 4 T cms SS tX EXIL e Chain pulling range at tie down condition 20 20 20 20 NT 00064 1 Chain pulling range at tie down condition Vehicle sinking volume at tie down condition Measure the distance L between tire highest point to arch highest point before tie down and after tie down Difference of measurement value drop height shall be within 50 8 mm 1 97 in Make sure to fix the vehicle securely NT 00065 NT 5 Note NOTE 9 TOWING Avoid towing vehicles except when the vehicle cannot be driven For models with AWD AT or VTD usea loader instead of towing When towing other vehicles to prevent excessive weight from damaging the ho
13. PERIODIC MAINTENANCE SERVICES 2 Schedule A MAINTENANCE SCHEDULE 1 1 FOR EUROPE AREA For periodic maintenance of over 120 000 km 75 000 miles or 96 months carry out inspection by referring to the following table For a maintenance period gone beyond these tables apply them repeatedly as a set of 120 000 km 75 000 miles or 96 months Maintenance interval Number of months or km miles whichever occurs first Month 12 24 36 48 60 72 84 96 Remarks x 1 000 km 15 30 45 60 75 90 105 120 x 1 000 miles 9 19 28 38 47 56 66 75 Engine oil R R R R R R R R Engine oil filter R R R R R R R R Spark plug For Turbo R Others Drive belt s Camshaft drive belt Fuel line Fuel filter Air cleaner element Cooling system Coolant Clutch system Adjust the clutch pedal free play every 1 600 km 1 000 miles OO CO NIO ny A 1 1 o Hill holder system Transmission oil ATF Front amp rear differential Brake line Brake fluid Disk brake pads amp discs Brake linings amp drums Parking brake Suspension Wheel bearing Axle boot amp joint Steering system Clutch cable x m m m 3 d d Symbols used R Replace I Inspection I Recommended service for safe vehicle operation NOTE 1 When the ve
14. ferential oil Replace more fre quently Brake line 6 months 12 500 km 7 500 miles Brake fluid 12 months 25 000 km 15 000 miles Brake pads 6 months 12 500 km 7 500 miles Brake linings and drums 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 6 months 12 500 km 7 500 miles Steering system Power steering 6 months 12 500 km 7 500 miles PM 6 Engine Oil 3 Engine Oil A REPLACEMENT 1 Open the engine oil filler cap for quick draining of the engine oil PM 00155 A Oillevel gauge B Oil filler cap 2 Remove the dip of service hole cover Turbo model 3 Drain the engine oil by loosening engine oil drain plug DOHC TURBO MODEL PERIODIC MAINTENANCE SERVICES e SOHC MODEL ie assy Le LU 00193 oio 4 Replace the drain plug gasket 5 Tighten the engine oil drain plug after draining engine oil Tightening torque 44 N m 4 5 kgf m 33 ft Ib e DOHC TURBO MODEL LU 00186 LU 00193 PM 7 Engine Oil
15. 1 mm 0 161 in Service limit 1 5 mm 0 059 in Y 4 se n PM 00052 A B C Rotational direction of drum Forward Wheel cylinder Upper shoe return spring Adjusting lever A A A G Trailing shoe Lower shoe return spring Leading shoe anann 3 Check the brake drum for wear dents or other damage If the inside surface of brake drum is streaked cor rect the surface with emery cloth 200 or more If it is 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 PM 00053 A Inside diameter 2 PARKING BRAKE REAR DISC BRAKE Inspect the brake linings and drums of both sides of the rear brake at the same time by removing brake drums 1 Inspect the brake shoes for damage or deforma tion and check brake linings for wear NOTE Always replace both primary and secondary brake shoes for the right and left wheels at the same time Brake lining thickness except back metal Standard value 3 2 mm 0 126 in Wear limit 1 5 mm 0 059 in PM 00054 A Forward B Brake shoe Primary side C Brake shoe Secondary side 2 Check the disk rotor for wear dents or oth
16. 16inch 24 0 94 Standard aes 17 inch 30 1 18 ee 14 15 16 inch 22 0 87 17 inch 28 1 10 Rear Disc rotor thicknessmm in 14 inch 15 inch 17 inch 14 inch 15 inch 17 inch 10 0 39 18 0 71 20 0 79 8 5 0 34 16 0 63 18 0 71 Standard Service limit 4 Remove the caliper body lt Ref to BR 31 Front Disc Brake Assembly gt lt Ref to BR 42 Rear Disc Brake Assembly gt 5 Tighten the wheel nuts to secure disk rotor 6 Set a dial gauge ata point less than 10 mm 0 39 in from outer periphery of rotor and then measure the disk rotor runout Disc rotor runout limit Front 0 075 mm 0 0030 in Rear 0 070 mm 0 0028 in PM 00051 PM 35 Brake Linings and Drums PERIODIC MAINTENANCE SERVICES 22 Brake Linings and Drums A INSPECTION 1 REAR DRUM BRAKE 1 Remove the brake drum and check that there is no fluid leakage from wheel cylinder If there is fluid leakage from wheel cylinder inspect the wheel cylinder and then repair or replace it 2 Inspect the brake shoes for damage or deformi ties and check brake linings for wear NOTE Always replace both leading and trailing brake shoes for the right and left wheels at the same time When either the right and left brake assembly is replaced always replace the leading shoe and trail ing shoe of the other Thickness of lining except back metal Standard value 4
17. 3 Erigie OE EE seme ee eco Mt uL E e M 7 9 d cba qo e Nu UE EE 10 MeO E EE PP E 11 Timing Belt rl 13 BHO Tm 16 FUCA i DE TINH 17 Air Cleaner Element esses enne en nennen nnne nnns 18 Cooling 19 Goolanbz este a 21 Idle MIXEUEO 5 ene 23 Clutch SYSTEM nasa ennen iedere eaten nnn drenten aem at dean ne 24 Transmission Gear Oil eese ennemis 26 Hill holder System s utet ae eel en Rn en e ecu 27 MO MN EN MRNA e ENT 28 Front amp Rear Differential Gear 30 Brake Lir ee Lo tede tv duce decet ode voten o desea de s 32 Fn e be dentist den ot eei osea eaa a 34 Disc Brake Pads and 35 Brake Linings DFEUITIS s c onere te rt rl quereis 36 SII 38 Wheel BSA ren ondertent len can bod edi tendo PEINE 40 Axle Boots amp Joints iR REIP REG ius 42 Steering System Power Steering 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
18. 4 1 695 66 7 1 710 67 3 1 740 68 1 Overall height at C W 1 440 56 7 1 465 57 7 1 485 58 5 1 475 58 1 1 495 58 9 1 440 56 7 Compartment Length 1 890 74 4 1 845 72 6 1 890 74 4 Width 1 380 54 3 Height 1 180 46 5 1 125 44 3 5 1 200 47 2 1 150 45 3 5 1 200 47 2 1 150 45 3 5 1 180 46 5 Wheelbase 2 525 99 4 Tread Front 1 485 58 5 1 460 57 5 1 465 57 7 1 460 57 5 1 490 58 7 Rear 1 475 58 1 1 480 58 3 1 450 57 1 1 1 455 57 3 1 455 57 3 1 480 58 3 Minimum road clearance t 16L 2 20L Without catalytic converter 150 5 9 155 6 1 150 5 9 155 6 1 160 6 3 With catalytic converter 3 20 L Turbo 4 With roof rail With sun roof 150 5 9 155 6 1 3 SPC 2 150 5 9 155 6 1 3 160 6 3 155 6 1 Impreza SPECIFICATIONS B ENGINE Model Engine type Valve arrangement Bore x Stroke Non turbo 2 0L Turbo 2 0L Horizontally opposed liquid cooled 4 cylinder 4 stroke gasoline engine Overhead camshaft type 92 x 75 3 62 x 2 95 1 994 121 67 8 0 0 2 1 3 2 4 700 100 7503100 160 215 5 600 168 225 6 000 3 165 221 5 600 292 29 8 215 4 3 600 300 30 6 221 3 3 600 8 4 000 92 x 75 8 62 x 2 95 1
19. 450 49 INSTALLATION Timing Belt As sembly gt 2 DOHC MODEL 1 Remove the radiator fan and air conditioner fan lt Ref to CO H4DOTC 28 Radiator Main Fan and Fan Motor gt Ref to CO HADOTO 30 Radiator Sub Fan and Fan Motor gt 2 Protect the radiator with cardboard and blanket 3 Remove the V belts lt Ref to ME H4DOTC 54 V belt gt 4 Remove the air conditioning compressor drive belt tensioner 5 Remove the pulley bolt To lock the crankshaft use ST Except for STi model ST 499977300 CRANKSHAFT PULLEY WRENCH STi model ST 499977300 CRANKSHAFT PULLEY WRENCH PM 00093 6 Remove the crankshaft pulley 7 Remove the air conditioning compressor drive belt tensioner 8 Remove the belt cover LH 9 Remove the belt cover RH 10 Remove the front belt cover 11 Remove the timing belt guide MT model ME 00727 ME 00729 12 Turn the crankshaft and align alignment marks on crankshaft and right and left camshaft sprock ets with notches of belt cover and cylinder block To turn the crankshaft use ST PM 14 Timing Belt ST 499987500 CRANKSHAFT SOCKET PM 00156 A Notch B Alignment mark 13 Remove the belt idler 14 Remove the timing belt 15 Remove the automatic belt tension adjuster as sembly Vj AN PM 00096 16 Install in the reverse order of
20. 994 121 67 8 0 0 2 99 5 x 79 3 92 x 3 11 2 457 149 9 10 0 0 2 87 9 x 65 8 3 461 x 2 591 1 597 97 45 10 0 0 2 Displacement i cm cu in Compression ratio Firing order Idle speed at Park Neutral position 650 100 2 700 100 rpm 650 100 2 700 100 650 100 700 100 Maximum output kW HP rpm 112 150 5 600 195 261 6 000 70 94 5 200 92 123 5 600 N m kgf m ft lb rpm Maximum torque 343 35 0 253 0 4 000 223 22 7 164 5 3 600 143 14 6 105 5 3 600 184 18 8 136 0 3 600 1 Without OBD With OBD 3 Australia model Europe model C ELECTRICAL Model Ignition timing at idling Spark plug 2 5L STi MT 10 10 15 10 1 6L Non turbo 2 0 L Turbo 2 0L 5 10 10 10 12 10 BKR6E without catalyst CHAMPION RC8YCA NGK BKR6E without catalyst CHAMPION RC10YC4 Without OBD Type and manufacturer CHAMPION RC10YC4 with catalyst NGK BKR6E 11 with catalyst with catalyst NGK BKR5E 11 with catalyst NGK BKR5E 11 With OBD CHAMPION RC8YCA CHAMPION RC10YC4 Alternate NGK BKR6E 11 Alternate NGK BKR5E 11 NGK PFR6G NGK PFR6G Generator 12V 75A Battery Type and capacity 5HR For Europe and South America 12V 48AH 55D23L MT 12
21. Component D Caution G Tightening torque B Process E Tool number of special tool H Illustration C Reference F Name of special tool HU 4 7 DIAGNOSIS How to Use This Manual 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 Example Tightening torque 44 N m 4 5 kgf m 33 ft Ib Item SI Units Conventional unit HOW TO USE THIS MANUAL Remarks Force N Newton kgf 1 kgf 2 9 80655 N Mass Weight kg g kg g Capacity 2 m2 or cm Q orcc 1cc 1cm 1m2 Torque N m kgf m kgf cm 1 kgf m 9 80655 N m Rotating speed rpm rpm Pressure kPa kilopascal kgf cm 1 kgf cm 98 0655 kPa mmHg 1 mmHg 0 133322 kPa Power Ww PS 1 PS 2 0 735499 kw Calorie W h cal 1 kcal 1 16279 W h Fuel consumption rate g PS h 1 g PS h 1 3596 g kW h The figure used in this manuals are described in the SI units and conventional units are described in HU 5 How to Use This Manual HOW TO USE THIS MANUAL 9 EXPLANATION OF TERMINOLOGY List AAI Air Assist Injection LH LH Left Hand A B Airbag LSD Limited Slip Differential ABS Antilock Brake System M B Main Fuse amp Relay Box A C Air conditioner MD Mini Disc A F Air
22. Fuel Ratio MPi Multi Point injection ALT Generator MP T Multi Plate Transfer ASSY Assembly MT Manual transmission AT Automatic transmission Non Natural Aspiration ATF Automatic transmission fluid turbo AVCS Active Valve Control System NC Normal Close Relay AWD All Wheel Drive NO Normal Open Relay BATT Battery OP Option Parts CD R RW CD Recordable ReWritable P S Power Steering COMPL Complete P W Power Window CPU Central Processing Unit PCD Pitch Circle Diameter DOHC Double Overhead Camshaft PCV Positive Crankcase Ventilation ECM Engine Control Module ECM RH RH Right Hand EGI Electronic Gasoline Injection SOHC Single Overhead Camshaft E G Engine SRC Supplemental Restraint System EGR Exhaust Gas Recirculation SSM Subaru Select Monitor ELR Emergency Locking Retractor ST Special Tool F B Fuse amp Joint Box SW Switch FL Fusible Link TGV Tumble generated valve FWD Front Wheel Drive T M Transmission HID High Intensity Discharge ViS C Viscous Coupling H U Hydraulic Unit VSV Vacuum Switching Valve IG Ignition VTD Variable Torque Distribution IN Intake W H Wiring harness INT Intermittent Pr Primary ISC Idle Speed Control 2ndr Secondary HU 6 SPECIFICATIONS SPECIFICATIONS 1 Impreza A DIMENSIONS Model Impreza Sedan Wagon OUTBACK STi Overall length 4 415 173 8 Overall width 1 740 68
23. PERIODIC MAINTENANCE SERVICES 6 Fill engine oil through the filler pipe up to center between upper level and lower level Make sure that the vehicle is placed level when checking oil level Use engine oil of proper quality and viscosity selected in accordance with the table in figure Recommended oil API classification SL or SJ with the words Energy Conserv ing or Energy conserving Il CCMC speci fication G4 or G5 ACEA specification A1 A2 or A3 or New API mark displayed on the container If it is impossible to get SL or SJ grade you may use SG or SH grade Engine oil capacity Upper level Approx 4 0 2 4 2 US qt 3 5 Imp qt Lower level Approx 3 0 2 3 2 US qt 2 6 Imp qt e SOHC MODEL SAE 1 C 30 20 15 0 15 30 40 F 22 4 5 32 59 86 104 10W 30 10W 40 5W 30 0W 20 2 LU 00071 1 Viscosity No and applicable temperature 2 Preferred e EXCEPT FOR SOHC MODEL SAE 1 C 30 20 15 0 15 30 40 F 22 4 5 32 59 86 104 10W 30 10W 40 5W 30 2 LU 00076 1 Viscosity No and applicable temperature 2 Preferred 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 clas
24. REPLACEMENT 1 FRONT SIDE BELT DRIVING POWER STEERING OIL PUMP AND GENERATOR NOTE Wipe off any oil or water on the belt and pulley 1 Remove the V belt cover NON TURBO MODEL 00154 11 V belt PERIODIC MAINTENANCE SERVICES TURBO MODEL Tightening torque 23 N m 2 3 kgf m 17 0 ft Ib Y 7 SC 00096 2 Loosen the lock bolt A 3 Loosen the slider bolt B 4 Remove the front side belt C 5 Install a new belt and tighten the slider bolt so as to obtain the specified belt tension 6 Tighten the lock bolt A 7 Tighten the slider bolt B Tightening torque Lock bolt 25 N m 2 5 kgf m 18 ft Ib Slider bolt 8 N m 0 8 kgf m 5 8 ft Ib 2 REAR SIDE BELT DRIVING AIR CONDI TIONER NOTE Wipe off any oil or water on the belt and pulley 1 Remove the front side belt 2 Loosen the lock nut A 3 Loosen the slider bolt B 4 Remove the rear side belt 5 Install a new belt and tighten the slider bolt so as to obtain the specified belt tension 6 Tighten the lock nut A 7 Install the front side belt SOHC model Ref to ME H4SO 43 FRONT SIDE BELT IN STALLATION V belt gt DOHC Turbo model lt Ref to ME H4DOTC 54 FRONT SIDE BELT INSTALLATION V belt gt PM 12 Timing Belt 7 Timing Belt A REPLACEMENT 1 NON TU
25. brake lever is 7 to 8 notches 42 AT SHIFT CONTROL Set the AT select lever to each gear position and check the shifting while driving the vehicle ga Pp By te 92 600 3 gt 1 1 2 Pl 00112 1 RHD model 2 LHD model 200027 VU S AT 00761 Selector Gear Position Position 2nd 3rd Yes Yes Yes Yes Yes 43 HEATER amp VENTILATION Operate the heater and ventilation system to check for normal outlet selection air inlet selection air flow and heating capacity 44 AIR CONDITIONER Operate the air conditioner Check that the A C compressor operates normally and enough cooling is provided 45 CRUISE CONTROL Operate the cruise control system Check that the system is activated and deactivated correctly PI 10 Pre delivery Inspection PRE DELIVERY INSPECTION 46 ATF LEVEL Check that the ATF level is normal when the engine at idle If insufficient check that no leaks are found Then add the necessary amount of the specified ATF 6 0 00191 A Level gauge B ATF level range when HOT 70 80 C 158 176 F C Upper level D Lower level E ATF level range when COLD 20 30 C 68 86 F 47 POWER STEERING FLUID LEVEL Check that the power steering fluid level is normal If insufficien
26. clutch case Transmission oil pan 6MT model Three Bond 1215B 004403007 Dow Corning s No 7038 Transmission oil pan AT model Three Bond 1217B K0877YA020 Rear differential Three Bond 1324 004403042 Rear differential Three Bond 1105 004403010 Dow Corning s No 7038 Steering adjusting screw Three Bond 1141 004403006 Camshaft cap Three Bond 1280B K0877YA018 Front sealing cover Rear sealing cover 3M Butyl tape 8626 RM 7 Recommended Materials RECOMMENDED MATERIALS RM 8 PRE DELIVERY INSPECTION PI Page 1 Pre delivery InSpBehON meerdere ees sc eerte eet gen 2 Pre delivery Inspection PRE DELIVERY INSPECTION 1 Pre delivery Inspection A GENERAL DESCRIPTION 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 ve hicle to its normal state Check if the vehicle before delivery is in a normal state Check for any damage to the vehicle or parts that may have taken place during transportation or storage Check if the vehicle after repair is in a normal state Make sure to provide a complete vehicle to the customer For the above reasons all SUBARU dealers dealerships carry out the PDIs before delivering a vehicle B PRE DELIVERY INSPECTION PDI PROCEDURE STATIC CHECKS JUST AFT
27. drain plug to specified torque Tightening torque 70 N m 7 1 kgf m 51 6 ft Ib 3 Fill differential gear oil through the oil level gauge hole up to the upper point of level gauge NOTE Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands Recommended gear oil GL 5 75W 90 or equivalent Differential gear oil capacity 1 1 1 3 0 1 2 1 4 US qt 1 0 1 1 Imp qt PI 00183 A Oil level gauge B Upper level C Lower level 3 REAR DIFFERENTIAL 1 Drain the oil by removing drain plug 2 Remove the filler plug or oil temperature switch for quick draining oil 3 Install the drain plug after draining oil NOTE Apply fluid packing to the drain plug threads for T type Fluid packing Three Bond 1105 Part No 004403010 Use a new aluminum gasket for VA type Tightening torque T type 49 0 N m 5 0 kgf m 36 2 ft Ib VA type 34 N m 3 5 kgf m 25 3 ft Ib 4 After installing the drain plug onto rear differen tial gear case firmly fill oil up fully to the mouth of filler plug TTYPE PM 00037 A Filler plug B Drain plug PM 30 Front amp Rear Differential Gear Oil VA TYPE PM 00102 A Filler plug B Drain plug Recommended gear oil Except for STi model with driver s control center differential GL 5 75W 90 or equivalent STi model with driver
28. level is normal Window washer fluid Check that the window washer fluid level is normal Front hood latch check Check that the hood is closed and latched securely Keyless entry system Check that the keyless entry system operates normally Seat 1 Check the seat surfaces for stain or dirt 2 Check the seat installation conditions and functionality Seat belt Check the seat belt installation conditions and functionality Wheel alignment Check that the wheel alignments are properly adjusted CHECKS WITH ENGINE RUNNING PROCEDURE Check point 26 Test mode connector Test mode connectors 27 Immobilizer system 1 Check that the engine starts with all keys that are equipped on vehicle 2 60 seconds after turning ignition switch from ON to ACC or OFF or imme diately after removing key check that the security indicator light blinking 28 Starting condition Start the engine and check that the engine starts smoothly 29 Exhaust system Check that the exhaust noise is normal and no leaks are found 30 Indicator and warning lights Check that all the indicator and warning lights are gone out 31 Clock Check that the clock operates normally 32 Audio Check the radio CD and MD player for normal operation 33 Front accessory power supply socket Check that the front accessory power socket operates normally 34 Lighting system Check that the lighting system operates normally 35 Window washer Ch
29. or binds disassemble the front axle and check condition of oil seals bearing etc B gt 8 PM 00061 A B C Inner oil seal Snapring Bearing Housing A A A G 2 REAR WHEEL BEARING AWD 1 Jack up the rear of vehicle 2 While holding the rear wheel by hand swing it in and out to check bearing free play 3 Loosen the wheel nuts and remove rear wheel Outer oil seal Hub bolt Hub p 4 If the bearing free play exists in step 2 above attach a dial gauge to the hub COMPL and mea sure axial displacement 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 DS 44 Rear Drive Shaft 6 While supporting the rear drive shaft horizontally with one hand turn the hub COMPL with the other to check for noise or binding If the hub COMPL is noisy or binds disassemble the rear axle and check condition of oil seals bear ings etc gt o Inner oil seal Rear housing Bearing Snap ring Outer oil seal Tone wheel Hub bolt Hub Socket bolt FWD 1 Jack up the rear of vehicle 2 While holding the rear wheel by hand swing it in and out to check bearing free play 3 Loosen the wheel nuts and remove rear wheel 4 If the bearing free play exists in step 2 above attach a dial ga
30. removal lt Ref to ME H4DOTC 58 Timing Belt Assembly gt PERIODIC MAINTENANCE SERVICES CAUTION When installing the timing belt be sure to align all alignment marks on the belt with corre sponding marks on the sprockets If incorrectly installed interference between pistons and valves may occur B INSPECTION 1 SOHC MODEL 1 Remove the front timing belt cover and timing belt cover LH 2 While cranking the engine at least four rotations check the timing belt back surface for cracks or damage Replace the faulty timing belt as needed 3 Measure the 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 alignment squareness Replace the worn timing belt PM 00016 4 Install the front timing belt cover and timing belt cover LH 2 DOHC MODEL 1 Remove the timing belt cover LH 2 While cranking the engine at least four rotations check the timing belt back surface for cracks or damage Replace the faulty timing belt as needed 3 Measure the 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 alignment squareness Replace the worn timing belt 4 Install the timing belt cover LH PM 00097 PM 15 Fuel Line PERIODIC MAINTENANCE SERVICES 8 Fuel Line A INSPECTION The fuel line is
31. s control center differ ential GL 5 LSD oil 90 or equivalent Oil capacity Except for STi model 0 8 0 0 8 US qt 0 7 Imp qt STi model 0 9 1 10 1 0 1 2 US qt 0 8 1 0 Imp qt NOTE Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands For STi model with driver s control center differ ential use mechanical LSD model 5 Install the filler plug or oil temperature switch onto rear differential gear case firmly NOTE Apply fluid packing to the filler plug or oil temper ature switch threads for T type Fluid packing Three Bond 1105 Part No 004403010 Use a new aluminum gasket for VA type Tightening torque T type 49 0 N m 5 0 kgf m 36 2 ft Ib VA type 34 N m 3 5 kgf m 25 3 ft Ib PM 31 PERIODIC MAINTENANCE SERVICES Brake Line PERIODIC MAINTENANCE SERVICES 19 Brake Line A INSPECTION 1 BRAKE LINE 1 Check scratches swelling corrosion traces of fluid leakage on the brake hoses or pipe joints 2 Check the possibility of adjacent parts interfering with brake pipes hoses during driving and loose connections clamps 3 Check any trace of fluid leakage scratches etc on the master cylinder wheel cylinder and pres sure 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 the brake hose
32. should not flow out of hose Replace both check valve and vacuum hose if the check valve is faulty Engine side of vacuum hose is indicated by marking ENG as shown PM 00046 A Engine side B Brake booster side C ENG 5 Check the vacuum hose for cracks or other dam age 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 33 Brake Fluid PERIODIC MAINTENANCE SERVICES 20 Brake Fluid A REPLACEMENT 1 Either jack up the vehicle and place a safety stand under it or lift up the vehicle 2 Remove both front and rear wheels 3 Draw out the brake fluid from master cylinder with syringe 4 Refill the reservoir tank with recommended brake fluid Recommended brake fluid FMVSS No 116 fresh DOT3 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 3 2 pm 00047 1 2 3 4 5 6 Front right Rear left Front left Rear right Secondary Primary A A A A A A 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
33. using a mirror where it is difficult to see for any damage BR 00095 1 Front brake hose 2 Front brake pipe BR 00096 1 Rear brake pipe 2 Brake hose 3 Clamp 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 0 5 2 0 mm 0 02 0 08 in PM 00078 A Brake pedal free play 2 If the free play is out of specifications above ad just the brake pedal as follows 1 Be sure the engine is off No vacuum is ap plied 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 N 1 kgf 2 Ib to a stroke of 0 5 to 2 0 mm 0 02 to 0 08 in 3 Depress the surface of brake pad by hand 4 If there is no free play between clevis pin and clevis turn the brake switch adjusting nut until the clearance between stopper and screw of brake switch becomes 0 3 mm 0 012 in PM 00041 Brake switch Adjusting nut 0 3 mm 0 012 in Stopper Clevis pin Clevis Brake pedal free play Lock nut Brake booster operating rod Play at pin lt Sash ee Sn ME 32 Brake Line PERIODIC MAINTENANCE SERVICES 3 Check the pedal stroke While the engine is idling depress the brake pedal with a 490 N 50 kgf 110 Ib load
34. 1 8 Imp qt of the undiluted solution of SUBARU coolant If a coolant concentration of 5096 is needed drain all the coolant and refill with the undiluted solution only 0 US qt Imp qt 2 PM 00026 Quantity of coolant to be drained Necessary concentration of coolant Concentration of coolant in vehicle cooling sys tem SS PM 22 Idle Mixture 13 Idle Mixture A INSPECTION AND ADJUSTMENT 1 IDLE MIXTURE Before measuring the idle mixture make sure that the ignition timing and the engine idle speed are within specifications 1 Set the gear position at Neutral for MT or N or P for AT 2 Warm up the engine sufficiently until cooling fan starts to operate 3 Measure the idle mixture using CO meter Engine idle speed CO 7004100 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 the 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 the CO adjusting screw A Specified data 0 28 4 22 V PM 00146 NOTE If driving the vehicle on out of specified data the DTC 49 is indicated in many case PM 23 PERIODIC MAINTENANCE SERVICES Clutch System PERIOD
35. 4 forward speeds and 1 reverse 6MT 6 forward speeds with synchromesh and 1 reverse DSPD Dry Single Plate Diaphragm TCC Torque Converter Clutch 1 Australia spec vehicle E STEERING Model Turbo 2 0 L 2 5L OUTBACK 2 0L NA 1 6L STi Type Rack and Pinion Turns lock to lock RHD 2 69 LHD 3 02 Minimum turning circle m ft Curb to curb 11 36 1 11 36 1 10 4 34 1 11 36 1 Wall to wall 12 0 39 4 11 6 38 1 11 2 36 7 12 0 39 4 3 02 3 22 2 69 F SUSPENSION Front Macpherson strut type Independent Coil spring Rear Dual link type Independent Coil spring SPC 4 Impreza SPECIFICATIONS G BRAKE Model 1 6L Non turbo 2 0 L 2 5 L Turbo 2 0 L STi Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Drum brake Disc brake Ventilated disc brake Parking brake Mechanical on rear brakes H TIRE Model BASE TS GX TS RS WRX OUTBACK WRX STi Rim size 14 x 51 0 15 x 6JJ 16 x 61 5JJ 16 x 61 5JJ 17 x 7JJ 17 x 71 40 Tire size 185 70R14 88H 195 60R15 88H 205 50R16 87V P205 55R16 89V 215 45R17 87W 225 45R17 90W Type Steel belted radial Tubeless I CAPACITY Model 1 6 L FWD 1 6 L AWD Non turbo 2 0 L Turbo 2 0L 2 5L 5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT Fuel tank Q US gal Imp gal Engine Total Q US qt oil capacity I
36. 45 545 545 570 570 1 202 1 202 1 202 1 257 1 257 Total kgf Ib 1 290 1 310 1 300 1 350 1 350 2 844 2 888 2 866 2 977 2 977 Maximum permissible Front kgf Ib 900 900 900 950 950 axle weight M P A W 1 984 1 984 1 984 2 094 2 094 Rear kgf Ib 910 910 910 960 960 2 006 2 006 2 006 2 116 2 116 Maximum permissible Total kgf ID 1 730 1 730 1 730 1 800 1 800 weight M P W 1 609 1 609 1 609 3 969 3 969 Option Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Spoiler pack Cruise control 1 For option code refer to ID section Ref to ID 7 Option code D R Dual range SPC 21 Impreza SPECIFICATIONS Option code EK Model 2 0 L Turbo AWD WRX 5MT Curb weight C W Front kgf Ib 825 830 1 819 1 830 Rear kgf Ib 590 600 1 301 1 323 Total kgf Ib 1415 1 430 3 120 3 153 Maximum permissible Front kgf Ib 990 990 axle weight M P A W 2 183 2 183 Rear kgf Ib 950 950 2 094 2 094 Maximum permissible Total kgf Ib 1 860 1 860 weight M P W 4 101 Option Air conditioner ABS O Side airbag O Sunroof Aluminium wheel Audio Seat in pure hide Spoiler pack Cruise control
37. B ATF level range at HOT 70 80 C 158 176 F C Upper level D Lower level E ATF level range at COLD 20 30 C 68 86 4 Make sure that ATF level is the center of upper and lower level at HOT side If the ATF level is below lower level check the transmission for leaks If there are leaks it is nec essary to repair or replace gasket oil seals plugs or other parts 5 If the ATF level is below the center between up per and lower level add the recommended ATF un til the ATF level is found above the center between upper and lower level CAUTION Use care not to exceed the upper level Addition of ATF to the upper level when the transmission is cold will result in overfilling of ATF causing a transmission failure 6 Check ATF level after raising ATF temperature to 70 80 C 158 176 F by running the vehicle or by idling the engine again B REPLACEMENT 1 AUTOMATIC TRANSMISSION FLUID 1 Drain the ATF Automatic Transmission Fluid by removing drain plug NOTE Before starting work cool off the ATF well Check the condition of ATF drained Ref to 4AT 32 CONDITION CHECK Automatic Trans mission Fluid dlh Ar 02389 A Oil pan B ATF drain plug 2 Replace the gasket with a new one and then tighten the specified torque Tightening torque 25 N m 2 55 kgf m 18 4 ft lb 3 Fill ATF up to the middle of the COLD sid
38. D model 5MT single range model 1 MANUAL TRANSMISSION 3 5 L 3 7 US qt 3 1 Imp qt 1 Drain the gear oil by removing drain plug AWD model 5MT dual range model NOTE 4 0 L 4 2 US qt 3 5 Imp qt Before starting work cool off the transmission 6MT gear oil well 4 1 L 4 3 US qt 3 6 Imp qt e f transmission gear oil adheres to the exhaust pipe wipe it off completely tf aii Xm 5MT PM 00030 A Oillevel gauge PM 00029 B Upper level C Lower level eMT A Drain plug Cil pan side B Drain plug Clutch housing side 2 Replace the gasket with new one and then tight en it to the specified torque Tightening torque 5MT 70 N m 7 1 kgf m 51 6 ft Ib 6MT Oil pan side 44 N m 4 5 kgf m 32 5ft Ib 6MT Clutch housing side 70 N m 7 1 kgf m 51 6 ft Ib 3 Fill transmission gear oil through the oil level gauge hole up to the upper point of level gauge NOTE Each oil manufacturer has its base oil and addi tives Thus do not mix two or more brands PM 26 Hill holder System PERIODIC MAINTENANCE SERVICES 16 Hill holder System A INSPECTION AND ADJUSTMENT 1 Confirm the stopping and starting performance by activating the hill holder on an uphill road of 3 or higher inclination 1 When the vehicle does not stop Tighten the adjusting nut of PHV cable 2 When the vehicle does not start pr
39. E ROD 1 Check the tie rod and tie rod ends for bends scratches or other damage PM 00069 A Tie rod end B Knuckle arm 2 Check the connections of knuckle ball joints for play inspect for damage on dust seals and check free play of ball studs If the castle nut is loose re tighten it to the specified torque then tighten further up to 60 until the cotter pin hole is aligned Tightening torque 27 N m 2 75 kgf m 19 9 ft Ib 3 Check the lock nut on tie rod end for tightness If it is loose retighten it to the specified torque Tightening torque 83 N m 8 5 kgf m 61 5 ft Ib 5 POWER STEERING FLUID LEVEL NOTE Check at power steering fluid temperature 20 C 68 F read the fluid level on the COLD side e Check at power steering fluid temperature 80 C 176 F read the fluid level on the HOT side 1 Place the vehicle with engine OFF on a flat and level surface 2 Check the fluid level using the scale on the out side of reservoir tank A If the level is below MIN B add fluid to bring it up to MAX C PM 00070 NOTE If the fluid level is at MAX level or above drain fluid to keep the level in specified range of indicator by using a syringe or the like Recommended fluid Dexron III Fluid capacity 0 7 0 0 7 US gt 0 6 Imp qt 6 POWER STEERING FLUID FOR LEAKS Inspect the underside of oil pump and gearbox for power steering system hoses
40. ER VEHICLE RECEIPT PROCEDURE Check point 1 Appearance 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 damage or stains in detail 2 Visually check the glass and light lenses for any damage cracks or excessive gaps to the body sheet metal 3 Visually check the plated parts for any damage 2 Tire check 1 Check the tires for damage abnormal conditions and dents on the wheels 2 Check the tire air pressure 3 Fuse installation If the vehicle is about to be delivered to the customer attach a back up fuse 4 Air conditioner harness connection If the vehicle is about to be delivered to the customer connect air conditioner harness 5 Check the doors for lock unlock and open close operations 1 Using the key check if the trunk lid can be locked or unlocked normally 2 Open and close all doors to see that there are no abnormal conditions 3 Operate the power door lock switch to check that the door rear gate is locked and unlocked normally 6 Double lock operation check Check the double lock for normal operations 7 Check the operation of child safety lock system Check that the child safety lock system operates normally 8 Check the trunk lid for open close operations 1 Operate the trunk lock release lever to check that
41. IC MAINTENANCE SERVICES 14 Clutch System A INSPECTION AND ADJUSTMENT 1 MECHANICAL CLUTCH TYPE 1 Inspect the free play of clutch pedal by operating pedal by hand If itis 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 A 10 20 mm 0 39 0 79 in XL YOO KOK RY KR KS PM 00151 Fork lever free play allowance A 2 4mm 0 08 0 16 in ab A PM 00152 1 Full stroke 25 5 mm 1 in 2 Pedal to floor plate gap in disengaged position 1 With the engine idling pull the parking brake lever completely 2 Slowly depress the clutch pedal while mov ing shift lever into reverse 3 Stop depressing the clutch pedal when gearshifting is complete With the clutch pedal in this position measure the distance between the upper side of pedal pad and the lower end of front panel intersection of front panel with floor Check that the measured value is within the specification Standard 80 mm 3 15 in or more 3 Pedal height Check that the clutch pedal pad surface is level with or higher than brake pedal pad surface 2 HYDRAULIC 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 rese
42. INE 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 ie je g D LU 00138 A Oil level gauge B Engine oil filler cap C Upper level D Lower level E Approx 1 0 2 1 1 US qt 0 9 Imp qt 16 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 PM 00030 A Oil level gauge B Upper level C Lower level 7 Pre delivery Inspection PRE DELIVERY INSPECTION 17 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 00183 Oil level gauge Upper level Lower level 18 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 19 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 A B C 20 WINDOW WASHER FLUID Check the window washer fluid amount If the amount is insufficient che
43. M 2 183 2 183 Rear kg Ib 920 920 2 028 2 028 Total kg Ib 1 850 1 850 4 079 Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Spoiler pack Front LSD Cruise control Driver s control center differential 1 For option code refer to ID section Ref to ID 7 Option code SPC 19 SPECIFICATIONS Option code Impreza KA Model 2 0 L Turbo AWD WRX 4AT Unladen weight U W Front kg Ib 860 1 896 865 1 907 Rear kg Ib 555 1 234 565 1 246 Total kg Ib 1 415 3 120 1 430 3 153 Gross vehicle mass G V M Front kg Ib 990 2 183 990 2 183 Rear kg Ib 920 2 028 920 2 028 Total kg Ib 1 850 Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Spoiler pack Front LSD Cruise control Driver s control center differential 1 For option code refer ID section Ref to ID 7 Option code SPC 20 Impreza SPECIFICATIONS Wagon Option code K1 Model AWD 5MT D R 5MT D R 5MT D R 5MT D R Curb weight C W Front kgf Ib 745 765 755 780 780 1 642 1 687 1 664 1 720 1 720 Rear kgf Ib 5
44. RBO MODEL 1 Remove the radiator fan and air conditioner fan Ref to CO H4SO 23 Radiator Main Fan and Fan Motor gt Ref to CO H4SO 24 Radiator Sub Fan and Fan Motor 2 Shield the radiator from any damage using card board and blanket 3 Remove the V belt cover PM 00003 4 Remove the V belts Ref to ME H4SO 43 V belt 5 Remove the air conditioning compressor drive belt tensioner 6 To lock the crankshaft use ST Remove the pul ley bolt 2 5 L model ST 499977100 CRANKSHAFT PULLEY WRENCH Except for 2 5 L model ST 499977400 CRANKSHAFT PULLEY WRENCH 22 00007 7 Remove the crankshaft pulley 8 Remove the left side belt cover 9 Remove the front timing belt cover PERIODIC MAINTENANCE SERVICES 10 Remove the timing belt guide MT model AP PM 00008 11 Turn the crankshaft and align alignment marks on crankshaft and right and left camshaft sprock ets with notches of belt cover and cylinder block ST 499987500 CRANKSHAFT SOCKET PM 00009 A Notch B Alignment mark 12 Remove the belt idler 13 Remove the belt idler No 2 PM 00010 14 Remove the timing belt PM 13 Timing Belt PERIODIC MAINTENANCE SERVICES 15 Remove the automatic belt tension adjuster as sembly PM 00011 16 Install in the reverse order of removal Ref to
45. REWORD 1 Foreword A FOREWORD These manuals are used when performing mainte nance repair or diagnosis of the Subaru IMPRE ZA Applied model GD GG from 2004MY The manuals contain the latest information at the time of publication Changes in specifications methods etc may be made without notice FW 2 HOW TO USE THIS MANUAL HU Page 1 How to Use This Manual aaneen m Immer rennen nnns 2 How to Use This Manual HOW TO USE THIS MANUAL 1 How to Use This Manual A HOW TO USE THIS MANUAL 1 STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each com ponent 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 3 COMPONENTS Illustrations are listed for each component The in formation necessary for repair work tightening torque grease up points etc is described on these illustrations Information is described using symbol To order the parts refer to parts catalogue HU 2 How to Use This Manual HOW TO USE THIS MANUAL Example
46. SOHC model with catalytic converter CHAMPION RC8YC4 NGK BKR6E 11 Alternate 1 6 L SOHC model without catalytic convert er NGK BKR6E 2 0 and 2 5 L SOHC model with catalytic con verter CHAMPION RC10YC4 NGK BKR5E 11 Alternate 2 0 SOHC model without catalytic converter NGK BKR6E 6 Tighten the spark plug lightly with hand and then secure with a plug wrench to the specified torque Tightening torque 21 N m 2 1 kgf m 15 2 ft Ib NOTE Be sure to place the gasket between the cylinder head and spark plug f a torque wrench is not available tighten the spark plug until gasket contacts cylinder head then tighten further 1 4 to 1 2 turns 2 DOHC MODEL 1 Disconnect the battery cables and then remove the battery and battery carrier 2 Remove the washer tank and put it aside 3 Remove the air cleaner lower case 4 Disconnect the connector from ignition coil 5 Remove the ignition coil PM 00145 6 Remove the spark plug with a spark plug socket PM 001 12 7 Set new spark plugs Recommended spark plug 2 0 L DOHC Turbo model NGK PFR6G 8 Tighten the spark plug lightly with hand and then secure with a plug wrench to the specified torque Tightening torque 21 N m 2 1 kgf m 15 2 ft Ib 9 Tighten the ignition coil Tightening torque 16 N m 1 6 kgf m 11 7 ft Ib NOTE Be sure to place the gasket between the
47. SUBARU IMPREZA 2004 Model Year PDF Service Manual GENERAL INFORMATION SECTION Pub No G1870GE1 ENGINE SECTION 1 Pub No G1870GE2 ENGINE SECTION 2 Pub No G1870GE3 TRANSMISSION SECTION Pub No G1870GE4 CHASSIS SECTION Pub No G1870GE5 BODY SECTION Pub No G1870GE6 WIRING SYSTEM SECTION Pub No G1870GE7 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION SECTION This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition When replacement of parts during repair work is needed be sure to use SUBARU genuine parts All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval FUJI HEAVY INDUSTRIES LTD FOREWORD HOW TO USE THIS MANUAL SPECIFICATIONS PRECAUTION NOTE IDENTIFICATION ID RM RECOMMENDED MATERIALS PRE DELIVERY INSPECTION PI PERIODIC MAINTENANCE SERVICES PM G1870GE1 FOREWORD Foreword FO
48. Set the child safety lock on both rear doors to the lock positions 2 Close the rear doors completely 3 Check that the lock levers of the rear doors are in the unlock positions Then pull the inner remotes of the rear doors to ensure that the doors will not open PRE DELIVERY INSPECTION 4 Next pull the outside door handles of the rear doors to ensure that the doors will open 00084 A Unlock B Lock C Child safety lock 8 CHECK THE TRUNK LID FOR OPEN CLOSE OPERATIONS 1 Operate the trunk lock release lever and verify that the trunk lid opens 2 Using the key open the trunk lid several times to check for normal operation 3 Open and close the trunk lid several times for smooth movement PI 00144 4 Set the trunk lid release lever to the cancel posi tion and check that the trunk lid can only be opened with the key 00149 Pre delivery Inspection PRE DELIVERY INSPECTION 9 CHECK THE REAR GATE FOR LOCK UNLOCK AND OPEN CLOSE OPERATIONS 1 Open and close the rear gate several times for smooth movement 2 Operate the rear gate lever to check that the rear gate is locked and unlocked normally 1 Remove the blind cover inside the rear gate o 00147 2 Check that the rear gate is locked correctly when lever is operated using a finger
49. V 48AH 55D23L AT 12V 52AH 65D23L 12V 48AH 55D23L For Australia 12V 27AH 84B19L 12V 40AH 50D20L 12V 27AH 34B19L 12V 40AH 50D20L Others 12V 27AH 34B19L SPC 3 Impreza SPECIFICATIONS D TRANSMISSION Model Non turbo 2 0 L Turbo 2 0L Transmission type 5MT 4AT 5MT 4AT Clutch type DSPD TCC DSPD TCC G ti 1st 3 454 PS 3 454 2 785 1 3 166 2nd eae 1 947 1 882 1 3rd 1 366 1 448 1 000 1 296 4th 1 088 0 694 0 972 0 694 5th 2 785 1 545 1 000 0 825 0 738 6th Reverse Dual range Reduction 1st Type of gear Front reduction gear drive Gear ratio Final Type of reduction gear Gear 4444 m 3 900 4 111 j 3 900 4 444 1 Helical Helical Helical Helical 1 000 1 000 1 000 1 000 Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid 4 444 4 111 4 111 3 900 Reduction Transfer Type of gear Rear reduction gear drive Gear 1 100 1 100 QUE 1 000 1 000 1000 1 1 000 1 000 1 Helical Helical Helical Helical Helical Final Type of reduction gear Gear 431 3 545 Ta 3 545 ratio 3309 4 444 1 3 900 Hypoid Hypoid Hypoid Hypoid Hypoid 5MT 5 forward speeds with synchromesh and 1 reverse 4AT Electronically controlled fully automatic
50. ag Rear spoiler Q A C Sunroof Airbag Audio Rear spoiler R A C Airbag Rear spoiler S A C Airbag Audio T A C Sunroof Airbag Side airbag Leather seat amp door trim decorative woodturning Audio U A C Sunroof Airbag Side airbag V A C Sunroof Airbag Side airbag Leather seat amp door trim decorative woodturning W A C Sunroof Airbag Rear spoiler Y A C Sunroof Airbag Side airbag Audio Z A C Sunroof Airbag Side airbag Leather seat amp door trim decorative woodturning Rear spoiler 1 Special edition model 2 Special edition model 3 Special edition model ID 8 RECOMMENDED MATERIALS HM Page 1 Recommended Materials aan eem 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 a substitute of equivalent quality 2 FUEL Always use a gasoline of the same or higher octane value than specified in the owner s manual 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 Model Pe
51. ally 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 e Check the window glass door glass and lights 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 tires for damage abnormal condi tions and dents on the wheels Check the tire size spare tire and tire air pres sure described on the tire air pressure label driv er s side 3 FUSE INSTALLATION A vehicle just delivered has no fuse for the back up circuit to prevent battery discharge Attach a 15 A fuse A as shown in the figure 5 y LEE III mi y A pi 00001 4 CONNECTION 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 00139 5 CHECK THE DOORS FOR LOCK UN LOCK AND OPEN CLOSE OPERATIONS 1 Using the key lock and unlock the door several times to check for normal operation Open and
52. and measure the distance between brake pedal and steering wheel With the brake pedal released measure the dis tance between pedal and steering wheel again The difference between the two measurements must be less than specified value If the distance is more than specified there is possibility of air inside the hydraulic unit Brake pedal reserve distance A 90 mm 3 54 in 490 N 50 kgf 110 Ib or less PM 00045 A Steering wheel B 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 the pedal height should not change 4 Check valve is built into the vacuum hose Dis connect the vacuum hose to inspect function of check valve Blow air into the vacuum hose from its brake boost er side end Air must flow out of engine side end of hose Next blow air into the hose from engine side Air
53. ansmission Transmission type Y Full time AWD MT center differential V Full time AWD AT center differential Z Full time AWD AT MPT M FWD MT A FWD AT Classification 75 SMT 85 eMT 1A AT 1B AT Series MT 4 SMT 6 6MT AT 4 AT Transmission specifica tions A FWD 4 speed AT R FWD Single Range 5 speed MT V Full time AWD 5 speed MT with viscous coupling center dif ferential single range W Full time AWD 6 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 Rear differential 1 VA type Reduction gear ratio Used when ordering parts See the parts catalog for details Rear differential 2 T type Reduction gear ratio No SURETRAC Viscous Viscous SURETRAC SURETRAC Mechanical Mechanical ID 6 Identification IDENTIFICATION Option code E2BL Meaning Details Destination EC Europe model LHD model EK Europe model RHD model EH China model KS Middle East model K4 Central and South America model KA Australia model E2 Israel model KO General model LHD model K1 General model RHD model Blank Hong Kong model Option equipment A Power window Power door lock ABS Alu
54. ck that no leaks are found Then add the necessary amount of washer fluid commercially available Reservoir tank MIN level MAX level 8 21 HOOD LATCH CHECK Retract the hood stay and close the hood Check that the hood is securely latched 22 KEYLESS ENTRY SYSTEM Check the keyless entry system operations as fol lows e Remove the key from the ignition switch and close all the doors including rear gate wagon mod el Press the LOCK button on the transmitter mo mentarily once and check that all the doors are locked and the hazard light flashes once PI 00108 F DD 00109 Press the OPEN button on the transmitter mo mentarily once and check that all doors are un locked the hazard light flashes twice and the interior 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 23 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 24 SEAT BELT Pull out the seat belt and then release it Check that the belt webbing retracts smoothly Pre delivery Inspection 25 WHEEL ALIGNMENT Check the wheel alignments Ref to FS 6 Wheel Alignment and Ref to RS 10 Wheel Align
55. cle identification number side Except Australia model Australia turbo model VIN 5 Saudi Arabia plate Saudi Arabia Emission control label ENGINE model Built date plate Australia model AUTOMATIC TRANSMISSION 10 00053 10 00054 1 Engine serial number Transmission serial number 1 ID 2 Identification IDENTIFICATION MANUAL TRANSMISSION 10 00055 1 Transmission serial number MODEL NUMBER PLATE REAR DIFFERENTIAL T type RES ze ID 00056 1 Type white paint e VA type DI 00396 1 Type label FUJI HEAVY INDUSTRIES LTD U x eae 9 0 0 c 2 77251 FTN TJvava FE Applied model G D 4 D L 3 G Option CODE E W 0 2 net 7 0 ET 1 6 1 RWS PID 0 B X A TM7 5 4RY 5 Transmission type O12 Liisa Engine type niea COLOR CODE 2 10 00075 10 3 Identification IDENTIFICATION 2 MEANING OF V I N The meaning of the VIN is as follows Europe Australia and General Except GCC JF1GD4LG94G002001 The starting and ending brackets are stop marks Details JF1 Passenger car FHI made IMPREZA D 4 Door Seda
56. close the door several times for smooth movement Ni c 1 00140 2 Close the driver s door completely and place the door lock knob A to the lock position Then pull in ner remotes B to ensure that doors will not open For other doors place the door lock knob A to the lock positions and then pull the inner remote to en sure that the doors will not open e p PI 00004 A Unlock B Lock A Door lock knob B Inner remote 3 Press the driver s side power door lock switch to lock side Check that all doors including rear gate are locked 00142 Pre delivery Inspection 4 Press the driver s side power door lock switch to unlock side Check that all doors including rear gate are unlocked 00143 6 CHECK DOUBLE LOCK OPERATION 1 Fully open all the windows 2 Remove the key 3 Lock all the doors using the door key cylinder or transmitter 4 Verify that all the doors including rear gate are not unlocked when pressing power door lock switch to unlock side 5 Verify that the door is not opened when operat ing door lock knob to unlock position and pulling in ner remote Perform the same check for other doors 6 Check that all the doors are unlocked when door is unlocked using door key cylinder or transmitter or ignition switch is turned to ON 7 CHECK THE OPERATION OF CHILD SAFETY LOCKS 1
57. code EC Model 2 0L Turbo AWD WRX 5MT Curb weight C W Front kgf Ib 840 835 1 852 1 840 Rear kgf Ib 570 565 1 257 1 246 Total kgf Ib 1 410 1 400 3 109 3 087 Maximum permissible Front kgf Ib 990 990 axle weight M P A W 2 185 2 185 Rear kgf Ib 920 920 2 028 2 028 Maximum permissible Total kgf Ib 1 850 1 850 weight M P W 4 079 Option Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Front LSD Driver s control center differential 1 For option code refer to ID section Ref to ID 7 Option code SPC 10 Impreza Option code SPECIFICATIONS Model 2 0 L Turbo AWD 5MT Curb weight C W Front kgf Ib 885 1 951 865 1 907 Rear kgf Ib 585 1 290 585 1 290 Total Ib 1 470 3 241 1 450 3 197 Maximum permissible Front kgf Ib 1 030 axle weight M P A W 2 271 1 030 2 271 Rear kgf Ib 920 2 028 920 2 028 Maximum permissible Total kgf Ib 1 880 weight M P W 1 880 Option Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Front LSD Driver s control center differential 1 For option cod
58. cyl inder Accelerator pedal Clutch pedal Brake pedal Clutch bearing Clutch release lever Steering shaft bear ing Steering gear box Valiant grease M 2 003608001 Disc brake Niglube RX 2 K0779GA102 Drum brake wheel cylinder Drum brake Molykote No 7439 003602001 Brake shoe Brake pad Molykote AS 880N K0777YA010 Front axle PTJ NSG301 28395AG020 Front axle EBJ NTG2218 M 28395FE010 Front axle BJ Rear axle EBJ Rear axle BJ Front axle DOJ NKG205 28395FE020 Rear axle DOJ Throttle cable end Silicolube G 30M 004404002 8 ADHESIVES Use the adhesives shown in the table below or equivalent Adhesive Application point Recommended Item number Alternative Adhesive Windshield rear window Dow Automotive s x glass rear quarter glass Adhesive Gurit ESSEX and body Betaseal 1502 or equivalent Glass primer Betawipe VP 04604 Betaprime 5001 Paint surface primer Betap rime 5402 Inner rearview mirror REPAIR KIT IN MR 65029 000 Soft vinyl Cemedine 540 3M s EC 776 EC 847 or EC 1022 Spray type Momentary sealant Cemedine 3000 Armstrong s Eastman 910 RM 6 Recommended Materials RECOMMENDED MATERIALS 9 SEAL MATERIAL Use seal material shown in the table below or equivalent Seal material Application point Recommended Item number Alternative Seal material Oylinder block Torque converter
59. cylinder head and spark plug f a torque wrench is not available tighten the spark plug until gasket contacts cylinder head then tighten further 1 4 to 1 2 turns PM 10 V belt 6 V belt A INSPECTION 1 Replace the belts if cracks fraying or wear is found 2 Check the V belt tension and adjust it if neces sary by changing the generator installing position and or idler pulley installing position Ref to PM 11 REPLACEMENT V belt gt Belt tension without belt tension gauge A When installing new one 7 9 mm 0 276 0 354 in At inspection 9 11 mm 0 354 0 433 in B When installing new one 7 5 8 5 mm 0 295 0 335 in At inspection 9 0 10 0 mm 0 354 0 394 in PM 00002 A Front side belt B Rear side belt C P Crankshaft pulley GEN Generator P S Power steering oil pump pulley A C Air conditioning compressor pulley VP Idler pulley PERIODIC MAINTENANCE SERVICES Belt tension with belt tension gauge A When installing new one 640 785 N 65 3 80 0 kgf 144 176 Ib At inspection 490 640 N 50 65 kof 110 144 Ib B When installing new one 620 760 63 77 kgf 140 170 Ib At inspection 350 450 N 36 46 kgf 79 101 Ib SA I AW A Front side belt B Rear side belt C P Crank pulley GEN Generator P S Power steering oil pump pulley A C A C compressor pulley VP Idler pulley B
60. diator cap tester NOTE Rust or dirt on the cap may prevent the valve from functioning normally be sure to clean the cap be fore testing Raise the pressure until the needle of gauge stops and see if the pressure can be retained for 5 to 6 seconds The radiator cap is normal if a pressure above the service limit value has been maintained for this period Radiator cap valve open pressure Non turbo model Standard value 93 123 kPa 0 95 1 25 kg cm 14 18 psi Service limit 83 kPa 0 85 kg cm 12 psi Turbo model Filler tank side Standard value 93 123 kPa 0 95 1 25 kg cm 14 18 psi Service limit 83 kPa 0 85 kg cm 12 psi Radiator side Standard value 122 152 kPa 1 24 1 55 kg cm 18 22 psi Service limit 112 kPa 1 14 kg cm 16 psi PM 00023 B A PM 00089 A Deformation B Deformation damage rust PM 19 Cooling System PERIODIC MAINTENANCE SERVICES 3 Start the engine and then check it does not overheat or it is cooled excessively If it overheats or it is cooled excessively check the cooling sys tem SOHC model Ref to CO H4SO 15 Water Pump Ref to CO H4SO 18 Thermostat Ref to CO H4SO 19 Radiator Ref to CO H4SO 22 Radiator Cap DOHC Turbo model Ref to CO H4DOTC Ref to CO H4DOTC Ref to CO HADOTO 23 Radiator Ref to CO H4DOTC 27 Radiator Cap 4 Ch
61. dily 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 regulations concerning disposal of refuse 7 AIRBAG MODULE Adhere to the following when handling and storing the airbag module to prevent bodily injury from un expected deployment Do not hold the harnesses or connectors to carry 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 recommended or alternative adhe sive when attaching glass to prevent it from coming loose and falling resulting in accidents and injury PC 2 NOTE lg ierat eene een Note NOTE 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 e
62. e refer to ID section Ref to ID 7 Option code SPC 11 SPECIFICATIONS Wagon Option code Impreza Model 5MT D R Curb weight C W Front kgf Ib 760 1 676 755 1 664 Rear kgf Ib 545 1 202 545 1 202 Total kgf Ib 1 305 2 877 1 300 2 866 Maximum permissible axle weight M P A W Front kgf Ib 900 1 984 900 1 984 Rear kgf Ib 910 2 006 910 2 006 Maximum permissible weight M P W Total kgf Ib 1 730 1 609 1 730 1 609 Option Air conditioner O O ABS O Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Spoiler pack 1 For option code refer to ID section lt Ref to ID 7 Option code gt D R Dual range SPC 12 Option code Impreza SPECIFICATIONS Model GX 5MT D R Curb weight C W Front kgf Ib 760 1 676 785 1 731 780 1 720 Rear kgf Ib 570 1 257 585 1 290 570 1 257 Total kgf Ib 1 330 2 932 1 370 3 020 1 350 2 977 Maximum permissible axle weight M P A W Front kgf Ib 950 2 094 950 2 094 950 2 094 Rear kgf Ib 960 2 0116 960 2 116 960 2 116 Maximum permissible weight M P W Total kgf Ib 1 800
63. e on level gauge by using the gauge hole Recommended fluid Dexron Ill type automatic transmission fluid Fluid capacity Fill the same amount drained from ATF drain plug hole PM 28 ATF PERIODIC MAINTENANCE SERVICES 4 Check the ATF level Ref to PM 28 INSPEC TION ATF gt O7 B 0 PM 00191 A Level gauge B ATF level range at HOT 70 80 C 158 176 F C Upper level D Lower level E ATF level range at COLD 20 30 C 68 86 2 ATF FILTER NOTE ATF filter is a maintenance free part ATF filter needs replacement when it has physically dam aged or ATF leaked For the replacement procedures of the ATF filter Ref to 4AT 73 ATF Filter PM 29 Front amp Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES 18 Front amp Rear Differential Gear Oil A REPLACEMENT 1 FRONT DIFFERENTIAL MT MODEL Differential oil works as manual transmission oil to lubricate differential Refer to Transmission Oil Ref to PM 26 Transmission Gear Oil 2 FRONT DIFFERENTIAL AT MODEL 1 Drain the differential gear oil by removing drain plug using TORX NOTE Before starting work cool off the differential gear oil well e f front differential gear oil adheres to the exhaust pipe wipe it off completely LAUS V PM 00157 2 Replace the gasket with a new one and then tighten the
64. eck that the window washer system operates normally 36 Wiper Check that the wiper system operates normally 37 Power window operation check Check the power window for normal operations 38 Sunroof Check that the sunroof operates normally 39 Door mirror Check that the remote control mirror operates normally DYNAMIC TEST WITH VEHICLE RUNNING PROCEDURE Check point 40 Brake test Check the foot brake for normal operations 41 Parking brake Check the parking brake for normal operations 42 AT shift control Check that the AT shift patterns are correct 43 Heater amp ventilation Check that the heater amp ventilation system operates normally 44 Air conditioner Check that the air conditioner operates normally 45 Cruise control Check that the cruise control system operates normally CHECKS AFTER DYNAMIC TEST PROCEDURE Check point 46 ATF level Check that the ATF level is correct 47 Power steering fluid level Check that the power steering fluid level is normal 48 Fluid leak check Check for fluid oil leaks 49 Water leak test Spray the vehicle with water and check for water leaks 50 Appearance check 2 1 Remove the protective coating if any 2 Check the body paints for damage and stain 3 Check the plated parts for damage and rust PI 3 Pre delivery Inspection PRE DELIVERY INSPECTION 1 APPEARANCE CHECK f the vehicle is covered with protective coating visu
65. eck the electric fan operates using Subaru Select Monitor when the coolant temperature ex ceeds 95 C 203 F If not operate check the elec tric fan system SOHC model Ref to CO H4SO 6 Radiator Main Fan Sys tem Ref to CO H4SO 9 Radiator Sub Fan System DOHC Turbo model Ref to CO HADOTO 8 Radiator Main Fan Sys tem Ref to CO HADOTO 13 Radiator Sub Fan Sys tem 20 Water Pump 22 Thermostat Sa ws PM 20 Coolant PERIODIC MAINTENANCE SERVICES 12 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 the under cover 3 Place a container under drain pipe 4 Loosen and remove the drain cock to drain en gine coolant into container 3 CO 00009 5 For quick draining open the radiator cap NOTE Be careful not to spill coolant on the floor 6 Drain the coolant from reservoir tank 7 Tighten the radiator drain cock securely after draining coolant 8 Pour the coolant to the filler neck of filler tank and then pour into reservoir tank up to FULL level Turbo model 9 Pour the coolant from radiator filler port to neck of filler then pour into reservoir tank up to FULL level Non turbo model Coolant capacity fill up to FULL level 1 6 L AT m
66. er damage If the inside surface of disk rotor is streaked correct the surface with emery cloth 200 or more If it is unevenly worn or tapered correct or replace it PM 36 Brake Linings and Drums Brake drum inside diameter Except for STi model Standard value 170 mm 6 69 in Wear limit 171 mm 6 73 in STi model Standard value 190 mm 7 48 in Wear limit 191 mm 7 52 in el PM 00055 LE A Inside diameter B Disk 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 B 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 the parking brake after bleeding air 1 Remove the rear cover rubber installed at back plate 2 Turn the adjuster toward arrow mark upward until it is locked slightly by using a flat tip screwdriv er as shown in illustration PM 00056 A Adjuster B Cover rubber C Back plate PERIODIC MAINTENANCE SERVICES 3 Turn back downward the adjuster 3 to 4 notch es 4 Install the cover rubber at original position cor rectly PM 37 Suspension PERIODIC MAINTENANCE SERVICES 23 Suspe
67. er plate indicates the applied model the option code the trim code the engine type the transmission type and the exterior color code This information is helpful when placing orders for parts GD9DL5R Meaning Details Series IMPREZA Body style 4 Door Sedan Wagon Engine displacement Drive system Suspension system 1 6L FWD 1 6L AWD 2 0 LAWD 2 0 LAWD Turbo 2 0 L AWD High power turbo 2 5 LAWD Model year 2004MY Destination Right hand drive model market Left hand drive model market Grade OUTBACK WRX STi Transmission fuel feed system The engine and transmission type are as follows Engine EJ161RW6AA Meaning SOHC MPI Dual range 5 speed MT SOHC MPI 5 speed MT SOHC MPI 4 speed AT DOHC B MPI 4 speed AT Sport Shift SOHC MPI 5 speed MT AWD D DOHC B MPI 5 speed MT AWD H DOHC B MPI 6 speed MT AWD SADODAMONOARO TADMBEOAROD Details Engine type EJ 4 cylinders Displacement 16 1 6L 20 2 0L 25 2 5L Fuel feed system 1 D MPI SOHC A 5 MPI Turbo 7 MPI High power 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 Transmission TM754RY5AA Meaning Details Transmission T Tr
68. f Ib Option 1 For option code refer to ID section Ref to ID 7 Option code Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Spoiler pack Front LSD Cruise control SPC 17 SPECIFICATIONS Option code Impreza EK Model 2 0L Turbo AWD WRX 5MT Curb weight C W Front kgf Ib 835 1 841 840 1 852 Rear kgf Ib 560 1 246 570 1 257 Total kgf Ib 1 395 3 075 1 410 3 109 Maximum permissible axle weight M P A W Front kgf Ib 990 2 183 990 2 183 Rear kgf Ib 920 2 028 920 2 028 Maximum permissible weight M P W Total kgf Ib 1 850 1 850 4 079 Option Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Spoiler pack Front LSD Cruise control 1 For option code refer to ID section Ref to ID 7 Option code SPC 18 Impreza SPECIFICATIONS Option code Model 2 0 L Turbo WRX 5MT Unladen weight U W Front kg Ib 840 835 1 852 1 841 Rear kg Ib 575 560 1 268 1 235 Total kg Ib 1 415 1 395 3 120 3 075 Gross vehicle mass Front kg Ib 990 990 G V
69. gh accuracy 32 AUDIO Check if the radio for functions fully speaker emitts sound normally and noise level is normal Also check the CD MD unit operations 33 FRONT ACCESSORY POWER SUPPLY SOCKET Check the front accessory power supply socket op erations 34 LIGHTING SYSTEM Check the headlight operations Check the stop light operations Check the other lights for normal operations 35 WINDOW WASHER Check that the window washer system injects washer fluid to the specified area of windshield shown in the figure Front injection position A 350 mm 13 78 in B 162 mm 5 91 in C 300 mm 11 81 in D 500 mm 23 62 in PI 00121 PI 9 Pre delivery Inspection PRE DELIVERY INSPECTION Rear injection position A 39 mm 2 36 in B 72 A PI 00104 36 WIPER Check the front and rear wipers for normal opera tions 37 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 38 SUNROOF Check that the sunroof operates normally 39 DOOR MIRROR Check that the remote control mirror operates nor mally 40 BRAKE TEST Check the foot brake for normal operations 41 PARKING BRAKE Check the parking brake for normal operations When applying the parking brake with force of 196 N 20 kgf 44 Ib check that the lever stroke of park ing
70. he water has been applied carefully check all areas that may have possibly contributed to the leak 50 APPEARANCE CHECK 2 1 Check the paint after removing the paint protec tive coating and washing the vehicle NOTE Use of steam eases peeling off the warp guard When performing on the vehicles left for a long time or during low temperature period sprinkle some water heated to 50 60 C 122 140 F over the vehicle to raise its surface temperature be fore peeling off the wrap guard Do not use the water heated to over 60 C 140 F e f the adhesive remains on the coated surface rub the portion with a flannel rag etc soaked with a coat of coating wax or a solvent such as oil ben zene and IPA and then wipe it off Avoid adhesion of the solvent to resin or rubber components Do not use coating wax or a solvent while the component surface temperature is high due to hot weather etc PI 11 Pre delivery Inspection PRE DELIVERY INSPECTION f the coated surface is swollen out due to seams or moisture expose the vehicle to the sun light for a few hours Otherwise heat the portion with seams or moisture using a dryer etc Dispose ofthe peeled wrap guard as burnable in dustrial garbage 2 Check the whole vehicle body for stains flaking damage caused by transportation rust dirt cracks or blistering NOTE t is better to determine an inspection pattern in order to avoid missing an a
71. hicle is used in extremely dusty conditions the air cleaner element should be replaced more often 2 ATF filter is a maintenance free part ATF filter needs replacement when it is physically damaged or ATF leaked PM 3 Schedule PERIODIC MAINTENANCE SERVICES 2 EXCEPT FOR EUROPE AREA For periodic maintenance of over 50 000 km 30 000 miles or 48 months carry out inspections by referring to the following tables For a maintenance period gone beyond these tables apply them repeatedly as a set of 50 000 km 30 000 miles or 48 months Maintenance Interval Number of months or km miles whichever occurs first Months 12 24 36 48 Remarks x 1 000 km 12 5 25 37 5 50 x 1 000 miles 7 5 15 22 5 30 Engine oil R R R R Engine oil filter R R R R 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 12 24 36 48 Remarks x 1 000 km 1 6 25 50 75 100 x 1 000 miles 1 15 30 45 Spark plugs For Turbo Others R R Drive belt s Camshaft drive belt Fuel line Fuel filter Air cleaner element Cooling system Coolant Idle mixture D D D D
72. id filled bushing If oil leaks replace the bushing PM 00060 A Rear bushing B Transverse link 3 WHEEL ARCH HEIGHT 1 Unload cargoes and set the vehicle in curb weight empty condition 2 Then check the wheel arch height of front and rear suspensions to ensure that they are within specified values Ref to FS 6 Wheel Alignment 3 When the wheel arch height is out of standard visually inspect the following components and re place deformed parts e Suspension components Front strut assembly and rear shock absorber assembly Parts connecting between suspension and body 4 When no components are deformed adjust the wheel arch height by replacing coil spring in the suspension which wheel arch height is out of stan dard Ref to FS 6 Wheel Alignment Ref to RS 10 Wheel Alignment PM 38 Suspension PERIODIC MAINTENANCE SERVICES 4 WHEEL ALIGNMENT OF FRONT SUS PENSION 1 Check the alignment of front suspension to en sure that following items conform to standard val ues Toe in Camber angle Caster angle e Steering angle Ref to FS 6 Wheel Alignment 2 When the caster angle does not conform to ref erence visually inspect the following components and replace deformed parts e Suspension components Strut assembly cross member transverse link etc Body parts to which suspensions are installed 3 When the toe in and camber are out of standard va
73. isually inspect the bleeder screws and brake pipe joints to make sure that there is no fluid leakage 12 Install the wheels and drive the vehicle for a short distance between 2 to 3 km 1 to 2 miles to make sure that brakes are operating properly PM 34 Disc Brake Pads and Discs PERIODIC MAINTENANCE SERVICES 21 Disc Brake Pads and Discs A INSPECTION 1 DISC BRAKE PAD AND DISC 1 Jack up the vehicle and support with rigid racks Then remove the wheels 2 Visually check the pad thickness through inspec tion hole of disc brake assembly Replace the pad if necessary NOTE When replacing a pad always replace the pads for both the right and left wheels at the same time Also replace the pad clips if they are twisted or worn PM 00049 A Inspection hole Front Pad thicknessmm in 14 15 inch 16 inch 17 inch 14 15 inch 16 inch 17 inch 11 0 43 10 0 39 9 2 0 36 1 5 0 059 1 5 0 059 1 2 0 047 Standard Service limit Rear Pad thicknessmm in 14 inch 15 inch 9 0 35 11 5 0 45 17 inch 9 0 35 14 inch 1 5 0 059 15 inch 1 5 0 059 17 inch 1 2 0 047 Standard Service limit PM 00140 A Thickness of pad B Back metal C Lining 3 Check the disc rotor and correct or replace if it is damaged or worn e Front Disc rotor thicknessmm in 14 15
74. located mostly internally so check pipes areas near pipes and engine compartment piping for rust hose damage loose bands etc If faulty parts are found repair or replace them SOHC model Ref to FU H4SO 63 Fuel Delivery Return and Evaporation Lines DOHC Turbo model Ref to FU H4DOTC 69 Fuel Delivery Return and Evaporation Lines PM 16 Fuel Filter 9 Fuel Filter A REPLACEMENT For fuel filter replacement procedures refer to FU section SOHC model Ref to FU H4SO 60 Fuel Filter DOHC Turbo model Ref to FU H4DOTC 66 Fuel Filter B INSPECTION 1 If it is clogged or if replacement interval has been reached replace it 2 If water is found in it shake and expel the water from inlet port PM 17 PERIODIC MAINTENANCE SERVICES Air Cleaner Element PERIODIC MAINTENANCE SERVICES 10 Air Cleaner Element A REPLACEMENT 1 NON TURBO MODEL 1 Remove the air intake duct from air cleaner case 2 Remove the bolt A which installs air cleaner case to stays 3 Remove the clip B above the air cleaner case 5 FE CA Cy e ZA 2 VTS IN 00039 4 Remove the air cleaner _ mn ed NS e Q 0 o HIS ENS LA acea JF PM 00142 5 Install in the reverse order of removal NOTE Fasten with a clip after inserting the l
75. lue adjust them so that they conform to respec tive service standard 4 When the right and left turning angles of tire are out of standard adjust to standard value 5 WHEEL ALIGNMENT OF REAR SUS PENSION 1 Check the alignment of rear suspension to en sure that following items are within standard val ues Toe in Camber angle Thrust angle Ref to RS 10 Wheel Alignment 2 When the camber angle does not conform to ref erence visually inspect parts listed below If defor mation is observed replace the damaged parts e Suspension components Shock absorber link F link R link UPR arm R sub frame etc Body parts to which suspensions are installed 3 When the toe in and thrust angle are out of stan dard value adjust them so that they conform to re spective service standard 6 OIL LEAKAGE OF STRUT Visually inspect the front strut and rear strut for oil leakage as instructed Replace front strut and rear strut if oil leaks excessively 7 TIGHTNESS OF BOLTS AND NUTS Check the bolts and nuts shown in the figure for looseness Retighten the bolts and nuts to speci fied torque If the self lock nuts and bolts are re moved replace them with new ones Front suspension Ref to FS 2 General Descrip tion Rear suspension Ref to RS 2 General Descrip tion 8 DAMAGE TO SUSPENSION PARTS 1 Check the following parts and the fastening por tion of the vehicle body for deformation
76. minum wheel B Power window Power door lock C Power window Power door lock Cruise control ABS Alumi num wheel D Power window Power door lock Cruise control ABS Front LSD Driver s control center differential E Power window Power door lock ABS F Power window Power door lock Cruise control ABS L Power window Power door lock ABS Roof rail Aluminum wheel M Power window Power door lock ABS Roof rail N Power window Power door lock Cruise control ABS Roof rail O Power window Power door lock Cruise control ABS Roof rail Aluminum wheel P Power window Power door lock Aluminum wheel Q Power window Power door lock Aluminum wheel R Power window Power door lock Roof rail Aluminum wheel T Power window Power door lock Cruise control ABS Front LSD V Power window Power door lock ABS Front LSD Y Power window Power door lock ABS Front LSD Driver s control center differential 6 Special edition model ID 7 Identification IDENTIFICATION Meaning Details Option equipment B A C Airbag Spoiler package C A C Airbag Rear spoiler F A C Airbag Sunroof G A C Airbag Side airbag I A C Airbag Audio Rear spoiler J A C Airbag Spoiler package Rear spoiler K Airbag Side airbag Audio L A C Airbag M Airbag O A C Sunroof Airbag Side airbag Leather seat amp door trim decorative woodturning Audio Rear spoiler P A C Sunroof Airbag Side airb
77. move the under cover 2 Remove the oil filter with ST ST 498547000 OIL FILTER WRENCH Outer diameter 80 mm 3 15 in ST 18332AA000 OIL FILTER WRENCH Outer diameter 68 mm 2 68 in ST 18332AA010 OIL FILTER WRENCH Outer diameter 65 mm 2 56 in e SOHC MODEL duc Sie LU 00190 3 Get a new oil filter and apply a thin coat of engine oil to the seal rubber 4 Install the oil filter by turning it by hand being careful not to damage the seal rubber 5 Tighten more approx 1 turn for outer diameter 68 mm 2 68 in oil filter and 2 3 to 3 4 turn except for outer diameter 68 mm 2 68 in oil filter after the seal rubber contacts the cylinder block Do not tighten excessively or oil may leak 6 After installing the oil filter run the 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 7 Check the engine oil level lt Ref to PM 8 IN SPECTION Engine Oil gt PM 9 PERIODIC MAINTENANCE SERVICES Spark Plugs PERIODIC MAINTENANCE SERVICES 5 Spark Plugs A REPLACEMENT 1 SOHC MODEL 1 Remove the intake duct and intake chamber Remove the washer tank and put it aside Disconnect the spark plug cord 2 3 4 Remove the spark plug with a plug wrench CS ESE 5 Set the new spark plugs Recommended spark plug 1 6 L
78. mp qt 4 0 4 2 3 5 4 5 4 8 4 0 4 0 4 2 3 5 50 13 2 11 0 60 15 9 13 2 Engine 0 US gt oil Imp qt amount for refill Transmission Q US qt 3 5 gear oil Imp qt 3 7 5 3 1 4 0 4 2 3 5 1 Approx 4 0 4 2 3 5 8 4 8 9 7 4 Front differential 1 2 gear oil 1 3 1 1 Rear differential gear oil 0 8 0 8 0 7 Power steering fluid Engine coolant 0 7 0 7 0 6 1 Dual range SPC 5 Impreza SPECIFICATIONS J WEIGHT 1 LHD MODEL Sedan Option code Model Curb weight C W Front kgf Ib Rear kgf Ib Total kgf Ib Maximum permissible Front kgf Ib axle weight M P A W Rear kgf Ib Maximum permissible Total kgf Ib weight M P W Option Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Front LSD Driver s control center differential 1 For option code refer to ID section Ref to ID 7 Option code SPC 6 Impreza SPECIFICATIONS Option code Model Curb weight C W Front kgf Ib Rear kgf Ib Total kgf Ib Maximum permissible Front kgf Ib axle weight M P A W Rear kgf Ib Maximum permissible Total kgf Ib weight M P W Option Air conditioner ABS Side ai
79. n G Wagon 1 6 L FWD 1 6 L AWD 2 0 L AWD 2 0 L AWD Turbo 2 0 L AWD High power turbo 2 5 L AWD RHD Right hand drive model LHD Left hand drive model SOHC MPI 5 speed MT SOHC MPI 4 speed AT SOHC MPI Full time AWD 5 speed MT SOHC MPI Full time AWD 5 speed MT Dual range DOHC Turbo Full time AWD 5 speed MT DOHC Turbo Full time AWD 6 speed MT DOHC Turbo 4 speed AT Sport Shift Full time AWD Single range Full time AWD Dual range AWD AT FWD PIOTMROATOAGSCIOA CA 2004MY G FHI Gunma Meaning Manufacturer body area Car line Body type Displacement Steering position Engine amp transmission Drive type 10 4 Model year 11 G Factory location 12 to 17 002001 Serial number GCC countries Saudi Arabia etc JF1GD45MX4G002001 The starting and ending brackets are stop marks Meaning Details Manufacturer body area JF1 Passenger car FHI made Car line IMPREZA Body type D 4 Door Sedan G Wagon Displacement 4 1 6 LAWD 8 2 0 L AWD Grade 5 TS 7 GX Restraint M Manual belts dual airbag Check digit 0to9g amp X Model year 4 2004MY Transmission type 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 Serial number 12 to 17 ID 4 Identification IDENTIFICATION 3 MODEL NUMBER PLATE The model numb
80. nsion A INSPECTION 1 SUSPENSION BALL JOINT 1 Jack up the vehicle until front wheels are off ground 2 Next grasp the bottom of tire and move it in and out If relative movement B is observed between the brake disc cover A and end of transverse link D ball joint C may be excessively worn PM 00057 3 Next grasp the end of transverse link and move it up and down Relative movement A between the housing D and transverse link C boss indi cates ball joint B may be excessively worn PM 00058 4 If relative movement is observed in the immedi ately preceding two steps remove and inspect the ball joint If free play exceeds standard replace the ball joint Ref to FS 18 Front Ball Joint 5 Damage of dust seal Visually inspect the ball joint dust seal If it is dam aged remove the transverse link Ref to FS 15 Front Transverse Link And measure free play of ball joint Ref to FS 18 Front Ball Joint 1 When looseness exceeds standard value replace the ball joint 2 If the dust seal is damaged replace with the new ball joint NOTE When the transverse link ball joint has been re moved or replaced check the toe in of front wheel If the front wheel toe in is not at specified value ad just the toe in Ref to FS 6 Wheel Alignment PM 00059 A Dust seal 2 TRANSVERSE LINK S REAR BUSHING Check oil leaks at around liqu
81. odel Approx 7 3 0 7 7 US qt 6 4 Imp qt 1 6 L MT model Approx 7 4 0 7 8 US qt 6 5 Imp qt 2 0 L Non turbo AT model Approx 6 9 0 7 3 US qt 6 1 Imp qt 2 0 L Non turbo MT model Approx 7 0 0 7 1 US qt 6 2 Imp qt 2 0 L Turbo AT model Approx 7 6 0 8 0 US qt 6 7 Imp qt 2 0 L Turbo MT model Approx 7 7 0 8 1 US qt 6 8 Imp qt 2 5 L AT model Approx 6 9 0 7 3 US qt 6 1 Imp qt 2 5 L MT model Approx 7 0 0 7 4 US qt 6 2 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 10 Securely install the radiator cap 11 Run the engine for more than 5 minutes at 2 000 to 3 000 rpm Run the engine until radiator becomes hot in order to purge the air trapped in cooling system 12 Stop the engine and wait until coolant temper ature lowers Then open the radiator cap to check coolant level and add coolant up to radiator filler neck or filler tank filler neck Next add coolant into reservoir tank up to FULL level 13 After adding coolant securely install the radia tor and reservoir tank caps PM 21 Coolant PERIODIC MAINTENANCE SERVICES 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 Meas
82. ok or vehicle Do not tow other vehicles with a front hook for tie down Make sure the vehicle towing is heavier that the vehicle being towed Front NT 00066 Rear 7 22 221 ERE Pe Em NT 00067 NT 6 Note NOTE NOTES Towing Notes Lifting up four wheels On a trailer g NT 00023 Towing the vehicle after lifting up all four wheels is a basic rule for AWD model 50 NT 00024 Check if both front and rear wheels are rotated nor mally AT model driving conditions Allow driving speed less than 30 km h 19 MPH Allow driving distance less than 30 km 19 miles Raising the front wheels T NT 00025 Prohibited for full time AWD model Lifting up the front wheels TG NT 00026 Prohibited due to damage on bumper front grille etc Do not raise the vehicle with bumper Marked O OK Marked X Prohibited Marked A Conditionally OK NT 7 Note NOTE CAUTION Check ATF gear oil and rear differential oil before driving Place the shift lever in N position during towing Do not lift up the rear wheels to avoid unsteady rotation Turn the ignition key to ACC then check the steering wheel moves freely Release the parking brake to avoid tire dragging Since the power steering does not work be careful for the heavy steering effort When engine is stopped
83. operly A When the hill holder is released later than en gagement of clutch engine tends to stall Loos en the adjusting nut gradually until smooth starting is enabled B When the hill holder is released earlier than engagement to clutch vehicle slips down slight ly Tighten the adjusting nut so that hill holder is released later than engagement of clutch status in A Then make adjustment the same as in A NOTE Whenever turning the adjusting nut hold the in ner cable with pliers to prevent it from turning Replace the pressure hold valve PHV or PHV cable with a new one if they are defective and or damaged PM 00077 A Lock nut B Adjusting nut C Pressure hold valve PM 27 ATF PERIODIC MAINTENANCE SERVICES 17 ATF A INSPECTION CAUTION The level of ATF varies with fluid temperature Pay attention to the fluid temperature when checking ATF level 1 Raise the ATF temperature by driving a distance of 5 to 10 km 3 to 6 miles Otherwise idle the en gine to raise ATF temperature to 70 80 C 158 176 F on Subaru Select Monitor Ref to 4AT diag 21 READ CURRENT DATA OPERA TION Subaru Select Monitor 2 Make sure the vehicle is level 3 After selecting all positions P R N D 3 2 1 set the select lever in P range Measure the ATF level with the engine idling for one or two minutes 6 0 00191 A Level gauge
84. or exces sive rusting which impairs the suspension If necessary replace the damaged parts with new ones If minor rust formation pitting etc are noted remove the rust and apply remedial anti corrosion measures Front suspension Transverse link Crossmember e Strut Rear suspension Crossmember ateral links e Trailing link e Strut 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 39 Wheel Bearing PERIODIC MAINTENANCE SERVICES 24 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 the front wheel by hand swing it in and out to check bearing free play 3 Loosen the wheel nuts and remove front wheel 4 If bearing free play exists in step 2 above at tach a dial gauge to the hub and measure axial dis placement in axial direction Service limit Straight ahead position within 0 05 mm 0 0020 in 5 Remove the bolts and self locking nuts and ex tract transverse link from front crossmember 6 Remove the SFJ of front drive shaft from trans mission Ref to DS 19 Front Axle 7 While supporting the front drive shaft horizontal ly with one hand turn the hub with the other to check for noise or binding If the hub is noisy
85. ower tab of the case 2 TURBO MODEL 1 Remove the clip B above the air cleaner case 2 Remove the air cleaner PM 00098 3 Install in the reverse order of removal NOTE Align the protruding portion of air cleaner upper cover with holes of air cleaner lower case then se cure upper cover to case PM 00100 PM 18 Cooling System PERIODIC MAINTENANCE SERVICES 11 Cooling System A INSPECTION 1 Check the radiator for leakage filling it with cool ant and attach the radiator cap tester A to filler neck Then apply a pressure Check the following points Non turbo model 157 kPa 1 6 kg cm 23 psi Turbo model 122 kPa 1 2 kg cm 18 psi Each portion of radiator for leakage Hose joints and other connections for leakage NOTE For turbo model be sure to install the tester to fill er tank side e When attaching or detaching tester and when operating tester use special care not to deform ra diator filler neck NON TURBO MODEL PM 00150 When performing this check be sure to keep the engine stationary and fill the radiator with coolant Wipe off check points before applying pressure Use care not to spill coolant when detaching the tester from radiator Do not remove the radiator side cap Turbo model 2 Check the radiator cap valve open pressure us ing ra
86. 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 repairing 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 7 HOSES OF OIL PUMP FOR DAMAGES Check the pressure hose and return hose of oil pump for crack swell or damage Replace the hose with a new one if necessary PM 44 Steering System Power Steering NOTE Prevent the hoses from revolving and or turning when installing hoses PM 00071 8 POWER STEERING PIPES FOR DAM AGE Check the power steering pipes for corrosion and damage Replace the pipes with a 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 C 2 Clips are fitted outside of A and B positions of boot 3 Boot does not have crack and hole NOTE Rotate B the position of gearbox boot against twist of it produced by adjustment of toe in etc TI PM 00090 10 FITTING BOLTS AND NUTS Inspect the fitting bolts and nuts of oil pump and bracket for looseness and retighten them if nece
87. rbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Front LSD Driver s control center differential 1 For option code refer to ID section Ref to ID 7 Option code SPC 7 Impreza SPECIFICATIONS Option code Model Curb weight C W Front kgf Ib Rear kgf Ib Total kgf Ib Maximum permissible Front kgf Ib axle weight M P A W Rear kgf Ib Maximum permissible Total kgf Ib weight M P W Option Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Front LSD Driver s control center differential 1 For option code refer to ID section Ref to ID 7 Option code SPC 8 Impreza SPECIFICATIONS Option code Model Curb weight C W Front kgf Ib Rear kgf Ib Total kgf Ib Maximum permissible Front kgf Ib axle weight M P A W Rear kgf Ib Maximum permissible Total kgf Ib weight M P W Option Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Front LSD Driver s control center differential 1 For option code refer to ID section Ref to ID 7 Option code SPC 9 Impreza SPECIFICATIONS Option
88. rea since the total in spection area is wide tis desirable not to make corrections to the body paint unless absolutely needed However if any corrections are required to remove scratches or rust the area to be corrected must be limited as much as possible Re painting and spray painting must be avoided whenever possible 3 Carefully check each window glass for scratch es Slight damage may be removed by polishing with cerium oxide Half fill a cup with cerium oxide and add warm water to it Then agitate the content until it turn to wax Apply this wax to a soft cloth and polish the glass 4 Check each portion of the vehicle body and un derside components for the formation of rust If rust is discovered remove it with 480 180 emery paper and treat the surface with rust preventive After this treatment is completed flush the portion thoroughly and prepare the surface for repair painting 5 Check each portion of the body and all of the chrome parts for deformation or distortion Also check each lamp lens for cracks 6 Peel the protective tape vinyl wrapping and identification seal attached to the following places Seat Door trim Floor carpet e Side sill Back of rear view mirror 12 PERIODIC MAINTENANCE SERVICES PM SE MO MIRO Po Po P PP PP aa SALGSSLSoOHBNSAR aNAS Page General Description sess 2 Sch d le 5 veter ict ead lee Bee EE e uec
89. right and left direc tions While the wheel is being rotated reach under the vehicle and check for looseness in gearbox Tightening torque 59 N m 6 0 kgf m 43 4 ft Ib S A 5 Geile La A Boot B Gear box mounting bolt PM 00067 2 Check the boot for damage cracks or deteriora tion 3 With the vehicle on a level surface quickly turn the steering wheel to the right and left While the 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 the adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft lb and then loosen Repeat this op eration twice PM 43 Steering System Power Steering PERIODIC MAINTENANCE SERVICES 2 Retighten the adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft lb and back off 25 3 Loosen the adjusting screw and apply liquid packing to at least 1 3 of entire perimeter of its thread PM 00068 A Apply liquid packing to at least 1 3 of entire perimeter 4 Tighten the adjusting screw to 7 4 N m 0 75 kgf m 5 4 ft lb and back off 25 5 Install the lock nut While holding the adjust ing screw with a wrench tighten the lock nut us ing ST ST 926230000 SPANNER Tightening torque Lock nut 39 N m 4 0 kgf m 29 ft Ib Hold the adjusting screw with a wrench to pre vent it from turning while tightening the lock nut 4 TI
90. rvoir tank rises or not NON TURBO MODEL PM 00075 A Release lever B Push rod C Operating cylinder PM 00101 A Release lever B Push rod C Operating cylinder 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 lt Ref to CL 40 Clutch Pedal gt 4 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 inspect the clutch master cylinder operating cylinder and hydraulic line for fluid leaks If fluid leaks are found repair or replace If fluid leaks are not found add clutch fluid to bring it up to MAX C of clutch reservoir tank PM 24 Clutch System Recommended clutch fluid FMVSS No 116 fresh DOT3 brake fluid CAUTION Prevent the clutch fluid from being splashed over vehicle body If the clutch fluid is splashed over vehicle body flush it and then wipe it up NOTE Avoid mixing different brakes of brake fluid to prevent degradation of the fluid Be careful not to allow dirt or dust to get into the reservoir tank di PM 00076 A Reservoir tank B MIN level C MAX level PM 25 PERIODIC MAINTENANCE SERVICES Transmission Gear Oil PERIODIC MAINTENANCE SERVICES 15 Transmission Gear Oil Gear oil capacity FWD model A REPLACEMENT 3 3 L 3 5 US qt 2 5 Imp qt AW
91. ry to the person doing the work or people in the area 1 ABS Handle the ABS as a total system Do not disas semble or attempt to repair parts which are not in structed in this manual Follow the instructions in this manual during performing the maintenance of ABSCM amp H U To disassemble parts without in structions could prevent the ABS system from op erating 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 e Wash out your eyes and seek immediate medical attention Wash your skin with soap and then rinse thor oughly with water 3 RADIATOR FAN The radiator 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 the airbag components or nearby and the airbag wiring harnesses or nearby To prevent unexpected deployment turn the igni tion switch to OFF and disconnect the ground cable from battery then wait at lease 20 seconds to dis charge electricity before beginning work 6 AIRBAG DISPOSAL To prevent bo
92. s sary Inspect and or retighten them when engine is cold PM 45 PERIODIC MAINTENANCE SERVICES Steering System Power Steering PERIODIC MAINTENANCE SERVICES PM 46
93. sification and SAE viscosity No designated by SUBARU f 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 SL or SJ SAE Viscosity No 30 40 10W 50 20W 40 20W 50 7 Close the engine oil filler cap 8 Start the engine and warm it up for a time 9 After the engine stops recheck the oil level Ref to PM 8 INSPECTION Engine Cil B INSPECTION 1 Park the vehicle on a level surface 2 Remove the 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 the F line LU 00138 A Oillevel gauge B Oil filler cap C Upper level D Lower level E Approx 1 2 1 1 Us qt 0 9 Imp qt 5 After turning off the engine wait a few minutes for the oil to drain back into 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 F 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 8 Engine Oil Filter 4 Engine Oil Filter A REPLACEMENT 1 Re
94. t check that no leaks are found Then add the necessary amount of the specified power steering fluid PM 00070 A Reservoir tank B MIN level C MAX level 48 FLUID LEAK CHECK Check the entire areas of the vehicle for any trace of coolant oil fluid leaks 49 WATER LEAK TEST Spray the vehicle with water and check that no wa ter enters the passenger compartment Before performing the water leakage test re move anything that may obstruct the operation or which must be kept dry Close all windows completely and then close all 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 25 0 5 3 6 6 US gal 4 4 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 por tion Door mating portions e Glass mating portions Rear quarter window mating portions Rear window and body framework mating portion Around roof drips If any dampness in the compartment is discovered after t
95. tc 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 control unit connectors logic boards and other such parts when there is a risk of static electricity Always use a static electricity pre vention cord or touch grounded metal before con ducting work 3 BATTERY When removing the battery cables always be sure to turn the ignition off to prevent electrical damage to the control unit 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 5 PROTECTING VEHICLE UNDER MAIN TENANCE Make sure to attach the fender cover seat covers etc before work 6 ENSURING SAFETY DURING WORK When working in a group of two or more perform the work with calling each other to ensure mutual safety NT 2 Note NOTE 7 LIFTS AND JACKS When using a lift or jack to raise a vehicle always follow instructions concerning jack up points and weight limits to prevent the vehicle from falling which could result in injury Be especially careful to make sure the vehicle is balanced before raising it Be sure to set the wheel stoppers when jacking up only the front or rear of the vehicle
96. the trunk opens nor mally 2 Open and close the trunk lid to see that there are no abnormal conditions 9 Check the rear gate for lock unlock and open close operations 1 Check if the rear gate can be unlocked normally through the emergency hole 2 Open and close the rear gate to see that there are no abnormal condi tions 10 Operation check of fuel lid opener lock release lever Operate the fuel lid opener to check that the fuel lid is unlocked normally 11 Accessory check Check that the following accessories are provided e Owner s manual Warranty booklet Maintenance note Spare key Jack Tool set Spare tire 12 Operation check of front hood lock release system Operate the front hood lock release lever to check that the front hood is unlocked normally 13 Battery Check the battery terminals for any abnormal conditions such as rust and trace of battery fluid leaks 14 Brake fluid Check that the fluid level is normal 15 Engine oil Check that the oil level is normal 16 Transmission gear oil Check that the transmission gear oil level is normal 2 Pre delivery Inspection PRE DELIVERY INSPECTION PROCEDURE Check point AT front differential oil Check that the AT front differential oil level is normal Engine coolant Check that the engine coolant level is normal Clutch fluid Check that the clutch fluid
97. trol RON More than 95 RON More than 90 RON SOHC Unleaded DOHC turbo Unleaded More than 98 RON KA KS model Leaded gasoline On vehicles without catalytic converter use leaded gasoline with an octane value of 90 RON or higher 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 Recommended Alternative API Spec CCMC Spec ACEA Spec API Spec Engine oil SL SJ Grade Energy conserving or SH RM 00006 RM 00001 RM 00002 G4 or G5 1 A2 or SG SF Manual transmission oil AT front differential gear oil Rear differential gear oil 1 Use LSD oil for model with driver s control center differential RM 3 RECOMMENDED MATERIALS Recommended Materials SAE viscosity No and applicable temperature Engine oil SOHC model 10W 30 or 10W 40 0W 20 Recommend RM 00007 DOHC turbo model 10W 30 or 10W 40 5W 30 Recommend RM 4 RM 00003 Recommended Materials SAE viscosity No and applicable temperature RECOMMENDED MATERIALS Manual transmission oil AT front differential gear oil and rear differential gear oil
98. turn the steering wheel to the right and left 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 PM 00065 A Steering wheel free play Move the 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 the vehicle and check the following items during 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 2 STEERING SHAFT JOINT When the steering wheel free play is excessive disconnect the 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 dam age to sealing or worn serrations If the joint is loose retighten the mounting bolts to the specified torque Tightening torque 24 N m 2 4 kgf m 17 4 ft lb PM 00066 3 GEARBOX 1 With wheels placed on a level surface turn the steering wheel 90 in both the
99. uge to the hub COMPL and mea sure axial displacement in axial direction Service limit Straight ahead position within 0 05 mm 0 0020 in PM 40 Wheel Bearing PERIODIC MAINTENANCE SERVICES 5 Turn the hub unit COMPL with hand to check for noise or binding If the hub unit COMPL is noisy or binds replace the hub unit COMPL PM 00153 Rear housing Tone wheel Hub bolt Hub unit COMPL Socket bolt Washer Hub nut O ring Hub cap TOUS E eS I nm M D A a PM 41 Axle Boots amp Joints PERIODIC MAINTENANCE SERVICES 25 Axle Boots amp Joints A INSPECTION 1 FRONT AND REAR AXLE BOOTS Inspect the front axle boots A and rear axle boots B for deformation damage or failure If faulty re place them with new ones Ref to DS 36 Front Drive Shaft Ref to DS 44 Rear Drive Shaft 7 NA JP ES IN GTS ie Q N y X IR N 5 T d 00063 00064 2 PROPELLER SHAFT Inspect the propeller shaft for damage or failure If faulty replace with a new one Ref to DS 16 Pro peller Shaft PM 42 Steering System Power Steering PERIODIC MAINTENANCE SERVICES 26 Steering System Power Steering A INSPECTION 1 STEERING WHEEL 1 Set the steering wheel in a straight ahead posi tion and check the wheel spokes to make sure they are correctly set in their specified positions 2 Lightly
100. uring 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 is 35 point A the safe operating temperature is 14 C 7 F point B and the freezing temperature is 20 C 4 F point C 40 30 20 10 0 10 20 30 40 50 40 22 4 14 32 50 68 86 104 122 C 00025 1 Coolant gravity 2 Safe operating temperature 3 Concentration of coolant 4 Freezing temperature 5 Coolant temperature 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 25 line of coolant concentration intersects with the 40 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 2 2 2 US qt 1 8 Imp qt Drain 2 1 Q 2 2 US qt 1 8 Imp qt of coolant from the cooling system and add 2 1 0 2 2 US qt

Subaru 2004 Automobile User Manual

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