Subaru 2004 manual

2004 Model Year PDF Service Manual GENERAL INFORMATION SECTION (Pub.No.G1870GE1) ENGINE SECTI ON 1 (Pub. No.G1870 GE2) ENGINE SECTI ON 2 (Pub. No.G1870 GE3) TRANSMISSION SECTION (Pub.No.G1870GE4) CHASSIS SECTION (Pub.N o.G1870GE5) BODY SECTION (Pub .No.G1870 GE6) WIRING SYSTEM SECTION (Pub.No.G1870GE7)[...]

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FUJI HEAVY INDUSTRIES LTD. G1870GE1 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX GENERAL INFORMATION SECT ION This ser vice manual ha s been prepared to prov ide SUBARU service personnel with the nec essary informati on and data for the corr ect mainte nance and repa ir of SUBA RU vehicles . This man ual incl udes the pr ocedures for mai ntena[...]

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FOREWORD FW Page 1. Forewo rd ...... ....... ....... ...... ....... ...... ....... ....... ...... ....... ....... ...... ....... ...... ....... .. 2[...]

FW-2 FOREWORD Foreword 1. Foreword A: FOREWORD These manuals are used when per forming maint e- nance, repai r, or diagnosi s of the Subaru IMPRE- ZA. Applied model: GD*****, GG** *** f rom 2004MY The manuals cont ain the lat est in formation a t the time of publi cation. Chang es in speci fications , methods, etc. may be made wit hout notice.[...]

HOW TO USE THIS MANUAL HU Page 1. How to Use This Manual ...... ........... ........... ......... .......... ......... ........... ......... . 2[...]

HU-2 HOW TO USE THIS MANUAL How to Use This Manual 1. How to Use This Man ual A: HOW TO USE T HIS MANUAL 1. STRUCTURE Each sectio n consists of SCT that ar e broken down into SC that are divided i nto sections for each com- ponent. The speci fication , maintenance and ot her informati on for t he components a re inclu ded, and diagnosis in formatio[...]

HU-3 HOW TO USE THIS MANUAL How to Use This Manual Example: HU-00017 (14) (9) (8) (7) (6) (10) (4) (10) (22) (11) (19) (17) (15) (13) (12) (18) (16) (1) (2) (3) (4) (5) (6) (7) (8) (11) (10) (9) (12) (13) (19) (18) (20) (17) (16) (24) (10) (25) (5) (4) (4) (4) (3) (3) (3) (2) (1) (21) (15) (23) T7 T2 T2 T2 T2 T2 T2 T4 T5 T5 T8 T6 T6 T6 T11 T10 T1 T[...]

HU-4 HOW TO USE THIS MANUAL How to Use This Manual 4. SPECIFICATIONS If necessar y, specif ications are a lso incl uded. 5. INSPECTION Inspections are included to be carried out bef ore and after maintenan ce. 6. MAINT ENANCE • Maintenan ce instruc tions for serviceable p arts des cribes work area and det ailed step s with illust ration. It also [...]

HU-5 HOW TO USE THIS MANUAL How to Use This Manual 7. DIAGNOSIS Tables showin g a step-by -step process mak e it easy to conduct diagnosis . 8. SI UNIT S Measurements in these man uals are according to the SI units. Metric and yard/pound measur ements are also incl uded. Example: Tightening t orque: 44 N·m (4.5 kg f-m, 33 ft-lb ) The figure used i[...]

HU-6 HOW TO USE THIS MANUAL How to Use This Manual 9. EX PLANATION OF TERMINOLOGY • List AAI : Air Ass ist Injecti on LH : LH (Left Hand) A/B : Airbag LSD : Limited Slip Dif ferential ABS : Antilock Brake Syst em M/B : Main Fu se & Relay Box A/C : Air co nditioner MD : Mini D isc A/F : Air Fuel Rat io MPi : Multi Po int injec tion ALT : Gener[...]

SPECIFICATIONS SPC Page 1. Imp reza .. ...... ....... ....... ...... ....... ...... ....... ....... ...... ....... ....... ...... ....... ...... ....... .. 2[...]

SPC-2 SPECI FICATION S Impre za 1. Impreza A: DIM ENS ION S ★ 1 : 1.6 L ★ 2 : 2.0 L ★ 3 : 2.0 L Turb o ★ 4 : With roof ra il ★ 5 : With sun roof Model Seda n Wagon OUT BACK STi Overal l length mm (in) 4,415 (17 3.8) Overal l width mm (in) 1,740 (68. 4) 1,695 (66.7) 1,710 (67 .3) 1,740 (68.1 ) Overal l height ( at C.W .) mm (in) 1,440 (56.[...]

SPC-3 SPECI FICATION S Impre za B: ENGI NE ★ 1 : Without O BD ★ 2 : With OBD ★ 3 : Australia model ★ 4 : Europe mo del C: ELECTRICAL Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi Engine t ype Horiz ontally o pposed, l iquid cooled, 4 -cyli nder, 4-stro ke ga soline en gine Valve a rrangement Overhea d camsha ft type Bore × Strok e mm ([...]

SPC-4 SPECI FICATION S Impre za D: TRANSMISSION 5MT: 5-forw ard spee ds with synchro mesh and 1-re verse 4AT: Electro n ical ly contro lled fu lly-autom atic, 4-fo rward speeds a nd 1-revers e 6MT: 6-forw ard spee ds with synchro mesh and 1-re verse DSPD: Dry Sing le Plate Diaphragm TCC: Torque Converter Clutch ★ 1 : Austral i a sp ec vehicle E: [...]

SPC-5 SPECI FICATION S Impre za G: BRAKE H: TIR E I: CAPACITY ★ 1 : Dual range Model 1.6 L Non-turbo 2.0 L, 2.5 L Turbo 2. 0 L, STi Service brake sy stem Dual circ uit hydrau lic with vacuum suspen ded pow er unit Front Ventilated disc brake Rear D rum brake Disc brake Ventil ated disc brake Parking brake Mecha nical on rear brakes Model BASE, TS[...]

SPC-6 SPECI FICATION S Impre za J: WEIGHT 1. LHD MODEL Sedan ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> Option code ★ 1 E2 EC K0 K4 KS Model 1. 6 L FWD AWD Base TS 5MT 4AT 5MT Curb weight (C.W .) Fr ont kgf (l b) 720 (1,587) 765 (1,687) 770 (1,698) 735 (1,620) 755 (1, 664) 750 (1,654) 750 (1,654) 740 (1, 631[...]

SPC-7 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> Option code ★ 1 EC K0 K4 KS EC Model 1.6 L 2.0 L AWD TS GX 4AT 5MT Curb weight (C.W .) Fr ont kgf (l b) 755 (1,644) 775 (1,709) 770 (1,698) 770 (1,698) 760 (1, 676) 750 (1,654) 770 (1,698) 765 (1, 687) Rear kgf ( lb) 52 0 (1,146) 520 [...]

SPC-8 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> Option code ★ 1 E2 K4 K0 KS EC Model 2. 0 L AWD GX 5MT 4 AT Curb weight (C.W .) Fr ont kgf (l b) 770 (1,698) 765 (1,687) 770 (1,698) 765 (1,687) 760 (1, 676) 765 (1,687) 775 (1,709) 795 (1, 753) Rear kgf ( lb) 53 5 (1,179) 535 (1,179)[...]

SPC-9 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> Option code ★ 1 EC E2 K4 K0 KS EC Model 2. 0 L 2.0 L Turbo AWD GX WRX 4AT 5MT Curb weight (C.W .) Fr ont kgf (l b) 790 (1,742) 795 (1,742) 790 (1,742) 795 (1,753) 790 (1, 742) 795 (1,753) 790 (1,753) 835 (1, 841) Rear kgf ( lb) 53 0 ([...]

SPC-10 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> Option code ★ 1 EC Model 2.0 L Turbo AWD WRX 5MT Curb weight (C.W .) Fr ont kgf (l b) 820 (1,808) 835 (1,841) 835 (1,841) 840 (1,852) 835 (1, 840) 840 (1,852) 840 (1,852) 840 (1, 852) Rear kgf ( lb) 55 0 (1,213) 555 (1,224) 560 (1,23[...]

SPC-11 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> Option code ★ 1 K4 EC Model 2.0 L Turbo AWD WRX S Ti 5MT Curb weight (C.W .) Fr ont kgf (l b) 835 (1,840) 840 (1,852) 840 (1,852) 885 (1,951) 865 (1, 907) 885 (1,951) 885 (1,951) 865 (1, 907) Rear kgf ( lb) 56 0 (1,235) 575 (1,268) 5[...]

SPC-12 SPECI FICATION S Impre za Wagon ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> D/R: Dual range Option code ★ 1 EC K0 K4 KS EC Model 1. 6 L AWD TS 5MT D/R 4AT Curb weight (C.W .) Fr ont kgf (l b) 740 (1,631) 740 (1,631) 760 (1,676) 755 (1,664) 755 (1, 664) 745 (1,643) 755 (1,664) 755 (1, 664) Rear kgf ( lb[...]

SPC-13 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> D/R: Dual range Option code ★ 1 EC K0 K4 KS EC Model 1.6 L 2.0 L AWD TS GX 4AT 5MT D/R Curb weight (C.W .) Fr ont kgf (l b) 775 (1,709) 770 (1,698) 770 (1,698) 760 (1,676) 760 (1, 676) 785 (1,731) 780 (1,720) 775 (1, 709) Rear kgf ( [...]

SPC-14 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> D/R: Dual range Option code ★ 1 K0 K4 KS EC Model 2. 0 L AWD GX 5MT D/R 4AT Curb weight (C.W .) Fr ont kgf (l b) 780 (1,720) 780 (1,720) 775 (1,709) 770 (1,698) 775 (1,709 800 (1,764) 795 (1,753) 790 (1, 742) Rear kgf ( lb) 57 0 (1,2[...]

SPC-15 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> D/R: Dual range Option code ★ 1 K0 K4 KS EC Model 2.0 L 2.0 L Turbo AWD GX WRX 4AT 5MT Curb weight (C.W .) Fr ont kgf (l b) 795 (1,753) 795 (1,753) 790 (1,742) 790 (1,742) 805 (1, 775) 825 (1,819) 830 (1,830) 830 (1, 830) Rear kgf ( [...]

SPC-16 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> D/R: Dual range Option code ★ 1 EC K4 Model 2.0 L T urbo AWD WRX 5MT Curb weight (C.W .) Fr ont kgf (l b) 830 (1,830) 830 (1,830) Rear kgf ( lb) 60 0 (1,322) 595 (1,311) Tota l k gf (l b) 1,43 0 (3,153) 1,425 (3,142) Maximu m permis [...]

SPC-17 SPECI FICATION S Impre za 2. RHD MODEL Sedan ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> Option code ★ 1 EK K1 EK K1 Model 1.6 L 2.0 L AWD TS GX 5MT 4AT 5MT 4AT 5MT 4AT 5MT Curb weight (C.W .) Fr ont kgf (l b) 740 (1,631) 760 (1,676) 760 (1,676) 750 (1,654) 770 (1, 698) 770 (1,698) 795 (1,753) 770 (1, [...]

SPC-18 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> Option code ★ 1 K1 EK Model 2.0 L 2.0 L Turbo AWD GX WRX STi 4AT 5MT 6MT Curb weight (C.W .) Fr ont kgf (l b) 795 (1,753) 835 (1,841) 835 (1,841) 840 (1,852) 840 (1, 852) 885 (1,952) 885 (1,952) Rear kgf ( lb) 53 0 (1,168) 565 (1,246[...]

SPC-19 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> Option code ★ 1 KA Model 2.0 L 2.5 L 2.0 L Turb o AWD GX RS W RX 5MT 4AT 5MT 4AT 5MT Unlad en weight (U .W.) Front kg (lb ) 750 (1,654) 765 (1,687) 775 (1,709) 790 (1,742) 780 (1, 720) 805 (1,775) 840 (1,852) 835 (1, 841) Rear kg ( l[...]

SPC-20 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> Option code ★ 1 KA Model 2.0 L Turb o AWD WRX STi 5MT 4AT 6MT Unlad en weight (U .W.) Front kg (lb ) 840 (1,852) 860 (1,896) 865 (1,907) 865 (1,907) 885 (1, 952) 885 (1,952) Rear kg ( lb) 5 70 (1,257) 555 (1,234) 565 (1,246) 570 (1,2[...]

SPC-21 SPECI FICATION S Impre za Wagon ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> D/R: Dual range Option code ★ 1 EK K1 EK K1 Model 1.6 L 2.0 L AWD TS GX 5MT D/R 4AT 5M T D/ R 4AT 5M T D /R 4AT 5 MT D /R Curb weight (C.W .) Fr ont kgf (l b) 745 (1,642) 765 (1,687) 760 (1,676) 755 (1,664) 770 (1, 698) 780 (1,[...]

SPC-22 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> D/R: Dual range Option code ★ 1 K1 EK Model 2.0 L 2.0 L Turb o AWD GX WRX 4AT 5MT Curb weight (C.W .) Fr ont kgf (l b) 795 (1,753) 825 (1,819) 825 (1,819) 830 (1,830) 830 (1, 830) Rear kgf ( lb) 56 5 (1,246) 585 (1,830) 590 (1,301) 6[...]

SPC-23 SPECI FICATION S Impre za ★ 1 : For option code, refe r to ID section. <Ref. to ID-7, Option code.> D/R: Dual range Option code ★ 1 KA Model 2.0 L 2.0 L Turbo AWD GX OUTBACK WRX 5MT D/R 4AT 5MT D/ R 4AT 5MT 4 AT Unlad en weight (U .W.) Front kg (lb ) 760 (1,676) 775 (1,709) 775 (1,709) 790 (1,742) 770 (1,698) 785 (1,731) 825 (1,819[...]

SPC-24 SPECI FICATION S Impre za[...]

PRECAUTION PC Page 1. Pre cautio n ....... ...... ....... ...... ....... ....... ...... ....... ....... ...... ....... ...... ....... ....... ...... 2[...]

PC-2 PRECAU TION Precaution 1. Precaution A: PRECAUTION Please clea rly under stand and adhere t o the fol low- ing general precautions. They must be strict ly fol- lowed to av oid minor or ser ious inj ury to the person doing the work or people in the area. 1. ABS Handle the ABS as a total system. Do not disa s- semble or attempt to repair par ts [...]

NOTE NT Page 1. Note . ....... ...... ....... ....... ...... ....... ...... ....... ....... ...... ....... ....... ...... ....... ...... ....... .. 2[...]

NT-2 NOTE Note 1. Note A: NOT E This is info rmation that can improve effic iency of maintenance and assure sound work . 1. FASTENER NO TICE Fasteners ar e used to p r event parts from damage and dislocation d ue to looseness. Fasteners must be tighten ed to the specified torque. Do not apply paint , lubricant , rust reta rdant, or ot h- er substan[...]

NT-3 NOTE Note 7. LIFTS AND JACKS When using a lift or jack to rai se a vehicle, always foll ow instruct ions concerni ng jack-u p points and weight limits t o prevent the vehi cle from f alling, which c ould result in inju ry. Be especia l ly car eful to make sur e the vehicle is balanced befo r e raising it . Be sure to set the wheel stopper s wh[...]

NT-4 NOTE Note 8. TIE-DOWN S Tie downs are used when transpor ting vehicles and when usi ng the chassis dynamo. Attach tie downs only to the spe cified points on the vehi cle. • Tie-down poi nt (A) F ront (B) Re ar (1) Front cros smember (2) Rear di fferential (1) Hook f or tie-down (2) Hook f or towing an d tie-dow n NT -00062 (1) (2) (A) (B) NT[...]

NT-5 NOTE Note • Chain direc tion at tie -down conditio n • Chain pull ing range at tie-down condit ion • Vehicle si nking volume at tie-down co ndition Measure the distanc e L between ti re highest point to arch highest poi nt before tie-down and af ter tie- down. Difference of measur ement value (drop height) sha ll be withi n 50.8 mm (1.97[...]

NT-6 NOTE Note 9. TOWING Avoid towing vehicles exc ept when the veh icle cannot be driven. For m odels with AWD, AT, or VTD, use a loader inste ad of towing. When towing other vehicles , to prevent excess ive weight fro m damaging the hook or vehicle: • Do not tow other vehicles wit h a front hook for tie down. • Make sure the vehicle towing is[...]

NT-7 NOTE Note • NOTES Marked ❍ : OK, Marked ✕ : Pro hibited, Marked  : Conditionally OK. Towing Notes MT AT Lifting up four wheels (On a trai ler) Towing the vehic le after l ifting up a ll four wheels is a basi c rule for AWD model. ❍❍ Rope • Check if both front and rear whee ls are rotated nor- mally . • AT model driving c ondit[...]

NT-8 NOTE Note CAUTION: • Check ATF, gear oil and rear diff erential oil before dri ving. • Place the shift lev er in “ N ” position during towi ng. • Do not lift up the rear wheels to avoi d unsteady rotation. • Turn the i gnition key to “ ACC ” , then check the steering wheel moves freely. • Release the parking brake to avoid ti[...]

NT-9 NOTE Note 11. TRAINING For informat ion about tr aining, cont act a dealer or agent. 12. G ENERAL SCA N TOOL Using general scan tools will greatl y improve ef fi- ciency of repairi ng engine elect ronic controls . The Subaru Select Monitor can be used to diagnose the engine and also the ABS, the air conditi oner, and other parts.[...]

NT-10 NOTE Note[...]

IDENTIFICATION ID Page 1. Identification .. ....... ..... ........ ....... ....... ........ ..... ....... ........ ....... ....... ........ ..... ..... 2[...]

ID-2 IDENTIFICATION Identifica tion 1. Identification A: IDENTI FICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The VIN (Vehi cle Ident ificati on Numbers) i s used t o classif y the vehi cle. • POSITIONING OF THE PLATE LABEL FOR IDENTIFICATION • ENGINE • AUTOMATIC TRANSMISSION (1) ID plat e (Europe m odel) ADR com pliance plate (Aust r[...]

ID-3 IDENTIFICATION Identifica tion • MANUAL TRANSMISSION • REAR DIFFERENTIAL • T-type • VA-type • MODEL NUMBER PLATE (1) Transmis sion se rial number ID-00055 (1) (1) Type (white pain t) (1) Typ e (lab el) ID-00056 (1) DI-00396 (1) ID-00075[...]

ID-4 IDENTIFICATION Identifica tion 2. MEANING OF V.I.N. The meaning of the VIN is as follows: • Europe, Australia and General (Ex cept GCC) ]JF1GD4LG94G002001[ The starting and ending bracke ts ( ][ ) are stop marks. • GCC countries (Saudi Arabia, etc.) ]JF1GD45MX4G002001[ The starting and ending bracke ts ( ][ ) are stop marks. Digits Co de M[...]

ID-5 IDENTIFICATION Identifica tion 3. MODEL NUMBER PLATE The model number plat e indicates: the applied model, the option code, the trim code, t he engine type, the transmissi on type, a nd the exte rior color code . This i nformation is helpful when placing order s for parts. GD9DL5R The engine and transmissi on typ e are as f ollows: • Engine [...]

ID-6 IDENTIFICATION Identifica tion • Transmission TM754RY5AA • Rear diff erentia l 1 VA-type • Rear diff erentia l 2 T-type Digits Code Meaning Detail s 1 T Tran smissi on T: Tran smissi on 2 M Transmis sion type Y: Full-ti me AWD MT c enter diffe rential V: Full-ti me AWD AT center dif ferential Z: Fu ll-t ime AW D AT MPT M: FWD MT A: FWD A[...]

ID-7 IDENTIFICATION Identifica tion • Option code E2BL Digit s Code Meaning Details 1 — 2 E2 D est ination EC: Europe mode l (LHD mo del) EK: Europe model (RHD model) EH: China model KS: Middle Eas t model K4: Centr al and Sout h America model KA: Australi a model E2: Israel model K0: Gener al model (LHD mode l) K1: Gener al model (RHD mo del) [...]

ID-8 IDENTIFICATION Identifica tion 4 L Option eq uipment B: A/ C , Airb ag, Spoi ler pack age C: A/C, Airb ag, Rear s poiler F: A/C, Airbag , Sunroof G: A/C, Airba g, Side airb ag I: A/C, Airb ag, Audio, Rear spo iler J: A/C, Ai rbag, Spoil er package, R ear spo iler K: Airbag, Si de airbag, Audio L: A/C, Airbag M: Air bag O: A/C, S unroof, Airba [...]

RECOMMENDED MATERIALS RM Page 1. Recommended Mat erials ......... ......... ......... ......... .......... ......... ......... ......... ... 2[...]

RM-2 RECOMMENDED M ATERIALS Recommended Materials 1. Recommen ded Materials A: RE COMME NDE D MATE RIALS 1. GENERA L To insure the best perfor mance, alway s use the specified oil, g asoline, adhesive, se alant, et c. or a substitut e of equivale nt quality. 2. FUEL Always use a gasoline of the s ame or higher octane value than specified in the o w[...]

RM-3 RECOMMENDED M ATERIALS Recommended Materials 3. LUBRICANTS Use either the lubri cants in the t able below o r equivalen t lubr icants. See t he table below to choose t he correct SAE viscosity. ★ 1 : Use LSD oil for model with driver ’ s control center di fferential. Lubricant Recommen ded Alternativ e API Spec. CCMC Spec. ACEA Spec . API [...]

RM-4 RECOMMENDED M ATERIALS Recommended Materials SAE viscosit y No. and a pplicabl e tempera ture Engine oil SOHC model DOHC turbo model RM-00007 (˚F) –22 –4 14 50 68 86 104 (˚C) –30 –20 –10 0 10 20 30 40 5W-30 32 10W-30 or 10W-40 0W-20 Recommend RM-00003 ( ˚ F) – 22 – 4 14 50 68 86 104 ( ˚ C) – 30 – 20 – 10 0 10 20 30 40 5[...]

RM-5 RECOMMENDED M ATERIALS Recommended Materials 4. FLUID Use the fl uids speci fied in the tabl e below. Do not mix t wo differ ent kinds or makes of fluid. 5. COOLANT Use genuin e coolant to protect the engi ne. 6. REFRIGERANT Standard air conditioners on Subaru vehicl es use HFC134a refriger ant. Do not mix it with other refrig erants. Also, do[...]

RM-6 RECOMMENDED M ATERIALS Recommended Materials 7. GREASE Use the greas e and su pplementary lubr icants shown in t he table below. 8. ADHESIVES Use the adhesives shown in the table below, or equi valent. Grease Applicati on poi nt Recommende d Item numb er Alternative Supplem entary lu bricants • O 2 s ensor • Bolts, etc . Spray type lubrica[...]

RM-7 RECOMMENDED M ATERIALS Recommended Materials 9. SEAL MATERIAL Use seal material shown i n the table below, or equi valent. Seal mat erial Application p oint Rec ommend ed Item number A l ternati ve Seal materi al • Cylin der blo ck • Torque c onverter clut ch case • Tran smissi on oil pan (6MT mo del) Three Bond 1 215B 004403007 Dow C or[...]

RM-8 RECOMMENDED M ATERIALS Recommended Materials[...]

PRE-DELIVERY I NSPECTION PI Page 1. Pre -del ivery I nspec tion ..... ....... ...... ....... ....... ...... ....... ....... ...... ....... ...... ....... .. 2[...]

PI-2 PRE-D ELIVER Y INS PECTION Pre-delivery Inspection 1. Pre-delivery Inspection A: GENERAL DESCRIPTION The purposes of the pre-del ivery inspec tion (PDI) are as foll ows. • Remove the addit ional part s used for ensur ing the vehicle qualit y during t ransportati on and restor e the ve- hicle t o its nor mal state. • Check if the vehicle be[...]

PI-3 PRE-DEL IVERY I NSPECTION Pre-delivery Inspection CHECKS WITH ENGINE RUNNING DYNAMIC TEST WITH VEHICLE RUNNING CHECKS AFTER DYNAM IC TEST 17. AT fron t differential oi l Check that the AT front differential oil level is norma l. 18. Engi ne coolant Check that the en gine coolant le vel is n ormal. 19. Cl utch flui d Check that the cl utch flui[...]

PI-4 PRE-D ELIVER Y INS PECTION Pre-delivery Inspection 1. APPEARANCE CHECK • If the vehicl e is covered wi th protecti ve coating, visually check the vehicle body for damage and dents. • If there is no prot ective coati ng, check the body paints for small ar eas of damage or stains a nd re- pair as necessary. • Check the window gla ss, door [...]

PI-5 PRE-DEL IVERY I NSPECTION Pre-delivery Inspection 4) Press the dr iver ’ s si de power door lock switch to unlock side. Check t hat all door s including r ear gate are unlocked. 6. CHECK DOUBLE LOCK OPERATION 1) Fully open all the windows. 2) Remove the key. 3) Lock all the doors usi ng the door key cyli nder or transmitt er. 4) Verify that [...]

PI-6 PRE-D ELIVER Y INS PECTION Pre-delivery Inspection 9. CHECK THE REAR GATE FOR LOCK/ UNLOCK AND OPEN/CLOSE OPERATIONS 1) Open and close the rear gate several times f or smooth movement. 2) Operate the rear gate lever to check that the r ear gate is l ocked and unl ocked no rmally. (1) Remove the blind cover i nside the rear gate. (2) Check that[...]

PI-7 PRE-DEL IVERY I NSPECTION Pre-delivery Inspection Operate th e lever (A) a nd check that the hood is opened normally. Then support the hood wit h hood stay. 13. BATTERY Check the batter y terminals t o make sure that no rust or co rrosions due to flui d leaks are found. Check that the batter y caps are securely ti ghtened. 14. BRAKE FLUID Chec[...]

PI-8 PRE-D ELIVER Y INS PECTION Pre-delivery Inspection 17. AT FRONT DIFFERENTIAL OIL Check the AT front diff erential oil amount. If the amount is insuffici ent, check that no lea ks are found. The n, add the neces sary amount of the specified AT fr ont different ial oil. 18. COOLANT Check the coolant amount on the res ervoir. If the amount is ins[...]

PI-9 PRE-DEL IVERY I NSPECTION Pre-delivery Inspection 25. WHEEL ALIGNMENT Check the wheel alignment s. <Ref. t o FS-6, Wheel Alignment.> and < Ref. to RS- 10, Wheel Ali gn- men t. > 26. TEST MODE CONNECTOR Turn the ignit ion switch to ON and check t hat the malfunction indicator lig ht starts bl inking. If the light blinks, ret urn the[...]

PI-10 PRE-D ELIVER Y INS PECTION Pre-delivery Inspection Rear injection posit ion: A: 39 m m (2.36 in) B: 72 ° ° ° ° 36.WIPER Check the front and re ar wipers for normal opera- tions. 37. POWER WINDOW OPERATION CHECK Manipulate th e power window switches one by one to check that each of the power windows goes up and down with no abnormal noises[...]

PI-11 PRE-DEL IVERY I NSPECTION Pre-delivery Inspection 46. ATF LEVEL Check that t he ATF level is normal when the engi ne at idle. If insuf ficient, c heck that no leaks are found. Then add the necessa ry amount of the specifi ed ATF. 47. POWER STEERING FLUI D LEVEL Check that the power st eering fl uid level is normal. If insuff icient, check tha[...]

PI-12 PRE-D ELIVER Y INS PECTION Pre-delivery Inspection • If the coated surfac e is swollen out due to seams or moisture, expose the vehicle to t he sun light f or a few hours. Otherwi se, heat the porti on with seams or moistur e using a dry er, etc. • Dispose of the peeled wrap guard as burnable in- dustrial gar bage. 2) Check the whole vehi[...]

PERIODIC MAINTENANCE SERVICES PM Page 1. General Description ...... ....... ........ ....... ......... ....... ........ ....... ......... ........ ....... . 2 2. Schedule ....... ............ ........ ....... ....... ........ ....... ..... .......... ..... ....... ........ ....... ... 3 3. En gine Oil ..... ..... ...... ....... ....... ...... .....[...]

PM-2 PERI ODIC MA INTEN ANC E SER VICES General Descript ion 1. General Description A: GENERAL Be sure to perform perio dic maintenance in order to maintain vehic le performance and fi nd problems before they become seri ous.[...]

PM-3 PERIODIC MAINTEN ANCE SERVICES Schedule 2. Schedule A: MAINTENA NCE SCHEDULE 1 1. FOR EUROPE AREA For periodic mai ntenance of over 120,000 km (75,000 miles) or 96 months, carry out inspect ion by referr ing to the fol lowing tabl e. For a main tenance perio d gone beyond these tables, apply them r epeatedly as a set of 120,000 km (75,000 mile[...]

PM-4 PERI ODIC MA INTEN ANC E SER VICES Schedule 2. EX CEPT FOR EUROPE AREA For periodi c maintenance of over 50, 000 km (30,000 miles) o r 48 months, carry ou t inspecti ons by ref errin g to the followi ng tables. For a mai ntenance perio d gone beyond these tabl es, apply them repeat edly as a set of 50,000 km (30,000 miles) or 48 months. For pe[...]

PM-5 PERIODIC MAINTEN ANCE SERVICES Schedule N O TE: (1) When the vehicle is us ed in extremel y dusty condi tions, the air cleaner elem ent shou ld be replaced m ore of ten. (2) ATF filter is a maintenan ce free pa rt. ATF filter needs replacem ent, whe n it is ph ysicall y damag ed or ATF leaked. B: MAINTENA NCE SCHEDULE 2 1. EUROPE AREA Item Eve[...]

PM-6 PERI ODIC MA INTEN ANC E SER VICES Schedule 2. EX CEPT FOR EUROPE AREA Item Every Re peat s hort distanc e drive Repea t roug h/mud dy road driv e Extremely cold weath er area Salt or other corr osi ve used or coast al are a High hum id- ity o r moun- tain area Repeat tow- ing trailer Engi ne oil Replac e more fre- quently Replac e more fre- q[...]

PM-7 PERIODIC MAINTEN ANCE SERVICES Engine Oil 3. Engine Oil A: REP LACE MENT 1) Open the engine o il filler cap f or quick draini ng of the engine oil. 2) Remove the dip of serv ice hole c over. (Turbo mod el) 3) Drain the en gine oil by loosening engine oil drai n plug. • DOHC TURBO MOD EL • SOHC MODEL 4) Replace the drai n plug gasket . 5) T[...]

PM-8 PERI ODIC MA INTEN ANC E SER VICES Engine Oil 6) Fi ll engine oi l through the f iller pipe up to center between upper level and lower level . Make sure that the vehicle is placed level when checking oil level. Us e engine oil of proper qual ity and viscosity, selected in accor dance with the table i n figure. Recommended oil API classi ficati[...]

PM-9 PERIODIC MAINTEN ANCE SERVICES Engine Oil F ilter 4. Engine Oil Filter A: REP LACE MENT 1) Remove the under cover. 2) Remove the oil fi lter 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)) ?[...]

PM-10 PERI ODIC MA INTEN ANC E SER VICES Spark Plugs 5. Spark Plugs A: REP LACE MENT 1. SOHC MODEL 1) Remove the intake duct and intake chamber . 2) Remove the washer tank and put it aside. 3) Disconnect the spar k plug cord. 4) Remove the spark plug with a plug-wrench. 5) Set the new spark plugs. Recommended spark plug: 1.6 L SOHC model (with cat [...]

PM-11 PERIODIC MAINTEN ANCE SERVICES V-belt 6. V-belt A: INSPECTION 1) Replace the belt s, if cracks, fr aying or wear is found. 2) Check the V-belt t ension and a djust it if neces- sary by changing the generator inst alling posi tion and/or idl er pull ey instal ling posit ion. <Ref . to PM- 11, REPLACEMENT, V-belt.> Belt tension (wit hout [...]

PM-12 PERI ODIC MA INTEN ANC E SER VICES V-belt TURBO MODEL 2) Loosen t he lock bol t (A). 3) Loosen t he slider bolt (B ). 4) Remove the front side belt (C) . 5) Install a new belt , and ti ghten the sli der bolt so as to obtain the speci fied belt tension. 6) Tighten the lock bolt ( A). 7) Tighten the slider bolt (B). Tightening t orque: Lock bol[...]

PM-13 PERIODIC MAINTEN ANCE SERVICES Timing Belt 7. Timing B elt A: REP LACE MENT 1. NON-TURBO MODEL 1) Remove the radiato r fan and air condit ioner fan. <Ref. to CO(H4SO)-23, Radi ator Main Fan and Fan Motor.>, <Ref. t o CO(H4SO)-2 4, Radiator Sub Fan and Fan Motor.> 2) Shield the radiat or from any damage using card- board and bl ank[...]

PM-14 PERI ODIC MA INTEN ANC E SER VICES Timing Belt 15) Remove the automati c belt te nsion adjust er as- sembly. 16) Instal l in the reverse or der of r emoval. < Ref. to ME(H4SO)-49, INSTALLATION, Timing Belt As- sembly.> 2. DOHC MODEL 1) Remove the radiato r fan and air condit ioner fan. <Ref. to CO(H4DOTC)-28, Radiator Main Fan and Fa[...]

PM-15 PERIODIC MAINTEN ANCE SERVICES Timing Belt ST 499987500 CRANKSHAFT SOC KET 13) Remove the belt idler . 14) Remove the timing belt. 15) Remove the automati c belt te nsion adjust er as- sembly. 16) Instal l in the reverse or der of r emoval. < Ref. to ME(H4DOTC)-58, Timi ng Belt Assembly.> CAUTION: When installin g the timing belt, be su[...]

PM-16 PERI ODIC MA INTEN ANC E SER VICES Fuel Line 8. Fuel Line A: INSPECTION The fuel line i s located mostly internall y, so check pipes, areas near pipes, and engin e compartm ent piping f or rus t, hose da mage, loo se bands, et c. If faulty pa rts are found, repair or r eplace them. SOHC model <Ref. to FU(H4SO)-6 3, Fuel Deli very, Return a[...]

PM-17 PERIODIC MAINTEN ANCE SERVICES Fuel Filter 9. Fuel Filter A: REP LACE MENT For fuel fil ter replacement procedur es, 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 cl ogged, or if repl acement interval has been reached, [...]

PM-18 PERI ODIC MA INTEN ANC E SER VICES Air Cleaner El ement 10. Air C leaner Element A: REP LACE MENT 1. NON-TURBO MODEL 1) Remove the air in take duct from air clea ner case. 2) Remove the bolt (A) which instal ls air cleaner case to stays. 3) Remove the clip (B) above the air cl eaner case. 4) Remove the air cleaner. 5) Install in the rev erse [...]

PM-19 PERIODIC MAINTEN ANCE SERVICES Cooling System 11. Coolin g System A: INSPECTION 1) Check the radiator for leakage, fil ling it with cool- ant and attach t he radiator c ap tester (A) to filler neck. Then app ly a pressure. Check the followi ng points: Non-turbo model 157 kPa (1.6 kg/c m 2 , 23 psi) Turbo model 122 kPa (1.2 kg/c m 2 , 18 psi) [...]

PM-20 PERI ODIC MA INTEN ANC E SER VICES Cooling System 3) Start the engine, and then check it does not overheat or i t is cooled excess ively. If it overheat s or it is cool ed excessivel y, check t he cooling sy s- tem. SOHC model <Ref. to CO(H4SO)-15, Water Pump.> <Ref. to CO(H4SO)-18, Thermostat.> <Ref. to CO(H4SO)-19, Radiator.&[...]

PM-21 PERIODIC MAINTEN ANCE SERVICES Coolant 12. C oolant A: REP LACE MENT 1. REPLACEMENT OF COOLANT WARNING: The radiator i s of the pressurized t ype. Do not attempt to open the radiat or cap immediately after the engine has been stopped. 1) Lift-up th e vehicle. 2) Remove the under cover. 3) Place a container under drai n pipe. 4) Loosen and rem[...]

PM-22 PERI ODIC MA INTEN ANC E SER VICES Coolant 2. RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEM- PERATURE The concentrati on and safe operating temperat ure of the SUBARU coola nt is shown i n the diagram. Measuring the t emperature and sp ecific gravi ty of the coolant will provide t his in formation. [Example] If the coolant t e[...]

PM-23 PERIODIC MAINTEN ANCE SERVICES Idle Mi xture 13. Idle Mixture A: INSPECTION AND ADJUSTMENT 1. IDLE MIX TURE Before measuring t he idle mixture , make sure t hat the ignit ion timing and the engine idl e speed are within spe cifications. 1) Set the gear position at “ Neutral ” for MT, or “ N ” or “ P ” fo r AT. 2) Warm up the engin[...]

PM-24 PERI ODIC MA INTEN ANC E SER VICES Clutch System 14. C lutch System A: INSPECTION AND ADJUSTMENT 1. MECHANICAL CLUTCH TYPE 1) Inspect the fr ee play of clutch pedal by operating pedal by hand. If it is out of the specified val ue, adju st it by turnin g wing nut on engine side of clutch cable at release fork . Tightening t orque (Adjusting nu[...]

PM-25 PERIODIC MAINTEN ANCE SERVICES Clutch System Recommended clutch fluid: FMVSS No. 116, fresh DOT3 brake fluid CAUTION: Prevent the clutch fluid fr om being splashed over vehicle body. If the clutch fluid is splash ed over vehicle body, flush it, and then wipe it up. NOTE: • Avoid mixing diff erent brakes of brake flui d to prevent degradati [...]

PM-26 PERI ODIC MA INTEN ANC E SER VICES Transmission Ge ar Oil 15. Transm ission Gear Oil A: REP LACE MENT 1. MANUAL TRANSMISSION 1) Drain the gear oi l by r emoving dr ain plug. NOTE: • Before star ting work, co ol off the transmission gear oil well. • If tran smission gear oil adhere s to the exhaus t pipe, wipe it off completely. 5MT 6MT 2)[...]

PM-27 PERIODIC MAINTEN ANCE SERVICES Hill-hol der System 16. Hill-ho lder System A: INSPECTION AND ADJUSTMENT 1) Confirm the sto pping and star ting perfo rmance by activati ng the hill-hol der on an uphill road of 3 ° or higher incl ination. (1) When the vehicle does not stop; Tighten the adjust ing nut of PHV cable. (2) When the vehicle does not[...]

PM-28 PERI ODIC MA INTEN ANC E SER VICES ATF 17. A TF A: INSPECTION CAUTION: The level of ATF varies with flui d temperature. Pay attenti on to the fluid temperature when checking ATF le vel. 1) Raise the ATF temperature by dri ving a distance of 5 to 1 0 km (3 to 6 mil es). Otherwi se, idle the en- gine to raise ATF t emperature to 70 — 80 ° C [...]

PM-29 PERIODIC MAINTEN ANCE SERVICES ATF 4) Check the ATF level. <Ref. to PM-28, INSPEC- TION, ATF.> 2. ATF FILTER NOTE: ATF filter is a maintenance free part . ATF filter needs replacement, when it has physical ly dam- aged or ATF leaked. For the replacement proce dures of the ATF filter : <Ref. to 4AT-73, ATF Filte r .> (A) Level gaug[...]

PM-30 PERI ODIC MA INTEN ANC E SER VICES Front & Rear Differe ntial Gear Oil 18. Front & Rear Differential Gear Oil A: REP LACE MENT 1. FRONT DIFFERENTIAL (MT MODEL) Different ial oil works as manual trans mission oil to lubricat e different ial. Refer to “ Transmission Oil ” . <Ref. to PM-26, Transmissi on Gear Oil.> 2. FRONT DIF[...]

PM-31 PERIODIC MAINTEN ANCE SERVICES Front & Rear Differe ntial Gear Oil VA TYPE Recommended gear oil: Except for STi model with driver ’ s control center di fferential GL-5 (75W-90) or equival ent STi model with driver ’ s contr ol center differ - ent ial GL-5 [LSD oi l (90)] or equival ent Oil capacit y: Except for STi model: 0.8 2 (0.8 U[...]

PM-32 PERI ODIC MA INTEN ANC E SER VICES Brake Line 19. B rake Line A: INSPECTION 1. BRAKE LINE 1) Check scratches, swelling, corrosion, trac es of fluid leakag e on the brake hoses or pipe joints. 2) Ch eck th e pos sibilit y of adja cent p arts in terfer ing with brake pipes/ hoses during dri ving, and loose connections/ clamps. 3) Check any trac[...]

PM-33 PERIODIC MAINTEN ANCE SERVICES Brake Line 3) Check the pedal stroke. While the engine i s idling, depres s the brake peda l with a 49 0 N (50 kgf, 1 10 lb) l oad and measur e the distance bet ween brake pedal and steerin g wheel. With the brake p edal released, measure the dis- tance between pedal and steering wheel again. The difference betw[...]

PM-34 PERI ODIC MA INTEN ANC E SER VICES Brake Fluid 20. B rake Fluid A: REP LACE MENT 1) Either jack -up the vehicle and pla ce a safety stand under it, or lift-up the vehicle. 2) Remove both front and rear wheels. 3) Draw out the br ake fluid fro m master cyl inder with syri nge. 4) Refill the reservoir tank wi th recommended brake flu id. Recomm[...]

PM-35 PERIODIC MAINTEN ANCE SERVICES Disc Brake Pads and Discs 21. Disc Brake Pad s and Discs A: INSPECTION 1. DISC BRAKE PAD AND DISC 1) Jack-up the vehicl e and support with rigid racks. Then remove the wheels. 2) Visually ch eck the pad thickn ess through inspe c- tion hole of disc brake assembl y. Replace the pad if necessary. NOTE: When replac[...]

PM-36 PERI ODIC MA INTEN ANC E SER VICES Brake Linings and Drums 22. B rake Linings and Drums A: INSPECTION 1. REAR DRUM BRAKE 1) Remove the brake drum, and check that there is no fluid leakage from wheel cyl inder. If there i s fluid leakage f rom wheel cy linder, in spect the wheel cylinder , and then repair or re place it. 2) Ins pect the br ake[...]

PM-37 PERIODIC MAINTEN ANCE SERVICES Brake Linings and Drums Brake drum insi de 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) 3) If the def ormation or wear of back pl ate, shoe, etc. is notic eable, replac e them. 4) When the shoe [...]

PM-38 PERI ODIC MA INTEN ANC E SER VICES Suspension 23.Suspensi on A: INSPECTION 1. SUSP ENSION BALL JOINT 1) Jack-up the vehicl e until front wheels are off ground. 2) Next, grasp the bottom of tir e and move it in and out . If rela tive mo veme nt (B) is ob ser ved bet ween the brake di sc cover (A) and end of transverse link (D), ball jo int (C)[...]

PM-39 PERIODIC MAINTEN ANCE SERVICES Suspension 4. WHEE L ALIG NMENT OF FRONT SUS- PENSION 1) Check the alignment of front suspension to en- sure that following items c onform to s tandard val - ues. • Toe-in • Camber angle • Caster angle • Steering angl e <Ref. to FS-6, Whee l Alignment.> 2) When the caster angle does not conform to [...]

PM-40 PERI ODIC MA INTEN ANC E SER VICES Wheel Bearing 24. Wheel Bearin g A: INSPECTION 1. FRONT WHEEL BEARING NOTE: Inspect the conditi on of front wheel bearing greas e. 1) Jack-up the f ront of vehi cle. 2) While holdi ng the front w heel by hand, swin g it in and out to check bearing fr ee play. 3) Loosen t he wheel nuts and r emove fro nt whee[...]

PM-41 PERIODIC MAINTEN ANCE SERVICES Wheel Bearing 5) Turn the hub uni t COMPL with hand to ch eck for noise or binding. If the hub unit COMPL is noisy or bi nds, replace the hub unit COMPL. (A) Rear ho using (B) Tone wh eel (C) Hub bol t (D) Hub uni t COMPL (E) Socke t bolt (F) Washe r (G) Hub nut (H) O-ring (I) Hub cap PM-00153 (A) (B) (C) (D) (F[...]

PM-42 PERI ODIC MA INTEN ANC E SER VICES Axle Boots & Joints 25. A xle Boots & Joints A: INSPECTION 1. FRONT AND REAR AXLE BOOTS Inspect the f ront axle boots (A) and rear axle boots (B) for deformation, damage or f ailure. If fa ulty, r e- place them wit h new ones. <Ref . to DS-36, Front Drive Shaft.> <Ref . to DS-44, Rear Drive [...]

PM-43 PERIODIC MAINTEN ANCE SERVICES Steering Syst em (Power Steering) 26. Steering System (Power Steering) A: INSPECTION 1. STE ERING WHEEL 1) Set the steering wheel in a straight- ahead posi- tion, and chec k the wheel spokes t o make sure they are c orrectly set in their sp ecified positions. 2) Lightly tu rn the steer ing wheel to t he right an[...]

PM-44 PERI ODIC MA INTEN ANC E SER VICES Steering Syst em (Power Steering) (2) Retighten the ad justing screw t o 7.4 N · m (0.75 kgf- m, 5.4 ft-lb) an d back off 25 ° . (3) Loosen the adjusti ng screw an d apply liquid packing to at least 1/3 of entire per imeter of its thread. (4) Tighten the adju sting screw t o 7.4 N · m (0 .75 kgf-m, 5.4 ft[...]

PM-45 PERIODIC MAINTEN ANCE SERVICES Steering Syst em (Power Steering) NOTE: Prevent the hoses from revol ving and/or turni ng when instal ling hoses. 8. POW ER STEERING PIPES FOR DAM- AGE Check the power steering pipes f or corros ion and damage. Replace the pipes with a new o ne if necessary. 9. GEARBOX BOOTS Inspect both si des of gearbox boots [...]

PM-46 PERI ODIC MA INTEN ANC E SER VICES Steering Syst em (Power Steering)[...]