Subaru Impreza 2004 User manual

FUJI HEAVY INDUSTRIES LTD. G1870GE5

2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

CHASSIS 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.

FRONT SUSPENSION FS

REAR SUSPENSION RS

WHEEL AND TIRE SYSTEM WT

DIFFERENTIALS DI

TRANSFER CASE TC

DRIVE SHAFT SYSTEM DS

ABS ABS

ABS (DIAGNOSTICS) ABS(diag)

BRAKE BR

PARKING BRAKE PB

POWER ASSISTED SYSTEM

(POWER STEERING) PS

POWER ASSISTED SYSTEM

(POWER STEERING)

Page

1. General Description ....................................................................................2

2. Steering Wheel..........................................................................................23

3. Universal Joint...........................................................................................24

4. Tilt Steering Column..................................................................................26

5. Steering Gearbox [LHD MODEL] ..............................................................29

6. Steering Gearbox [RHD MODEL] .............................................................47

7. Pipe Assembly [LHD MODEL] ..................................................................64

8. Pipe Assembly [RHD MODEL]..................................................................72

9. Oil Pump ...................................................................................................80

10. Reservoir Tank..........................................................................................85

11. Power Steering Fluid.................................................................................86

12. General Diagnostic Table..........................................................................87

PS-47

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD MODEL]

6. Steering Gearbox [RHD MOD-

EL]

A: REMOVAL

1) Set the vehicle on a lift.

2) Disconnect the ground cable from battery.

3) Loosen the front wheel nut.

4) Lift-up the vehicle, and then remove the front

wheels.

5) Remove the under cover.

6) Remove the sub frame.

7) Remove the front exhaust pipe assembly. (Non-

turbo model)

<Ref. to EX(H4SO)-6, REMOVAL, Front Exhaust

Pipe.>

WARNING:

Be careful, the exhaust pipe is hot.

8) Using a puller, remove the tie-rod end from

knuckle arm after pulling off cotter pin and remov-

ing castle nut.

9) Remove the jack-up plate and front stabilizer.

10) Remove the one pipe joint at center of gearbox,

and connect vinyl hose to pipe and joint. Discharge

fluid by turning the steering wheel fully clockwise

and counterclockwise. Discharge fluid similarly

from the other pipe.

11) Remove the universal joint. <Ref. to PS-24,

REMOVAL, Universal Joint.>

12) Disconnect the lower pipe C from gear box first,

and upper pipe D second.

13) Remove the clamp bolts securing the gearbox

to crossmember, and then remove the gearbox.

(1) Castle nut

(2) Tie-rod end

(3) Knuckle arm

(1) Jack-up plate

PS-00043

PS-00044

(1) Pipe A

(2) Pipe B

(1) Pipe C

(2) Pipe D

(1) Clamp

PS-00045

PS-00046

PS-00047

PS-48

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD MODEL]

B: INSTALLATION

1) Insert the gearbox into crossmember, being

careful not to damage the gearbox boot.

2) Tighten the gearbox to crossmember bracket via

clamp with bolts to specified torque.

Tightening torque:

60 N·m (6.1 kgf-m, 44.1 ft-lb)

3) Connect the pipe D first to gear box, and pipe C

second.

Tightening torque:

T: 15 N·m (1.5 kgf-m, 10.8 ft-lb)

4) Install the universal joint. <Ref. to PS-24, IN-

STALLATION, Universal Joint.>

5) Connect the tie-rod end and knuckle arm, and

tighten with castle nut.

Castle nut tightening torque:

27 N·m (2.75 kgf-m, 19.9 ft-lb)

CAUTION:

When connecting, do not hit the cap at bottom

of tie-rod end with hammer.

6) After tightening the castle nut to the specified

tightening torque, tighten it further within 60° until

cotter pin hole is aligned with slot in the nut. Fit the

cotter pin into nut, and then bend the pin to lock.

7) Install the front stabilizer to vehicle.

8) Install the front exhaust pipe assembly.

9) Install the sub frame.

10) Install the under cover.

11) Align the center of roll connector. <Ref. to AB-

18, ADJUSTMENT, Roll Connector.>

12) Install the steering wheel. <Ref. to PS-23, IN-

STALLATION, Steering Wheel.>

13) Install the front wheels.

14) Tighten the wheel nuts to specified torque.

Tightening torque:

90 N·m (9.1 kgf-m, 65.8 ft-lb)

15) Connect the battery ground cable to battery.

16) Pour fluid into the oil tank, and bleed air.

<Ref. to PS-86, Power Steering Fluid.>

17) Check for fluid leaks.

18) Install the jack-up plate.

19) Lower the vehicle.

20) Check the fluid level in oil tank.

(1) Clamp

(1) Pipe C

(2) Pipe D

PS-00047

PS-00049

(A) Cotter pin

(B) Castle nut

DS-00042

(C)

(B)

(A)

PS-49

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD MODEL]

21) After adjusting the toe-in and steering angle,

tighten the lock nut on tie-rod end.

Tightening torque:

83 N·m (8.5 kgf-m, 61.5 ft-lb)

NOTE:

When adjusting the toe-in, hold boot as shown to

prevent it from being rotated or twisted. If twisted,

straighten it.

C: DISASSEMBLY

1) Secure the gearbox removed from vehicle in

vise using the ST.

ST 926200000 STAND

CAUTION:

Secure the gearbox assembly in a vise using

the ST as shown. Do not attempt to secure it

without this ST.

2) Remove the tie-rod end and lock nut from gear-

box.

3) Remove the clip on outside of boot using pliers,

and then slide the boot to tie-rod end side.

4) Using flat tip screwdriver, remove the band from

boot.

NOTE:

Check the boot for crack, damage or deterioration.

Replace the boot with a new one if necessary.

5) Using the ST, loosen lock nut.

ST 926230000 SPANNER

(1) Clamp

PS-00051

PS-00052

(1) Clip

(1) Band

(1) Lock nut

PS-00053

PS-00054

PS-00056

PS-50

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD MODEL]

6) Tighten the adjusting screw until it no longer

tightens.

7) Using a wrench (32 mm (1.26 in) width across

flats) or adjustable wrench with cinching boot, re-

move the tie-rod.

8) Loosen the adjusting screw, and then remove

the spring and sleeve.

9) Disconnect the pipes A and B from steering body

and control valve housing.

10) Clean the dirt of input shaft. Remove the dust

cover taking care not to scratch the housing or in-

put shaft and allow foreign matter to enter gear box

interior.

11) Align the ST pin to plug hole to install. Rotate

the ST counterclockwise to remove plug.

ST 34199AE090 PLUG WRENCH

(1) Adjusting screw

(1) Tie-rod

(1) Pipe A

(2) Pipe B

PS-00057

PS-00058

PS-00059

(1) Dust cover

(1) Plug

PS-00060

PS-00061

PS-51

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD MODEL]

12) Remove the valve assembly taking care not to

scratch seal ring and valve housing inner surface.

13) Remove the holder using a wrench (32 mm

(1.26 in) width across flats) or adjustable wrench.

14) Install the ST on valve side of rack and press

outer side oil seal out taking care not to contact

rack with steering body inner surface.

ST 34099FA030 INSTALLER & REMOVER

NOTE:

Block the pipe connection of steering body to pre-

vent fluid from flowing out.

(1) Valve ASSY

(2) Seal ring

PS-00062

PS-00063

(1) Rack piston

(2) Outer side oil seal

PS-00064

PS-52

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD MODEL]

15) Insert the ST from valve side and press back-

up ring and oil seal out.

ST 927580000 REMOVER

16) Using the ST1 and ST2, repair the cylinder’s

clinched sections.

ST1 34099FA080 PUNCH

ST2 34099FA070 BASE

17) If the cylinder edge is deformed in a convex

shape, repair using an oil stone.

18) Remove the oil seal using ST and press from

plug.

ST 34199AE100 PLUG OIL SEAL REMOVER

NOTE:

Do not apply force on the plug edge surface.

19) Set the ST on drawing dimension.

ST 34199AE120 GEARBOX OIL SEAL RE-

MOVER

(1) Cylinder

PS-00065

PS-00066

(1) Oil seal

(2) O-ring

(1) 70 mm (2.76 in)

PS-00067

PS-00068

PS-00069

PS-53

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD MODEL]

20) Set the stopper to gear box, and then insert the

tip of ST to gear box.

21) By fixing the 2-surface width, press in by rotat-

ing the rod and attach to oil seal.

22) While fixing the 2-surface width, pull out the oil

seal by rotating nut.

CAUTION:

Take care not to scratch the gear box inner sur-

face.

D: ASSEMBLY

1) Apply a coat of grease to inside and outside of

new oil seal.

Specified steering grease:

VALIANT GREASE M2 (Part No. 003608001)

2) Verify the oil seal direction and installation posi-

tion. Using the ST and press, press fit the oil seal to

gear box.

ST 34199AE130 GEARBOX OIL SEAL IN-

STALLER

(1) Stopper

(2) Oil seal

(1) Rod

(2) 2-surface width

PS-00070

PS-00071

(1) 2-surface width

(2) Nut

(1) Oil seal

PS-00072

PS-00073

PS-54

POWER ASSISTED SYSTEM (POWER STEERING)

Steering Gearbox [RHD MODEL]

3) Attach the steering body to ST as shown in the

figure. Apply a coat of grease to needle bearing.

ST 926200000 STAND

CAUTION:

Ensure the needle bearing is free from defects.

If it is faulty, replace the steering body with a

new one.

4) Using the ST·B and ST·C, attach the oil seal to

ST·A.

ST 927490000 INSTALLER A, B, C

NOTE:

Face the oil seal in direction shown in the figure.

5) Insert the ST·A with oil seal assembled, through

gear side of rack. Remove the oil seal from ST·A

near piston, and then remove the ST·A from rack.

6) Install the back-up washer from gear side of

rack.

(1) Steering body

(A) Oil seal

PS-00074

PS-00075

ST A

ST B

ST C

(A)

(A) Oil seal

(B) Rack

(1) Oil seal

(2) Back-up washer

(3) Rack

PS-00076

ST A

(A)

(B)

(C)

PS-00077

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