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

FRONT SUSPENSION

Page

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

2. Wheel Alignment .........................................................................................6

3. Front Transverse Link ...............................................................................15

4. Front Ball Joint ..........................................................................................18

5. Front Strut .................................................................................................19

6. Front Stabilizer ..........................................................................................23

7. Front Crossmember ..................................................................................24

8. Sub Frame ................................................................................................25

9. Front Support Arm.....................................................................................27

10. General Diagnostic Table..........................................................................28

FS-2

FRONT SUSPENSION

General Description

1. General Description

A: SPECIFICATIONS

*1 WRX: 20 mm (0.79 in)

STi: 19 mm (0.75 in)

*2 TS, GX: None

RS: 10 mm (0.39 in)

NOTE:

•Front and rear toe-ins and front camber can be

adjusted. If toe-in or camber tolerance exceeds

specifications, adjust toe-in and camber to the

specification.

•The other items indicated in the specification ta-

ble cannot be adjusted. If the other items exceeds

specifications, check suspension parts and con-

nections for deformities, and replace with new ones

as required.

Model Sedan Wagon OUTBACK

Non-turbo Turbo Non-turbo Turbo

Front

Camber (tolerance: ±0°45′)−0°15′−0°25′−0°10′−0°20′−0°05′

Caster 3°25′3°30′3°25′3°30′3°25′

Toe-in mm (in) 0±3 (0±0.12) Each toe angle: ±0°07′30″

Kingpin angle 14°20′14°35′13°30′13°45′13°20′

Wheel arch height

[tolerance:+12 -24 mm

(+0.47 -0.94 in)]

mm (in) 406

(15.98)

396

(15.59)

397

(15.28)

387

(15.24)

402

(15.83)

Diameter of stabilizer mm (in) 20 (0.79) *1 20 (0.79)

Rear

Camber (tolerance: ±0°45′)−1°25′−1°30′−1°15′−1°20′−1°10′

Toe-in mm (in) 0±3 (0±0.12) Each toe angle: ±0°09′

Thrust angle (Tolerance: ±0°30′) 0°

Wheel arch height

[tolerance:+12 −24 mm

(+0.47 −0.94 in)]

mm (in) 381

(15.0)

376

(14.80)

381

(15.0)

376

(14.80)

386

(15.20)

Diameter of stabilizer mm (in) *2 *1 —17

(0.67) —

(1) Front

A −B = Positive: Toe-in, Negative: Toe-out

α= Each toe angle

FS-00001

(1)

FS-3

FRONT SUSPENSION

General Description

B: COMPONENT

FS-00137

(16)

(33)

(34)

(15)

(11)

(28)

(26)

(25)

(24)

(23)

(22)

(21)

(20)

(19)

(18)

(17)

(28)

(1) (2)

(5)

(4)

(3)

(6)

(28)

(7)

(8)

(9)

(27)

(10)

(28)

(4)

(11)

(8)

(31)

(9)

(27)

(28) (10)

(12)

(15)

(30)

(32)

(29)

(28)

(14)

(13) (12)

T11

T15

T14

T5 T12

T6 T3

T10

T13

(28)

T10

FS-4

FRONT SUSPENSION

General Description

C: CAUTION

•Wear working clothing, including a cap, protec-

tive goggles, and protective shoes during opera-

tion.

•Before removal, installation or disassembly, be

sure to clarify the failure. Avoid unnecessary re-

moval, installation, disassembly, and replacement.

•Use SUBARU genuine grease etc. or the equiv-

alent. Do not mix grease etc. with that of another

grade or from other manufacturers.

•Before securing a part on a vise, place cushion-

ing material such as wood blocks, aluminum plate,

or shop cloth between the part and the vise.

•Be sure to tighten fasteners including bolts and

nuts to the specified torque.

•Place shop jacks or rigid racks at the specified

points.

(1) Front crossmember (18) Strut mount Tightening torque: N·m (kgf-m, ft-lb)

(2) Bolt ASSY (19) Spacer T1: 20 (2.0, 14.5)

(3) Housing (20) Upper spring seat T2: 25 (2.5, 18.1)

(4) Washer (21) Rubber seat T3: 30 (3.1, 22)

(5) Stopper rubber (Rear) (22) Dust cover T4: 34 (3.5, 25)

(6) Rear bushing (23) Helper T5: 40 (4.1, 30)

(7) Stopper rubber (Front) (24) Coil spring T6: 45 (4.6, 33)

(8) Ball joint (25) Damper strut T7: 50 (5.1, 37)

(9) Transverse link (26) Adjusting bolt T8: 55 (5.6, 41)

(10) Cotter pin (27) Castle nut T9: 70 (7.1, 52)

(11) Front bushing (28) Self-locking nut T10: 95 (9.7, 70)

(12) Stabilizer link (29) Sub frame T11: 105 (10.7, 77)

(13) Clamp (30) Cover T12: 155 (15.8, 114)

(14) Bushing (31) Boss T13: 175 (17.8, 129)

(15) Stabilizer (32) Clip T14: 186 (19.0, 137)

(16) Jack-up plate (33) Front support arm T15: 250 (25.5, 184)

(17) Dust seal (34) Sedan turbo model

FS-5

FRONT SUSPENSION

General Description

D: PREPARATION TOOL

1. SPECIAL TOOLS

2. GENERAL PURPOSE TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

927380002 ADAPTER Used as an adapter for camber & caster gauge

when measuring camber and caster.

(1) 28199AC000 PLATE

(2) 28199AC010 BOLT

927680000 INSTALLER &

REMOVER SET

Used for replacing transverse link bushing.

927760000 STRUT MOUNT

SOCKET

Used for disassembling and assembling strut

and shock mount.

TOOL NAME REMARKS

Alignment gauge Used for wheel alignment measurement.

Turning radius gauge Used for wheel alignment measurement.

Toe-in gauge Used for toe-in measurement.

Dial gauge Used for damper strut measurement.

Coil spring compressor Used for strut disassembly/assembly.

(1)

(2)

ST-927380002

ST-927680000

ST-927760000

FS-6

FRONT SUSPENSION

Wheel Alignment

2. Wheel Alignment

A: INSPECTION

Check the following items before taking wheel alignment measurement.

Check items before taking wheel alignment measurement:

•tire air pressure

•unbalanced right and left tire wear, size difference

•tire run-out

•ball joint excessive play, wear

•tie rod end excessive play, wear

•wheel bearing excessive play

•right and left wheel base imbalance

•steering link part deformed, excessive play

•suspension part deformed, excessive play

Check, adjust and/or measure the wheel alignment in accordance with procedures indicated in the figure:

Wheel arch height (Front and rear)

<Ref. to FS-7, WHEEL ARCH HEIGHT, INSPECTION, Wheel Alignment.>

↓

Camber (Front and rear)

<Ref. to FS-8, CAMBER, INSPECTION, Wheel Alignment.>

↓

Caster (Front)

<Ref. to FS-9, CASTER, INSPECTION, Wheel Alignment.>

↓

Steering angle

<Ref. to FS-10, STEERING ANGLE, INSPECTION, Wheel Alignment.>

↓

Front wheel toe-in

<Ref. to FS-10, FRONT WHEEL TOE-IN, INSPECTION, Wheel Alignment.>

↓

Rear wheel toe-in

<Ref. to FS-11, REAR WHEEL TOE-IN, INSPECTION, Wheel Alignment.>

↓

Thrust angle

<Ref. to FS-13, THRUST ANGLE, INSPECTION, Wheel Alignment.>

FS-7

FRONT SUSPENSION

Wheel Alignment

1. WHEEL ARCH HEIGHT

1) Set the vehicle on a level surface.

2) Set the vehicle to “curb weight”conditions. (Empty luggage compartment, install spare tire, jack, service

tools, and top up fuel tank.)

3) Set the steering wheel in a straight line, then remove the vehicle straight ahead more than 5 m (16 ft) to

settle the suspension.

4) Suspend the thread from wheel arch (point “A”in figure below) to determine a point directly above center

of wheel.

5) Measure the distance between measuring point “A”and center of wheel.

(1) Wheel arch height (4) Front wheel arch height (7) Measuring point

(2) Front fender (5) Rear wheel arch height (8) End of spindle

(3) Rear quarter (6) Flange bend line

Model Specified wheel arch height mm (in) (tolerance: +12 −24 mm (+0.47 −0.94 in))

Non-turbo Turbo

Sedan Front 406 (15.98) 396 (15.59)

Rear 381 (15.0) 376 (14.80)

Wagon Front 397 (15.63) 387 (15.24)

Rear 381 (15.0) 376 (14.80)

OUTBACK Front 402 (15.83) —

Rear 386 (15.20) —

FS-00094

(4)

(1)

(2) (3)

(1)

(5) (1)

(7)

(6)

(8)

FS-8

FRONT SUSPENSION

Wheel Alignment

2. CAMBER

•Inspection

1) Place the front wheel on turning radius gauge.

Make sure ground contacting surfaces of front and

rear wheels are set at the same height.

2) Set the ST into the center of wheel, and then in-

stall the wheel alignment gauge.

ST 927380002 ADAPTER

3) Follow the wheel alignment gauge operation

manual to measure camber angle.

•Front Camber Adjustment

1) When adjusting the camber, adjust it to the fol-

lowing value.

2) Loosen the two self-locking nuts located at lower

front portion of strut.

NOTE:

When adjusting bolt needs to be loosened or tight-

ened, hold its head with a wrench and turn self-

locking nut.

3) Turn the camber adjusting bolt so that camber is

set at the specification.

NOTE:

Moving the adjusting bolt by one scale graduation

changes camber by approx. 0°15′.

(1) Alignment gauge

(2) Turning radius gauge

Model Camber (Differences between

RH and LH: 45′or less)

Sedan Non-turbo −0°15′±0°45′

Turbo −0°25′±0°45′

Wagon Non-turbo −0°10′±0°45′

Turbo −0°20′±0°45′

OUTBACK −0°05′±0°45′

Model Camber (Differences between

RH and LH: 45′or less)

Sedan Non-turbo −0°15′±0°30′

Turbo −0°25′±0°30′

Wagon Non-turbo −0°10′±0°30′

Turbo −0°20′±0°30′

OUTBACK −0°05′±0°30′

FS-00007

(1)

(2)

(1) Strut

(2) Adjusting bolt

(3) Housing

(4) Outer

(5) Inner

(6) Camber is increased.

(7) Camber is decreased.

(1)

(4)

(6) (7)

(2)

(3)

FS-00008

(5)

FS-9

FRONT SUSPENSION

Wheel Alignment

4) Tighten the new two self-locking nuts.

Tightening torque:

175 N·m (17.8 kgf-m, 129 ft-lb)

3. CASTER

•Inspection

1) Place the front wheel on turning radius gauge.

Make sure ground contacting surfaces of front and

rear wheels are set at the same height.

2) Set the ST into center of wheel, and then install

the wheel alignment gauge.

ST 927380002 ADAPTER

3) Follow the wheel alignment gauge operation

manual to measure caster angle.

Camber is increased.

Rotate camber adjusting bolt LH counterclockwise. Rotate camber adjusting bolt RH clockwise.

FS-00009 FS-00010

Camber is decreased.

Rotate camber adjusting bolt LH clockwise. Rotate camber adjusting bolt RH counterclockwise.

FS-00010 FS-00009

(1) Alignment gauge

(2) Turning radius gauge

Model Caster

Sedan Non-turbo 3°25′

Turbo 3°30′

Wagon Non-turbo 3°25′

Turbo 3°35′

OUTBACK 3°25′

FS-00007

(1)

(2)

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