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.
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, reassembling, inspection and adjustment of components and diagnostics for guidance of experienced mechanics.
FOREWORD FW 1. Page Foreword .....................................................................................................
Foreword FOREWORD 1. Foreword A: FOREWORD These manuals are used when performing maintenance, repair, or diagnosis of the Subaru IMPREZA. 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.
HOW TO USE THIS MANUAL HU 1. Page How to Use This Manual .............................................................................
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 component. 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.
How to Use This Manual HOW TO USE THIS MANUAL Example: (7) (5) (20) (21) T2 (5) T6 (8) (1) T1 T3 (4) (2) T8 T2 (3) (6) T3 (1) T5 T3 T2 T10 T3 (2) T4 (4) (4) (3) (12) (22) (23) (16) (14) (9) (6) (10) (11) (11) (10) (9) T3 (18) T1 (13) (15) T2 (17) (19) T6 (4) (3) (7) T4 (10) (4) (15) T2 T11 T5 (22) T6 (3) (12) (35) T4 (8) T3 (26) (23) (14) T2 T5 (27) T2 (10) (34) (24) (25) T7 (24) (36) (25) (13) (31) (30) T2 T5 (29) (10) (17) (16) (37) (32
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.
How to Use This Manual HOW TO USE THIS MANUAL 7. DIAGNOSIS Tables showing a step-by-step process make it easy to conduct diagnosis. 8. SI UNITS 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.
How to Use This Manual HOW TO USE THIS MANUAL 9.
SPECIFICATIONS SPC 1. Page Impreza .......................................................................................................
Impreza SPECIFICATIONS 1. Impreza A: DIMENSIONS Model Overall length Overall width Overall height (at C.W.) Compartment Wheelbase Tread Minimum road clearance Sedan mm (in) mm (in) mm (in) Length Width Height mm (in) mm (in) mm (in) Front mm (in) mm (in) Rear mm (in) Without catalytic converter mm (in) With catalytic converter mm (in) 1,740 (68.4) 1,440 (56.7) 1,890 (74.4) 1,180 (46.5), 1,125 (44.3)★5 Wagon OUTBACK 4,415 (173.8) 1,695 (66.7) 1,710 (67.3) 1,465 (57.7), 1,475 (58.
Impreza SPECIFICATIONS B: ENGINE Model Engine type Valve arrangement Bore × Stroke 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Overhead camshaft type mm (in) 87.9 × 65.8 92 × 75 99.5 × 79 92 × 75 (3.461 × 2.591) (3.62 × 2.95) (3.92 × 3.11) (3.62 × 2.95) Displacement cm3 (cu in) Compression ratio Firing order Idle speed at Park/Neutral position 1,994 (121.67) 10.0±0.2 rpm Maximum output Maximum torque 1,597 (97.
Impreza SPECIFICATIONS D: TRANSMISSION Model Transmission type Clutch type Gear ratio 1st 2nd 3rd 4th 5th 6th Reduction 1st gear (Front reduction drive) Final reduction Reduction gear (Rear drive) (AWD model) Transfer reduction Final reduction Reverse Dual range Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio Type of gear Gear ratio 1.6 L 5MT 4AT DSPD TCC Non-turbo 2.0 L 5MT 4AT DSPD TCC Turbo 2.0 L 5MT 4AT DSPD TCC 3.454, 2.785 3.166★1 1.947, 1.545 1.882★1 1.366, 1.000 1.
Impreza SPECIFICATIONS G: BRAKE Model Service brake system Front Rear Parking brake 1.6 L Non-turbo 2.0 L, 2.5 L Turbo 2.
Impreza SPECIFICATIONS J: WEIGHT 1. LHD MODEL Sedan Option code★1 Model E2 EC 1.6 L FWD Base Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.
Impreza SPECIFICATIONS Option code★1 Model EC K0 KS K4 EC 2.0 L 1.6 L AWD Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.
Impreza SPECIFICATIONS Option code★1 Model E2 K4 K0 EC KS 2.0 L AWD GX 5MT Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.
Impreza SPECIFICATIONS Option code★1 Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: EC E2 K4 K0 KS 2.0 L Turbo 2.
Impreza SPECIFICATIONS Option code★1 Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.
Impreza SPECIFICATIONS Option code★1 Model K4 EC 2.0 L Turbo AWD WRX STi 5MT Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.
Impreza SPECIFICATIONS Wagon Option code★1 Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option EC K0 K4 KS EC 1.
Impreza SPECIFICATIONS Option code★1 Model EC K4 K0 EC KS 1.6 L 2.0 L AWD TS 4AT Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.
Impreza SPECIFICATIONS Option code★1 Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option K0 K4 EC KS 2.
Impreza SPECIFICATIONS Option code★1 Model K0 K4 2.0 L EC KS 2.0 L Turbo AWD GX 4AT Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.
Impreza SPECIFICATIONS Option code★1 Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option EC Front kgf (lb) Rear kgf (lb) Total kgf (lb) Front kgf (lb) Rear kgf (lb) Total kgf (lb) Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Spoiler pack K4 2.
Impreza SPECIFICATIONS 2. RHD MODEL Sedan Option code★1 Model EK EK K1 1.6 L K1 2.0 L AWD 5MT Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.
Impreza SPECIFICATIONS Option code★1 Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option ★1: K1 EK 2.0 L Front kgf (lb) Rear kgf (lb) Total kgf (lb) Front kgf (lb) Rear kgf (lb) Total kgf (lb) Air conditioner ABS Side airbag Sunroof Aluminium wheel Audio Seat in pure hide Rear spoiler Spoiler pack Front LSD Cruise control GX 4AT 795 (1,753) 530 (1,168) 1,325 (2,921) 950 (2,094) 910 (2,006) 1,760 (3,880) ❍ ❍ — — — — — — — — — 2.
Impreza SPECIFICATIONS Option code★1 Model KA 2.0 L 2.5 L 2.0 L Turbo RS WRX 5MT AWD GX 5MT Unladen weight (U.W.) Gross vehicle mass (G.V.M.
Impreza SPECIFICATIONS Option code★1 Model KA 2.0 L Turbo AWD WRX Unladen weight (U.W.) Gross vehicle mass (G.V.M.
Impreza SPECIFICATIONS Wagon Option code★1 Model EK K1 EK 1.6 L K1 2.0 L AWD Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.
Impreza SPECIFICATIONS Option code★1 Model Curb weight (C.W.) Maximum permissible axle weight (M.P.A.W.) Maximum permissible weight (M.P.W.) Option K1 2.
Impreza SPECIFICATIONS Option code★1 Model KA 2.0 L 2.0 L Turbo AWD GX 5MT D/R Unladen weight (U.W.) Gross vehicle mass (G.V.M.
Impreza SPECIFICATIONS SPC-24
PRECAUTION PC 1. Page Precaution ...................................................................................................
Precaution PRECAUTION 1. Precaution 7. AIRBAG MODULE A: PRECAUTION Adhere to the following when handling and storing the airbag module to prevent bodily injury from unexpected 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. Please clearly understand and adhere to the following general precautions.
NOTE NT 1. Page Note.............................................................................................................
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 other substances to the surface around bolts, fasteners, etc. Doing so will make it difficult to obtain the correct torque and result in looseness and other problems. 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.
Note NOTE (1) (A) (2) (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.
Note NOTE • Chain direction at tie-down condition NT-00038 • Chain pulling range at tie-down condition 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 20˚ 45˚ 45˚ 45˚ : (1) 45˚ 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 tiedown. Difference of measurement value (drop height) shall be within 50.8 mm (1.97 in). Make sure to fix the vehicle securely.
Note NOTE 9. TOWING Avoid towing vehicles except when the vehicle cannot be driven. For models with AWD, AT, or VTD, use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damaging the hook 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.
Note NOTE • NOTES Towing Lifting up four wheels (On a trailer) Notes Towing the vehicle after lifting up all four wheels is a basic rule for AWD model. MT ❍ AT ❍ • Check if both front and rear wheels are rotated normally. • AT model driving conditions: Allow driving speed less than 30 km/h (19 MPH). Allow driving distance less than 30 km (19 miles). ❍ ▲ Prohibited for full-time AWD model. ✕ ✕ • Prohibited, due to damage on bumper, front grille, etc. • Do not raise the vehicle with bumper.
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.
Note NOTE 11.TRAINING For information about training, contact a dealer or agent. 12.GENERAL SCAN TOOL Using general scan tools will greatly improve efficiency 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 NOTE NT-10
IDENTIFICATION ID 1. Page Identification ................................................................................................
Identification IDENTIFICATION 1. Identification A: IDENTIFICATION 1. IDENTIFICATION NUMBER AND LABEL LOCATIONS The VIN (Vehicle Identification Numbers) is used to classify the vehicle.
Identification IDENTIFICATION • MANUAL TRANSMISSION • REAR DIFFERENTIAL • T-type (1) (1) ID-00055 ID-00056 (1) Transmission serial number (1) Type (white paint) • VA-type (1) DI-00396 (1) Type (label) • MODEL NUMBER PLATE ID-00075 ID-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. Digits Code 1 to 3 4 5 JF1 G D 6 4 7 L 8 G 9 9 10 11 12 to 17 4 G 002001 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 L FWD 5: 1.6 L AWD 9: 2.0 L AWD A: 2.0 L AWD Turbo B: 2.
Identification IDENTIFICATION 3. MODEL NUMBER PLATE The model number 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.
Identification IDENTIFICATION • Transmission TM754RY5AA 1 2 Digits T M Code Meaning Transmission Transmission type 3 and 4 75 Classification 5 4 Series 6 R Transmission specifications 7 to 10 Y5AA Detailed specifications Details T: Transmission 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 75: 5MT 85: 6MT 1A: AT 1B: AT MT 4: 5MT 6: 6MT AT 4: AT A: FWD 4-speed AT R: FWD Single Range 5-speed MT V: Full-time AWD 5-sp
Identification IDENTIFICATION • Option code E2BL Digits 1—2 E2 Code Meaning Destination 3 B Option equipment Details 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 K0: General model (LHD model) K1: General model (RHD model) Blank: Hong Kong model A: Power window, Power door lock, ABS, Aluminum wheel B: Power window, Power door lock C: Power window, Power door lock, Cruise control
Identification IDENTIFICATION Digits 4 Code L Meaning Option equipment Details 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 & door trim decorative woodturning, Audio, Rear spoiler P: A/C, Sunroof, Airbag, Side airbag, Rear spoiler Q: A/C, Sunroof, Airba
RECOMMENDED MATERIALS RM 1. Page Recommended Materials ............................................................................
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. Ignoring the specifications below will result in damage or poor operation of the engine and fuel injection system. Use the specified gasoline to correct performance.
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. L E GY NG EN SAE 0W-20 R ACEA Spec. A1, A2 or A3 Alternative API Spec. SG, SF SERVICE S PI A Engine oil Recommended API Spec. CCMC Spec.
Recommended Materials RECOMMENDED MATERIALS SAE viscosity No.
Recommended Materials RECOMMENDED MATERIALS SAE viscosity No. and applicable temperature Manual transmission oil, AT front differential gear oil and rear differential gear oil (˚F) –30 –20 –10 0 10 20 30 40 (˚C) –22 –4 14 32 50 68 86 104 90 85W 80W 75W-90 RM-00004 4. FLUID Use the fluids specified in the table below. Do not mix two different kinds or makes of fluid.
Recommended Materials RECOMMENDED MATERIALS 7. GREASE Use the grease and supplementary lubricants shown in the table below. Grease Supplementary lubricants Grease Application point • O2 sensor • Bolts, etc.
Recommended Materials RECOMMENDED MATERIALS 9. SEAL MATERIAL Use seal material shown in the table below, or equivalent. Seal material Seal material Application point • Cylinder block • Torque converter clutch case • Transmission oil pan (6MT model) Transmission oil pan (AT model) Rear differential Rear differential Steering adjusting screw Camshaft cap • Front sealing cover • Rear sealing cover Recommended Three Bond 1215B Item number 004403007 Alternative Dow Corning’s No.
Recommended Materials RECOMMENDED MATERIALS RM-8
PRE-DELIVERY INSPECTION PI 1. Page Pre-delivery Inspection................................................................................
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 vehicle 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.
Pre-delivery Inspection PRE-DELIVERY INSPECTION PROCEDURE 17. AT front differential oil 18. Engine coolant 19. Clutch fluid 20. Window washer fluid 21. Front hood latch check 22. Keyless entry system 23. Seat 24. Seat belt 25. Wheel alignment Check point Check that the AT front differential oil level is normal. Check that the engine coolant level is normal. Check that the clutch fluid level is normal. Check that the window washer fluid level is normal. Check that the hood is closed and latched securely.
Pre-delivery Inspection PRE-DELIVERY INSPECTION 1. APPEARANCE CHECK 5. CHECK THE DOORS FOR LOCK/UNLOCK AND OPEN/CLOSE OPERATIONS • If the vehicle is covered with protective coating, visually check the vehicle body for damage and dents. • If there is no protective coating, check the body paints for small areas of damage or stains and repair as necessary. • Check the window glass, door glass, and lights for any cracks or damage and repair or replace the parts as necessary.
Pre-delivery Inspection PRE-DELIVERY INSPECTION 4) Next, pull the outside door handles of the rear doors to ensure that the doors will open. 4) Press the driver’s side power door lock switch to unlock side. Check that all doors including rear gate are unlocked. (C) (A) (B) PI-00084 PI-00143 (A) Unlock (B) Lock (C) Child safety lock 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.
Pre-delivery Inspection PRE-DELIVERY INSPECTION 9. CHECK THE REAR GATE FOR LOCK/ UNLOCK AND OPEN/CLOSE OPERATIONS 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) 1) Open and close the rear gate several times for smooth movement.
Pre-delivery Inspection PRE-DELIVERY INSPECTION 15.ENGINE OIL Operate the lever (A) and check that the hood is opened normally. Then support the hood with hood stay. Check the engine oil amount. If the amount is insufficient, check that no leaks are found. Then, add the necessary amount of the specified engine oil. (A) (B) (C) (E) (D) LU-00138 (A) (B) (C) (D) (E) Oil level gauge Engine oil filler cap Upper level Lower level Approx. 1.0 2 (1.1 US qt, 0.9 Imp qt) 16.
Pre-delivery Inspection PRE-DELIVERY INSPECTION 17.AT FRONT DIFFERENTIAL OIL 21.HOOD LATCH CHECK 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. 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 follows.
Pre-delivery Inspection PRE-DELIVERY INSPECTION 25.WHEEL ALIGNMENT 28.STARTING CONDITION Check the wheel alignments. and Start the engine and check that the engine starts smoothly. If any battery voltage problems are found, recharge or replace the battery. If any abnormal noises are observed, immediately stop the engine and check and repair the necessary components. 26.
Pre-delivery Inspection PRE-DELIVERY INSPECTION 42.AT SHIFT CONTROL Rear injection position: A: 39 mm (2.36 in) B: 72° Set the AT select lever to each gear position and check the shifting while driving the vehicle. P A R N D 3 2 1 B PI-00104 (1) 36.WIPER (2) PI-00112 (1) RHD model (2) LHD model Check the front and rear wipers for normal operations. 37.
Pre-delivery Inspection PRE-DELIVERY INSPECTION 46.ATF LEVEL 49.WATER LEAK TEST 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. Spray the vehicle with water and check that no water enters the passenger compartment. • Before performing the water leakage test, remove anything that may obstruct the operation or which must be kept dry.
Pre-delivery Inspection PRE-DELIVERY INSPECTION • If 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 of the peeled wrap guard as burnable industrial garbage. 2) Check the whole vehicle body for stains, flaking, damage caused by transportation, rust, dirt, cracks, or blistering.
PERIODIC MAINTENANCE SERVICES PM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Page General Description ....................................................................................2 Schedule .....................................................................................................3 Engine Oil....................................................................................................7 Engine Oil Filter..............................
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.
Schedule 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.
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] 12 24 36 48 Remarks 5 12.5 25 37.5 50 3 7.5 15 22.
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.
Schedule PERIODIC MAINTENANCE SERVICES 2.
Engine Oil PERIODIC MAINTENANCE SERVICES 3. Engine Oil • SOHC MODEL A: REPLACEMENT 1) Open the engine oil filler cap for quick draining of the engine oil. (A) (B) LU-00193 4) Replace the drain plug gasket. 5) Tighten the engine oil drain plug after draining engine oil. PM-00155 Tightening torque: 44 N·m (4.5 kgf-m, 33 ft-lb) • DOHC TURBO MODEL (A) Oil level gauge (B) Oil filler cap 2) Remove the dip of service hole cover.
Engine Oil 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.
Engine Oil Filter PERIODIC MAINTENANCE SERVICES 4. Engine Oil Filter A: REPLACEMENT 1) Remove 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)) • SOHC MODEL LU-00194 • DOHC TURBO MODEL LU-00190 3) Get a new oil filter and apply a thin coat of engine oil to the seal rubber.
Spark Plugs PERIODIC MAINTENANCE SERVICES 5. Spark Plugs 5) Remove the ignition coil. A: REPLACEMENT 1. SOHC MODEL 1) Remove the intake duct and intake chamber. 2) Remove the washer tank and put it aside. 3) Disconnect the spark plug cord. 4) Remove the spark plug with a plug-wrench. PM-00145 6) Remove the spark plug with a spark plug socket. PM-00001 5) Set the new spark plugs. Recommended spark plug: 1.6 L SOHC model (with catalytic converter) CHAMPION: RC8YC4 NGK: BKR6E-11 (Alternate) 1.
V-belt PERIODIC MAINTENANCE SERVICES 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 necessary by changing the generator installing position and/or idler pulley installing position. 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.
V-belt PERIODIC MAINTENANCE SERVICES TURBO MODEL Tightening torque: 23 N·m (2.3 kgf-m, 17.0 ft-lb) (B) (A) 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-lb) Slider bolt: 8 N·m (0.8 kgf-m, 5.8 ft-lb) (C) (B) (A) PM-00004 2.
Timing Belt PERIODIC MAINTENANCE SERVICES 7. Timing Belt 10) Remove the timing belt guide. (MT model) A: REPLACEMENT 1. NON-TURBO MODEL 1) Remove the radiator fan and air conditioner fan. , 2) Shield the radiator from any damage using cardboard and blanket. 3) Remove the V-belt cover.
Timing Belt PERIODIC MAINTENANCE SERVICES 15) Remove the automatic belt tension adjuster assembly. 11) Remove the timing belt guide. (MT model) PM-00008 PM-00011 16) Install in the reverse order of removal. 2. DOHC MODEL 1) Remove the radiator fan and air conditioner fan. , 2) Protect the radiator with cardboard and blanket.
Timing Belt PERIODIC MAINTENANCE SERVICES ST 499987500 CRANKSHAFT SOCKET CAUTION: When installing the timing belt, be sure to align all alignment marks on the belt with corresponding marks on the sprockets. If incorrectly installed, interference between pistons and valves may occur. (A) (B) (B) (B) (B) B: INSPECTION 1. SOHC MODEL (A) (A) 1) Remove the front timing belt cover and timing belt cover (LH).
Fuel Line PERIODIC MAINTENANCE SERVICES 8. Fuel Line A: INSPECTION The fuel line is 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 DOHC Turbo model
Fuel Filter PERIODIC MAINTENANCE SERVICES 9. Fuel Filter A: REPLACEMENT For fuel filter replacement procedures, refer to “FU” section. SOHC model DOHC Turbo model 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.
Air Cleaner Element PERIODIC MAINTENANCE SERVICES 10.Air Cleaner Element 2) Remove the air cleaner. 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. (B) (A) PM-00098 (B) 3) Install in the reverse order of removal.
Cooling System PERIODIC MAINTENANCE SERVICES 11.Cooling System A: INSPECTION 1) Check the radiator for leakage, filling it with coolant 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/cm2, 23 psi) Radiator cap valve open pressure Turbo model 122 kPa (1.
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 system. SOHC model DOHC Turbo model
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 engine coolant into container.
Coolant PERIODIC MAINTENANCE SERVICES 2. RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE The concentration and safe operating temperature of the SUBARU coolant is shown in the diagram. Measuring 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.
Idle Mixture PERIODIC MAINTENANCE SERVICES 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 700±100 rpm CO 1.0±0.
Clutch System PERIODIC 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 it is 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-lb) Standard: 80 mm (3.
Clutch System PERIODIC MAINTENANCE SERVICES 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.
Transmission Gear Oil PERIODIC MAINTENANCE SERVICES 15.Transmission Gear Oil A: REPLACEMENT 1. MANUAL TRANSMISSION 1) Drain the gear oil by removing drain plug. NOTE: • Before starting work, cool off the transmission gear oil well. • If transmission gear oil adheres to the exhaust pipe, wipe it off completely. 5MT Gear oil capacity: FWD model 3.3 L (3.5 US qt, 2.5 Imp qt) AWD model (5MT single range model): 3.5 L (3.7 US qt, 3.1 Imp qt) AWD model (5MT dual range model): 4.0 L (4.2 US qt, 3.
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 properly; A; When the hill-holder is released later than engagement of clutch (engine tends to stall): Loosen the adjusting nut gradually until smooth starting is enabled.
ATF PERIODIC MAINTENANCE SERVICES 17.ATF B: REPLACEMENT A: INSPECTION 1. AUTOMATIC TRANSMISSION FLUID 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 engine to raise ATF temperature to 70 — 80°C (158 — 176°F) on Subaru Select Monitor.
ATF PERIODIC MAINTENANCE SERVICES 4) Check the ATF level. (C) (E) COLD L F (D) L F HOT (A) (B) (C) (D) 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°F)] 2. ATF FILTER NOTE: ATF filter is a maintenance free part. ATF filter needs replacement, when it has physically damaged or ATF leaked. For the replacement procedures of the ATF filter:
Front & Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES 18.Front & Rear Differential Gear Oil Differential gear oil capacity: 1.1 — 1.3 2 (1.2 — 1.4 US qt, 1.0 — 1.1 lmp qt) A: REPLACEMENT (A) 1. FRONT DIFFERENTIAL (MT MODEL) (A) (B) Differential oil works as manual transmission oil to lubricate differential. Refer to “Transmission Oil”. (C) 2. FRONT DIFFERENTIAL (AT MODEL) 1) Drain the differential gear oil by removing drain plug using TORX®.
Front & Rear Differential Gear Oil PERIODIC MAINTENANCE SERVICES VA TYPE (A) (B) 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’s control center differential GL-5 [LSD oil (90)] or equivalent Oil capacity: Except for STi model: 0.8 2 (0.8 US qt, 0.7 lmp qt) STi model: 0.9 — 1.12 (1.0 — 1.2 US qt, 0.8 — 1.0 lmp qt) NOTE: • Each oil manufacturer has its base oil and additives.
Brake Line PERIODIC MAINTENANCE SERVICES 19.Brake Line Brake pedal free play: 0.5 — 2.0 mm (0.02 — 0.08 in) 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 pressure control valve.
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 lb) load and measure the distance between brake pedal and steering wheel. With the brake pedal released, measure the distance 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 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.
Disc Brake Pads and Discs PERIODIC MAINTENANCE SERVICES 21.Disc Brake Pads and Discs (A) A: INSPECTION (C) (B) 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 inspection hole of disc brake assembly. Replace the pad if necessary. PM-00140 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.
Brake Linings and Drums PERIODIC MAINTENANCE SERVICES 22.Brake Linings and Drums If deformation or wear of back plate, shoe, etc. is noticeable, replace the affected parts. 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 deformities and check brake linings for wear.
Brake Linings and Drums PERIODIC MAINTENANCE SERVICES 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) 3) Turn back (downward) the adjuster 3 to 4 notches. 4) Install the cover (rubber) at original position correctly. (B) (A) PM-00055 (A) Inside diameter (B) Disk 3) If the deformation or wear of back plate, shoe, etc. is noticeable, replace them.
Suspension PERIODIC MAINTENANCE SERVICES 23.Suspension NOTE: When the transverse link ball joint has been removed or replaced, check the toe-in of front wheel. If the front wheel toe-in is not at specified value, adjust the toe-in. 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.
Suspension PERIODIC MAINTENANCE SERVICES 4. WHEEL ALIGNMENT OF FRONT SUSPENSION 8. DAMAGE TO SUSPENSION PARTS 1) Check the alignment of front suspension to ensure that following items conform to standard values. • Toe-in • Camber angle • Caster angle • Steering angle 2) When the caster angle does not conform to reference, visually inspect the following components and replace deformed parts. • Suspension components [Strut assembly, crossmember, transverse link, etc.
Wheel Bearing PERIODIC MAINTENANCE SERVICES 24.Wheel Bearing 4) If the bearing free play exists in step 2) above, attach a dial gauge to the hub COMPL and measure axial displacement in axial direction. 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.
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.
Axle Boots & Joints PERIODIC MAINTENANCE SERVICES 25.Axle Boots & 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, replace them with new ones. (A) PM-00063 (B) PM-00064 2. PROPELLER SHAFT Inspect the propeller shaft for damage or failure. If faulty, replace with a new one.
Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES 26.Steering System (Power Steering) 2. STEERING SHAFT JOINT A: INSPECTION 1. STEERING WHEEL 1) Set the steering wheel in a straight-ahead position, and check the wheel spokes to make sure they are correctly set in their specified positions. 2) Lightly 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 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. 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-lb) 5.
Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES NOTE: Prevent the hoses from revolving and/or turning when installing hoses. PM-00071 8. POWER STEERING PIPES FOR DAMAGE 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.
Steering System (Power Steering) PERIODIC MAINTENANCE SERVICES PM-46
