Subaru 2002 Impreza Service Manual Download Page 60 | Manualshive

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Summary of Contents for 2002 Impreza

Page 1: ...nspection 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...

Page 2: ...I...

Page 3: ...FOREWORD FWa Page Foreword 2 1...

Page 4: ...sis of the Subaru IMPREZA Applied model GG and GD from 2001MY The additional manuals below are also available AL Pub No G0853ZE AUTOMATIC TRANSMISSION SERVICE MANU The manuals contain the latest infor...

Page 5: ...HOW TO USE THIS MANUALS HU Paae 1 How to Use This Manuals 2...

Page 6: ...section is an alphabetical index 3 COMPONENTS For each component a composition drawing is in cluded 4 SPECIFICATIONS ff necessary specifications are also included 5 INSPECTION Inspections are include...

Page 7: ...SPECIFICATIONS SPC 1 lmpreza 2 Page a...

Page 8: ...3 I 1 150 45 3 3 I 1 I80 46 5 mm in I Rear mm in I 1 455 57 3 1 455 57 3 1 475 58 1 1 480 58 3 1 Minimum road clearance mm in 160 6 3 150 5 9 150 5 9 155 6 1 1 155 6 1 1 B ENGINE Model Turbo 2 0 L 2 5...

Page 9: ...1O k10 700 12 10 750 Ignitiontiming at idling speed BTDC rpm Transmissiontype 5MTSrl 4ATlr2 Clutch type DSPD TCC Gear ratio I 1st 3 454 2 785 r M m I Turbo 2 0 L I 5th 0 738 Reverse 3 333 2 272 Reduc...

Page 10: ...hromeshand I reverse 4AT 2 Electronicallycontrolled fully automatic 4 forward speeds and 1 reverse DSPD Dry Single Plate Diaphragm TCC Torque Converter Clutch E STEERING Gear ratio 1 ooo 1 000 Type of...

Page 11: ...Q US qt Imp qt I 5MT I 4AT I 5MT I 4AT I 9 5 10 0 8 4 1 2 1 3 1 I 1 2 1 3 1 1 9 3 9 8 8 2 0 8 0 8 0 6 0 7 0 7 0 6 7 7 8 1 6 8 I 7 6 8 0 6 7 I 7 0 7 4 6 2 1 6 9 7 3 6 1 Turbo 2 0 L WRX 5MTlrl 4ATJrl 2...

Page 12: ...4 190 Curb weight C W Front kg Ib Rear kg Ib Total kg Ib Gross vehicle weight Front kg Ib G v w Rear kg Ib 2 5 L TS OUTBACK 5 M T t l 4ATt1 5MT 4AT 773 1 705 796 1 755 783 1 725 805 1 775 603 1 330 6...

Page 13: ...sweight of air conditioner Front kg Ib 826 1 820 851 1 875 778 1 715 803 1 770 Rear kg Ib 573 1 265 573 1 265 567 1 250 567 1 250 Total kg Ib 1 399 3 085 1 424 3 140 1 345 2 965 1 370 3 020 Front kg I...

Page 14: ...IMPREZA SPECIFICATIONS c SPC 8...

Page 15: ...I PRECAUTION PC Page Precaution 2 1...

Page 16: ...nance on the airbag components or nearby and the airbag wiring harnesses or nearby To prevent unexpecteddeployment perform one of the steps below and then wait at least 20 seconds to discharge electri...

Page 17: ...I NOTE NT Page 1 Note 2...

Page 18: ...t in looseness and other prob lems 2 STATIC ELECTRICITYDAMAGE Do not touch the ECM connectors logic boards and other such parts when there is a risk of static electricity Always use a static electrici...

Page 19: ...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...

Page 20: ...NOTE NOTE I Front nt cross member Rear Rear differential GI0121 NT 4...

Page 21: ...wns are used when transporting vehicles and when using the chassis dynamo Attach tie downs only to the specified points on the vehicle Hook for towing 1 Hook for tie down Hook for tie down Hook for to...

Page 22: ...e hook or vehicle Do not tow other vehicles with a front towing hook Make sure the vehicle towing is heavier than the vehicle being towed 8 TRAINING For an information about training contact a dealer...

Page 23: ...IDENTIFICATION ID Page Identification 2 1...

Page 24: ...LOCATIONS The VIN Vehicle Identification Numbers is used to classify the vehicle Positioning of the plate label for identification I Vacuum hose piping label number plate pressure label Vehicle Model...

Page 25: ...IDENTIFlCATlON r z it b I L3 F trim code engine type 9 L2 F 2 3 0 s v 5 3 w I IDENTIFICATION E J 2 0 E N M A B A Model number plate U GlOOllA ID 3...

Page 26: ...Displacement ID 7 8 9 10 5 Grade 5 Restraint X Check digit 2 Model year 11 G Transmissiontype 12to 17 Details 500001 Manufacture number JFI Passengercar FHI made G IMPREZA D 4 Door Sedan G Waaon 2 2 0...

Page 27: ...SOHC A A Exhaust reuulations US Federal California Meaning Series 8 9to10 Body style 3 Minor change 3 3 is applied for this vehicle AB Detailedspecifications Used when ordering parts See the parts cat...

Page 28: ...and 4 Transmissionspecifica tions 1 4 5 A T 14 New A T V Full timeAWD 5 speed MT with viscous coupling center dif ferentialsingle range Z Full timeAWD 4 speed A T with MPT Y Full timeAWD 4 speed A T w...

Page 29: ...I RECOMMENDED MATERIALS RIM Page Recommended Materials 2 1...

Page 30: ...soline of the same or higher octane value than specified in the owner s manual Ignor ing the specifications below will result in damage or poor operation of the engine and fuel injection sys tem Use t...

Page 31: ...ee the table below to choosethe correct SAE viscosity Recommended Alternative API Spec ACEA Spec A1 A2 or A3 SJ Grade Energy conserving API SH or SG Manualtransmissionoil GL 5 Front differential GL 5...

Page 32: ...lant Coolant Water for dilution I OF 22 4 14 32 50 68 86 104 Recommended Item number Alternative Distilledwater Tap water SUBARU coolant 000016218 None I I I I I I I I Air conditioner Refrigerant Comp...

Page 33: ...FX clutch clrease I 000040901 I Molylex No 2 723223010 VU 3A702 23223GA050 Slicolube G 30M 004404002 Adhesive I Drum brake I Molvkote No 7439 I 72519460 Windshield and body Essex ChemicalCrop s Ure Su...

Page 34: ...RECOMMENDED MATERIALS RECOMMENDEDMATERIALS I c 1 RM 6...

Page 35: ...I PRElDELlVERY INSPECTION PI Page Pre delivery Inspection 2 1...

Page 36: ...tate Check if the vehicle before delivery is in a normal state Check for any damage or missing parts that may have taken place during transportation or storage Make sure to provide a complete vehicle...

Page 37: ...locked and unlocked normally 8 Open and close all doors to see that there are no abnormal conditions 9 Operate the power door locking switch to check that all doors is locked and unlocked normally 10...

Page 38: ...126 Wheel alignment Checks with the Engine Running I 18 Check that the wheel alignmentsare properly adjusted Step 37 Brake test 38 Parkina brake I Step I Check point I Check point 1 Check that the fo...

Page 39: ...referring to the fol lowing table Tire size Tire inflationpressure kPa kg cm2 psi Front PI95 60R1587H 220 2 2 32 200 2 0 25 P205 55R1689V 220 2 2 32 200 2 0 25 3 FUSE INSTALLATION A vehicle just deli...

Page 40: ...he rear gate sev eral times to check for normal opeartion Open and close the rear gate several times for smooth movement 171 Operate the power door locking switch to check that the rear gate is locked...

Page 41: ...cap is se curely closed 1O 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 Too...

Page 42: ...add the necessary amount of the specified engine oil P Upper level About 1 Oe 1 1 us qt 0 9 Imp qt Lower level 16 TRANSMISSION FLUID Check the transmission fluid amount If the amount is insufficient...

Page 43: ...that condition lastsfor 30 sec onds or until any button of the transmitter is pressed Pressthe LOCWARM button on the transmitter momentarily once with one of the doors including the rear gate wagon op...

Page 44: ...ar Then bring all the doors including the rear gate wagon in closed condition and check if the arming condition is brought about all the doors are locked the horn chirps once and the parking lights fl...

Page 45: ...d recharge or replace the battery If any ab normal noises are observed immediately stop the engine and check and repairthe necessarycompo nents 30 EXHAUST SYSTEM Listen to the exhaust noise to see if...

Page 46: ...d Then add the necessary amount of the specified power steering fluid 46 FLUID LEAK CHECK Check the entire areas of the vehicle for any trace of coolant oil fluid leaks 47 WATER LEAK TEST Spray the ve...

Page 47: ...dampness in the compartments is discov ered after the water has been applied carefully check all areas that may have possibly contributed to the leak 48 APPEARANCECHECK 2 Check the vehicle body paints...

Page 48: ...PRE DELIVERY INSPECTION PRE DELIVERY INSPECTION I PI I4...

Page 49: ...9 Camshaft Drive Belt 11 Fuel Line 14 Fuel Filter 15 Air Cleaner Element 16 Cooling System 17 Clutch System 21 Transmission Oil 22 Front Rear Differential Oil 24 Brake Line 25 Brake Fluid 27 Disc Brak...

Page 50: ...RAL DESCRIPTION PERIODIC MAINTENANCESERVICES I 1 General Description A GENERAL Besureto performperiodicmaintenance inorder to maintain vehicle performance and find problems before they become serious...

Page 51: ...25 Supplement restraintsystem Inspect every 10years Symbols used R Replace I Inspection R or I Recommendedservicefor safe vehicle operation NOTE 1 This inspectionis not requiredto maintainemissionwarr...

Page 52: ...road drive 3 75 months R 6 000 km 3 750 miles 15 months 24 000 km 15 000 miles 15 months 24 000 km 15 000 miles 15 months 15 000 miles 15 months 24 000 km 15 000 miles 15 months I I 24 000 km 15 000...

Page 53: ...0 0 4 2 US qt 3 5 Imp qt 3 0 0 3 2 US qt 2 6 Imp qt Engine oil capacity TURBO model 4 5 0 4 8 US qt 4 0 Imp qt 3 5 0 3 7 US qt 3 1 Imp qt Upper level Lower level Thc SAE Viscosity No and Applicable T...

Page 54: ...level gauge is correctly inserted and in the proper orientation 4 Remove it again and note the reading If the en gine oil level is below the L line add oil to bring the level up to the F line 5 After...

Page 55: ...nd being careful not to damage seal rubber 4 Tighten more approximately2 3 to 3 4 turn af ter the seal rubber contacts the oil pump case Do not tighten excessively or oil may leak 5 After installingoi...

Page 56: ...rd Spark plug gap 1 0 1 1 mm 0 039 0 043 in NGK PFRGG Sparkplug gap 0 7 0 8 mm 0 028 0 031 in Non Turbo model NGK BKRSE 11 NGK BKRGE 11 Turbo model 6 Tighten the spark plug lightlywith hand and then s...

Page 57: ...tioner 98 N 10 ka 22 Ib C P Crankshaft pulley GEN Generator P S A C Air conditioning compressor pulley I P Idler pulley Power steering oil pump pulley B REPLACEMENT 1 V BELT COVER 1 Remove the V belt...

Page 58: ...y Before removing the rear side belt remove the front side belt 1 Loosenthe lock nut A 2 Loosenthe slider bolt 9 3 Remove the rear side belt 4 Installa new belt and tightenthe slider bolt so as to obt...

Page 59: ...ulley bolt To lock crankshaft use ST ST 499977t00 CRANKSHAFT PULLEY WRENCH 6 Remove the crankshaft pulley 7 Remove the left side belt cover 8 Remove the front belt cover 9 Remove the timing belt guide...

Page 60: ...lignment marks on crankshaft and left and right camshaft sprock ets with notchesof belt cover and cylinder block To turn crankshaft use ST ST 499987500CRANKSHAFT SOCKET Alignment mark Alignment mark A...

Page 61: ...the timing belt back surface for cracks or damage Replace the faulty timing belt as needed 3 Measurethe timing belt width W If it is less than 27 mm 1 06 in check the idlers tensioner water pump pull...

Page 62: ...nally so check the pipes areas near pipes and engine compart ment piping for rust hose damage loose bands etc If the faulty parts are found repair or replace them Ref to FU S0HC 68 Fuel Delivery Re tu...

Page 63: ...UEL FILTER PERIODIC MAINTENANCESERVICES 9 Fuel Filter A REPLACEMENT For fuel filter replacement procedures referto FU section Ref to FU S0HC 65 Fuel Filter or Ref to FU D0HC TURBO 65 Fuel Filter PM 15...

Page 64: ...lter paper If this filter paper is cleaned the filtration layer thus formed will be lost along with the viscous liquid 1 NON TURBO MODEL 1 Remove the bolt A which install air cleaner case to stays 2 R...

Page 65: ...Check the radiator cap valve open pressure us ing radiator cap tester NOTE Rust or dirt on cap may prevent valve from func tioning normally be sure to clean cap before test ing Raise the pressure unt...

Page 66: ...areful not to spill coolant on the floor 6 Drain the coolant from reservoir tank 7 Tighten the radiator drain screw securely after draining coolant 8 Slowly pour the prepared coolant from radiator fil...

Page 67: ...cessary amount of coolant with an undiluted so lution of SUBARU genuine coolant concentration 50 The amount of coolant that should be replaced can be determined using the diagram Example Assume that t...

Page 68: ...ition 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 Meas...

Page 69: ...he underside of master cylinder clutch damper and operating cylinder for clutch system hoses piping and their couplings for fluid leaks If the fluid leaks are found correct them by retight ening their...

Page 70: ...ining gear oil and tighten it to the specified torque Tighteningtorque 44 N m 4 5 kgf m 32 5 ft lb NOTE Be sure to place a gasket between the transmis sion case and drain plug Replace the gasket with...

Page 71: ...s Of the ATF filter for 3 to 4 hours NOTE Before starting work cool off the engine well 2 Reinstall the drain plug after draining ATF and tighten it to the specified torque Tighfening torque 24 5 N m...

Page 72: ...ential gear oil through the oil level gauge hole up to the upper point of level gauge Differential gear oil capacity 44 N m 4 5 kgf m 32 5 ff lb 1 1 1 3 8 1 2 11 4US9t l 0 11 11mp9t Upper level Lower...

Page 73: ...NG 1 SERVICE BRAKE 1 Check the free play of brake pedalwith a force of less than 10 N 1 kgf 2 Ib Brake pedal free play 1 3mm 0 04 0 12 in Brake booster operating rod Pedal play 1 3 0 04 0 12 in G10050...

Page 74: ...the engine off depress the brake pedal severaltimes applyingthe same pedalforce Make sure the travel distance should not change 2 With the brake pedal depressed start the en gine Make sure the pedal...

Page 75: ...e two men working The amount of brake fluid required is approxi mately500 m 0 16 9 USfl oz 17 6 Impfl 02 for to tal brake system 6 Instruct your co worker to depress the brake pedal slowly two or thre...

Page 76: ...14 0 55 Front Standard 24 0 94 Wear limit 22 0 87 I 1 I IService limit I 7 5 0 295 I 6 5 0 256 I Rear 10 0 39 8 5 0 335 Thickness of pad 3 Check the disc rotor and correct or replace if it is damaged...

Page 77: ...ingshoe To replace the trailing shoe remove the cotter pin Clevis pin should also be replaced if worn 3 Check the brake drum for wear dents or other damage If the inside surface of brake drum is strea...

Page 78: ...rake is adjusted automatically and so there is no need to adjust it 2 PARKING BRAKE REAR DISC BRAKE For rear disc brake adjust parking brake after bleedingthe air 1 Remove rear cover rubber installed...

Page 79: ...play exceeds standard re place the ball joint Ref to FS 19 Front Ball Joint Transv Disc cover Ball join w i v e movement G10064A Relative movement Transverse link G10065A Ball join 5 Damage of dust s...

Page 80: ...ber angle Thrust angle Ref to RS 9 Wheel Alignment 2 When the camber angle does not conform to standard value visually inspect parts listed below If the deformation is observed replace damaged parts S...

Page 81: ...d self locking nuts and ex tract transverse link from the front crossmember 6 While lightly hammering spring pin which se cures S F J to transmission spindle remove it 7 Extract S F J from the transmi...

Page 82: ...t the front axle boots A and rear axle boots B for deformation damage or failure If faulty re place them with new ones Ref to DS 32 Front Drive Shaft Ref to DS 39 Rear Drive Shaft I c 2 PROPELLER SHAF...

Page 83: ...eering wheel should return to its original posi tion after it has been turned and then released 0 5 mm 0 020 in Maximumpermissibleplay 2 STEERING SHAFT JOINT 1 When the steering wheel free play is exc...

Page 84: ...se retighten it to the specified torque Tightening torque 83 N m 8 5 kgf m 67 5 ft lb 5 POWER STEERING FLUID LEVEL NOTE The fluid level must be checked when the temper ature of the reservoir tank surf...

Page 85: ...ecessary 9 GEARBOX BOOTS Inspect both sides of gearbox boots as follows and correct the defects if necessary 1 A and B positions of gearbox boot are fitted correspondingly in A and B grooves of gearbo...

Page 86: ...fault U 2 Turn the ignition switch ON and connect the airbag diagnosis terminal of the service connector located below lower cover to the ground terminal 3 The warning light blinks to indicate a trou...

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