Subaru 2001 IMPREZA User manual

FUJI HEAVY INDUSTRIES LTD. G1830GE5
2001 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
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM
(POWER STEERING) PS

DRIVE SHAFT SYSTEM DS
Page
1. General Description ....................................................................................2
2. Propeller Shaft ..........................................................................................16
3. Front Axle..................................................................................................19
4. Rear Axle ..................................................................................................24
5. Front Drive Shaft.......................................................................................32
6. Rear Drive Shaft........................................................................................37
7. General Diagnostic Table..........................................................................41

DS-2
DRIVE SHAFT SYSTEM GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
1. PROPELLER SHAFT
Propeller shaft type DOJ type UJ type
Front propeller shaft Joint-to-joint length: L1mm (in) AT —584 (22.99)
MT 638 (25.12) 643 (25.32)
Rear propeller shaft Joint-to-joint length: L2mm (in) 713 (28.07) 708 (27.87)
Outside diameter of tube: mm (in) D163.5 (2.500)
D257.0 (2.244)
D1
L1
D1
L1
D2
L2
D2
L2
(A)
(B)
DR0008
(A) UJ type (Non-turbo model) (B) DOJ type (Turbo model)

DS-3
DRIVE SHAFT SYSTEM
GENERAL DESCRIPTION
2. FRONT DRIVE SHAFT ASSEMBLY
Type of drive shaft assembly SHAFT
Shaft diameter
EBJ87+SFJ82 Non-turbo 26 mm (1.02 in)
Turbo 28 mm (1.10 in)
B4M2218E
(A) EBJ87+SFJ82 (B) Measuring point

DS-4
DRIVE SHAFT SYSTEM GENERAL DESCRIPTION
3. REAR DRIVE SHAFT ASSEMBLY
Size Model No. of identification
protrusion on shaft L1 (mm) φD (mm)
A EBJ82/DOJ82 Sedan RH Sedan Turbo 2 (Two) 363 24
B EBJ82/DOJ82 Sedan LH 1 (One) 353 24
C BJ79/DOJ79 Sedan R160RH Sedan 2.0L NA MT 2 (Two) 368 23
D BJ79/DOJ79 Sedan R160LH 1 (One) 358 23
E BJ79/DOJ79 Sedan R152R/L Sedan 1.6L, 2.0L NA AT 3 (Three) 363 23
F BJ79/DOJ79 Wagon R152R/L Wagon 1.6L, 2.0L NA AT None 355 23
G EBJ82/DOJ82 Wagon RH Wagon Turbo 2 (Two) 353 24
H EBJ82/DOJ82 Wagon LH 1 (One) 343 24
I BJ79/DOJ79 Wagon R160RH Wagon 2.0L NA MT 2 (Two) 358 23
J BJ79/DOJ79 Wagon R160LH 1 (One) 348 23
DR0009

DS-5
DRIVE SHAFT SYSTEM
GENERAL DESCRIPTION
(A) EBJ82/DOJ82 Sedan RH (E) BJ79/DOJ79 Sedan R152R/L (I) BJ79/DOJ79 Wagon R160RH
(B) EBJ82/DOJ82 Sedan LH (F) BJ79/DOJ79 Wagon R152R/L (J) BJ79/DOJ79 Wagon R160LH
(C) BJ79/DOJ79 Sedan R160RH (G) EBJ82/DOJ82 Wagon RH (K) Identification protrusion
(D) BJ79/DOJ79 Sedan R160LH (H) EBJ82/DOJ82 Wagon LH

DS-6
DRIVE SHAFT SYSTEM GENERAL DESCRIPTION
B: COMPONENT
1. PROPELLER SHAFT
DR0010
(1) Propeller shaft (Turbo model) (4) Rear differential (T-type) Tightening torque: N·m (kgf-m, ft-lb)
(2) Propeller shaft (Non-Turbo model) (5) Bush T1: 31 (3.2, 23.1)
(3) Rear differential (VA-type) T2: 52 (5.3, 38.3)

DS-7
DRIVE SHAFT SYSTEM
GENERAL DESCRIPTION
2. FRONT AXLE
B4M2213A
(1) Baffle plate (SFJ) (9) Boot (SFJ) (17) Housing
(2) Spring pin (10) Boot (EBJ) (18) Oil seal (OUT)
(3) Outer race (SFJ) (11) EBJ ASSY (19) Hub bolt
(4) Snap ring (12) Tone wheel (With ABS) (20) Hub
(5) Trunnion (13) Baffle plate (21) Axle nut
(6) Free ring (14) Oil seal (IN)
(7) Circlip (15) Snap ring Tightening torque: N·m (kgf-m, ft-lb)
(8) Boot band (16) Bearing T1: 186 (19, 137)

DS-8
DRIVE SHAFT SYSTEM GENERAL DESCRIPTION
3. REAR AXLE
•AWD Model
DR0011
(1) Circlip (12) Non-Turbo: BJ ASSY
Turbo: EBJ ASSY (22) Hub
(2) Baffle plate (DOJ) (23) Axle nut
(3) Outer race (DOJ) (13) Baffle plate (*)
(4) Snap ring (14) Oil seal (IN. No. 2) Tightening torque: N·m (kgf-m, ft-lb)
(5) Inner race (15) Oil seal (IN. No. 3) T1: 13 (1.3, 9.4)
(6) Ball (16) Housing T2: 186 (19, 137)
(7) Cage (17) Bearing
(8) Circlip (18) Snap ring * Non-Turbo model: BJ
Turbo model: EBJ
(9) Boot band (19) Oil seal (OUT)
(10) Boot (DOJ) (20) Tone wheel (With ABS)
(11) Boot (*) (21) Hub bolt

DS-9
DRIVE SHAFT SYSTEM
GENERAL DESCRIPTION
•FWD Model
DR0012
(1) Hub cap (5) Hub unit Tightening torque: N·m (kgf-m, ft-lb)
(2) O-ring (6) Hub bolt T1: 6 (0.6, 4.4)
(3) Axle nut (7) Tone wheel (With ABS) T2: 186 (19, 137)
(4) Washer (8) Spindle

DS-10
DRIVE SHAFT SYSTEM GENERAL DESCRIPTION
C: CAUTION
•Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
•Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
•Keep the disassembled parts in order and pro-
tect them from dust or dirt.
•Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
•Be careful not to burn your hands, because each
part on the vehicle is hot after running.
•Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
•Be sure to tighten fasteners including bolts and
nuts to the specified torque.
•Place shop jacks or safety stands at the specified
points.
•Apply grease onto sliding or revolution surfaces
before installation.
•Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
•Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.

DS-11
DRIVE SHAFT SYSTEM
GENERAL DESCRIPTION
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
922431000 AXLE SHAFT
INSTALLER •Used for installing axle shaft into housing. •Used with ADAPTER (927390000).
925091000 BANDTIGHTENING
TOOL •Used for tightening boot band. (A) Jig for band
(B) Ratchet wrench
926470000 AXLE SHAFT
PULLER Used for removing axle shaft.
927060000 HUB REMOVER •Used for removing front hub.
•Used with HUB STAND (927080000).
B4M2386
B4N2387A
B4M2388
B4M2389

DS-12
DRIVE SHAFT SYSTEM GENERAL DESCRIPTION
927420000 HUB REMOVER •Used for removing rear hub.
•Used with HUB STAND (927080000).
927080000 HUB STAND Used for disassembling and assembling hub bolt
in hub.
927100000 BEARING PULLER •Used for disassembling and assembling front
housing bearing.
•Used with HOUSING STAND (927400000).
927140000 AXLE SHAFT
PULLER PLATE Same as plate 2 included in AXLE SHAFT PULLER (926470000).
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
H5M0981
B4M2390
B4M2391
B4M2392

DS-13
DRIVE SHAFT SYSTEM
GENERAL DESCRIPTION
927390000 ADAPTER Used as an adapter for AXLE SHAFT
INSTALLER (922431000).
927400000 HOUSING STAND •Used for disassembling and assembling front
housing bearing.
•Used with BEARING PULLER (927100000).
927410000 OIL SEAL
INSTALLER •Used for installing oil seal into front housing. •Used with HOUSING STAND (927400000).
927430000 HOUSING STAND •Used for disasembling and assembling rear
housing bearing.
•Used with BEARING PULLER (927440000).
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B4M2393
B4M2394
B4M2395
H5M0982

DS-14
DRIVE SHAFT SYSTEM GENERAL DESCRIPTION
927120000 HUB INSTALLER Used for installing hub.
927440000 BEARING
REMOVER •Used for disassembling and assembling rear housing bearing.
•Used with HOUSING STAND (927430000).
927460000 OIL SEAL
INSTALLER •Used for installing outer bearing and sub bear- ing into houding.
•Used with HOUSING STAND (927430000).
927450000 HUB INSTALLER •Used for installing hub unit into hub ASSY.
•Used with BEARING SPACER (28499AE000)
and HUB STAND (927080000).
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B4M2399
H5M0983
H5M0984
B4M2400

DS-15
DRIVE SHAFT SYSTEM
GENERAL DESCRIPTION
2. GENERAL PURPOSE TOOLS
28099PA090 OIL SEAL PROTEC-
TOR •Used for installing rear drive shaft into rear dif- ferential.
•For potecting oil seal.
28099PA100 DRIVE SHAFT
REMOVER Used for removing rear drive shaft from rear dif- ferential.
28099AC000 BOOT BAND PLI-
ERS Used for tightening front BJ boot band.
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
B4M2401
B4M2402
B4M2403
TOOL NAME REMERKS
Puller Used for removing ball joint from knuckle arm.
Dial gauge Used for inspecting propeller shaft run-out.
Snap ring pliers Used for installing and removing snap ring.

DS-16
DRIVE SHAFT SYSTEM PROPELLER SHAFT
2. Propeller Shaft
A: REMOVAL
NOTE:
•Before removing propeller shaft, wrap metal
parts with a cloth or rubber material.
•In case of DOJ type, before removing propeller
shaft, wrap metal parts (installed at the rubber boot
of center DOJ) with a cloth or rubber material, as
shown in the figure. Rubber boot may be damaged
due to interference with adjacent metal parts while
bending the DOJ during removal.
1) Disconnect ground terminal from battery.
2) Move select lever or gear shift lever to “N”.
3) Release the parking brake.
4) Jack-up vehicle and support it with sturdy racks.
5) Remove center exhaust pipes.
6) Remove rear exhaust pipe and muffler.
7) Remove differential mount front cover.
8) Remove the four bolts which hold propeller shaft
to rear differential.
NOTE:
•Put matching mark on affected parts before re-
moval.
•Remove all but one bolt.
9) Remove the two bolts which hold center bearing
to vehicle body.
10) Remove propeller shaft from transmission.
CAUTION:
•not to damage oil seals and frictional surface
of sleeve yoke.
•Cover the center exhaust pipe with a cloth to
keep off any ATF or oil spilled from transmis-
sion when removing propeller shaft.
NOTE:
•Be sure to use an empty oil can to catch oil flow-
ing out when removing propeller shaft.
•Be sure to plug the opening in transmission after
removal of propeller shaft.
S3M0030
DR0004
(A) Matching mark
B3M1587C
S3M0028
G3M0025

DS-17
DRIVE SHAFT SYSTEM
PROPELLER SHAFT
11) Install the extension cap to transmission.
NOTE:
If extension cap is not available, place vinyl bag
over opening and fasten with string to prevent gear
oil or ATF from leaking.
B: INSTALLATION
1) Insert sleeve yoke into transmission and attach
center bearing to body.
Tightening torque:
52 N·m (5.3 kgf-m, 38.3 ft-lb)
2) Align matching marks and connect flange yoke
and rear differential.
Tightening torque:
31 N·m (3.2 kgf-m, 23.1 ft-lb)
3) Install differential mount front cover.
Tightening torque:
88 N·m (9.0 kgf-m, 65 ft-lb)
4) Install center exhaust pipes.
5) Install rear exhaust pipe and muffler.
C: INSPECTION
NOTE:
Do not disassemble propeller shaft. Check the fol-
lowing and replace if necessary.
1) Tube surfaces for dents or cracks
2) Splines for deformation or abnormal wear
3) Joints for non-smooth operation or abnormal
noise
4) Center bearing for free play, noise or non-
smooth operation
5) Oil seals for abnormal wear or damage
6) Center bearing for breakage
Check the following points with propeller shaft in-
stalled in vehicle.
1. JOINTS AND CONNECTIONS
1) Remove center exhaust pipes.
2) Remove heat shield cover.
3) Check for any looseness of yoke flange connect-
ing bolts and center bearing retaining bolts.
2. SPLINES AND BEARING LOCATIONS
1) Remove center exhaust pipes.
2) Remove rear exhaust pipe and muffler.
3) Remove heat shield cover.
4) Turn propeller shaft by hand to see if abnormal
free play exists at splines. Also move yokes to see
if abnormal free play exists at spiders and bearings.
(A) Extension cap
(A) Matching mark
S3M0498A
S3M0028
B3M1587C
DR0004
B3M1602

DS-18
DRIVE SHAFT SYSTEM PROPELLER SHAFT
3. RUNOUT OF PROPELLER SHAFT
1) Remove center exhaust pipes.
2) Remove rear exhaust pipe and muffler.
3) Remove heat shield cover.
4) Turn rear wheels by hand to check for “runout”of
propeller shaft.
NOTE:
Measure runout with a dial gauge at the center of
front and rear propeller shaft tubes.
Runout:
Limit 0.6 mm (0.024 in)
4. CENTER BEARING FREE PLAY
1) Remove front and center exhaust pipes.
2) Remove rear exhaust pipe and muffler.
3) Remove heat shield cover.
4) While holding propeller shaft near center bearing
with your hand, move it up and down, and left and
right to check for any abnormal bearing free play.
(A) Propeller shaft
(B) Dial gauge
B3M1603A
B3M1604

DS-19
DRIVE SHAFT SYSTEM
FRONT AXLE
3. Front Axle
A: REMOVAL
1) Disconnect ground cable from battery.
2) Jack-up vehicle, support it with safety stands,
and remove front wheels.
3) Unlock axle nut.
4) Remove axle nut using a socket wrench.
CAUTION:
Be sure to loose and retighten axle nut after re-
moving wheel from vehicle. Failure to follow
this rule may damage wheel bearings.
5) Remove stabilizer link.
6) Remove disc brake caliper from housing, and
suspend it from strut using a wire.
7) Remove front drive shaft assembly from hub. If it
is hard to remove, use STs.
ST1 926470000 AXLE SHAFT PULLER
ST2 927140000 AXLE SHAFT PULLER
PLATE
CAUTION:
•Be careful not to damage oil seal lip when re-
moving front drive shaft.
•When replacing front drive shaft, also replace
inner oil seal.
8) Remove disc rotor from hub.
If disc rotor seizes up withinhub,drive disc rotor out
by installing an 8-mm bolt in screw hole on the ro-
tor.
9) Remove cotter pin and castle nut which secure
tie-rod end to housing knuckle arm.
G4M0214
G4M0215
(A) Cotter pin
(B) Castle nut
(C) Tie-rod
G4M0216
B4M1678
B4M2214A