Subaru 2001 IMPREZA User manual

FUJI HEAVY INDUSTRIES LTD. G1830GE6
2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
BODY 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.
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C) AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTICS) AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTICS) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEMS WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOWS/MIRRORS GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEATS SE
SECURITY AND LOCKS SL
IMMOBILIZER (DIAGNOSTICS) IM
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF) SR
EXTERIOR/INTERIOR TRIM EI

2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G1830GE6
EXTERIOR BODY PANELS EB
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTICS) CC

EXTERIOR BODY PANELS EB
Page
1. General Description ....................................................................................2
2. Front Hood..................................................................................................9
3. Fender Panel.............................................................................................10
4. Front Door Panel.......................................................................................11
5. Front Sealing Cover..................................................................................13
6. Rear Door Panel .......................................................................................14
7. Rear Sealing Cover...................................................................................16
8. Trunk Lid Panel.........................................................................................17
9. Rear Gate Panel .......................................................................................18

EB-2
EXTERIOR BODY PANELS GENERAL DESCRIPTION
1. General Description
A: SPECIFICATIONS
Front hood
Front fender
Front fender Front door
SECTION A
SECTION D
SECTION C
SECTION B
SECTION E,F
Rear door
Door panel
Side sill
Rear door Rear quarter
Front door
BO0260
Section Part Specification
A Front hood to Front fender NA: 4.0 ± 1.0 (0.16 ± 0.04 in)
TURBO: 3.7 ± 1.0 (0.15 ± 0.04 in)
B Front fender to Front door 4.7 ± 1.0 (0.19 ± 0.04 in)
C Front door to Rear door 5.1 (0.20 in)
D Rear door to Rear quarter 4.6 (0.18 in)
E, F Door panel to Side sill 5.9 (0.23 in)

EB-3
EXTERIOR BODY PANELS
GENERAL DESCRIPTION
B: COMPONENT
1. FRONT HOOD
BO0248
(1) Front hood (5) Packing Tightening torque: N·m (kg-m, ft-lb)
(2) Seal (Front hood) (6) Clip T: 7.35 (0.75, 5.4)
(3) Hinge (7) Locking piece T1: 24.5 (2.5, 18.1)
(4) Hood grille

EB-4
EXTERIOR BODY PANELS GENERAL DESCRIPTION
2. FRONT DOOR PANEL
BO0249
(1) Gusset (7) Sealing cover Tightening torque: N·m (kg-m, ft-lb)
(2) Weatherstrip (Outer) (8) Checker T1: 7.35 (0.75, 5.4)
(3) Clip (Weatherstrip, outer) (9) Lower hinge T2: 18 (1.8, 13)
(4) Stabilizer (Lifter) (10) Upper hinge T3: 30 (3.1, 2.2)
(5) Stabilizer (Outer) (11) Door panel
(6) Stabilizer (Inner)

EB-5
EXTERIOR BODY PANELS
GENERAL DESCRIPTION
3. REAR DOOR PANEL
BO0250
(1) Weatherstrip (Outer) (7) Sealing cover Tightening torque: N·m (kg-m, ft-lb)
(2) Clip (Weatherstrip, outer) (8) Checker T1: 7.35 (0.75, 5.4)
(3) Stabilizer (Outer) (9) Lower hinge T2: 18 (1.8, 13)
(4) Stabilizer (Inner) (10) Upper hinge T3: 30 (3.1, 2.2)
(5) Door panel
(6) Bracket

EB-6
EXTERIOR BODY PANELS GENERAL DESCRIPTION
4. TRUNK LID PANEL
BO0251
(1) Torsion bar (4) Hinge ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Trunk lid (5) Cover T1: 7.5 (0.76, 5.5)
(3) Weatherstrip T2: 14 (1.8, 13)

EB-7
EXTERIOR BODY PANELS
GENERAL DESCRIPTION
5. REAR GATE PANEL
C: CAUTION
•Exterior body panels are heavy. Do not drop and
damage the panels. During removal and installa-
tion, do not damage the panel painting surface.
•While removing mounting bolts, using assistance
devices such as a support jack will help support the
panel.
•Be careful not to lose small parts.
BO0252
(1) Gas stay Tightening torque: N·m (kg-m, ft-lb)
(2) Hinge T: 25 (2.5, 18.1)
(3) Rear gate

EB-8
EXTERIOR BODY PANELS GENERAL DESCRIPTION
D: PREPARATION TOOL
1. SPECIAL TOOLS
2. GENERAL TOOL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
925610000 WRENCH Used for removing and installing door hing.
927780000 REMOVER Used for removing and installing trunk torsion
bar.
B5M1117
B5M1118
TOOL NAME REMARKS
Support Jack Used for supporting door panel.

EB-9
EXTERIOR BODY PANELS
FRONT HOOD
2. Front Hood
A: REMOVAL
1) Open front hood to remove washer nozzles.
2) Release clips to remove hood insulator.
3) Remove bolts to disconnect hood from hinges.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust clearance between hood and fender.
Clearance must be equal at both sides.
C: ADJUSTMENT
1) Use hinge mounting holes to align front hood
longitudinally and laterally.
2) Adjust height at front end of hood. <Ref. to SL-
40, ADJUSTMENT, Front Hood Lock Assembly.>
3) Rotate hood buffer to adjust lateral height.
B5M1090
B5M0747
B5M0747
B5M0750

EB-10
EXTERIOR BODY PANELS FENDER PANEL
3. Fender Panel
A: REMOVAL
1) Disconnect ground (−) cable from battery.
2) Remove side sill spoilers. <Ref. to EI-19, Side
Sill Spoiler.> (If fitted)
3) Remove front bumper face. <Ref. to EI-8, RE-
MOVAL, Front Bumper.>
4) Remove mud guard. <Ref. to EI-16, REMOVAL,
Mud Guard.>
5) Loosen bolts to remove front fender.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When fender panel is installed, clearance be-
tween fender panel and hood or front fender must
be equal.
BO0153

EB-11
EXTERIOR BODY PANELS
FRONT DOOR PANEL
4. Front Door Panel
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove front door trim. <Ref. to EI-20, REMOV-
AL, Front Door Trim.>
3) Remove outer mirror assembly. <Ref. to GW-46,
REMOVAL, Outer Mirror Assembly.>
4) Remove front door regulator and motor. <Ref. to
GW-31, REMOVAL, Front Regulator and Motor As-
sembly.>
5) Remove front door latch assembly. <Ref. to SL-
30, REMOVAL, Front Door Latch Assembly.>
6) Remove front outer handle. <Ref. to SL-29, RE-
MOVAL, Front Outer Handle.>
7) Remove front pillar lower trim to disconnect con-
nector from body harness.
8) Put wooden block on jack and place jack under
door. Support door with a support jack to protect it
from damage.
9) Remove checker bolts.
10) Remove door-side bolts for upper and lower
hinges to remove door.
11) Using special tool, remove body-side bolts for
upper and lower hinges, and remove door hinges.
ST 925610000 DOOR HINGE WRENCH
CAUTION:
•During removal and installation of doors, do
not damage body.
•Doors are heavy. Be careful not to drop and
damage them.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Apply grease to sliding area of door hinges.
B5M0726
BO0261
S5M0183
G5M0385
B5M0933A

EB-12
EXTERIOR BODY PANELS FRONT DOOR PANEL
C: ADJUSTMENT
1) Using special tool, loosen body-side bolts of up-
per and lower hinges to align the position of front
door panel longitudinally and vertically.
ST 925610000 DOOR HINGE WRENCH
2) Loosen door-side bolts of upper and lower hing-
es to align the position of front door panel vertically
and laterally at the front end.
3) Loosen screw (A) and tap striker (B) using plas-
tic hammer to adjust striker.
CAUTION:
Do not use impact wrench. Welding area on
striker nut plate is easily broken.
B5M0933A
G5M0385
B5M0934A

EB-13
EXTERIOR BODY PANELS
FRONT SEALING COVER
5. Front Sealing Cover
A: REMOVAL
1) Remove front door trim. <Ref. to EI-20, REMOV-
AL, Front Door Trim.>
2) Remove front speaker. <Ref. to ET-10, REMOV-
AL, Front Speaker.>
3) Using a spatula, remove sealer.
CAUTION:
•Carefully remove sealer. Excessive force will
easily break the cover.
•If cover gets broken, replace it with a new
one.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When replacing sealing cover, use CEMEDINE
5430L sealer.
3) Press sealer-applied area firmly to prevent any
floating on surface.
Sealer:
CEMEDINE 5430L or equivalent
CAUTION:
•Apply a uniform bead of sealer.
•Attach sealing cover, keeping it from becom-
ing wrinkled.
•Breaks in the bead will allow water leakage
and contamination.
C: INSPECTION
If sealing cover is damaged, replace it with a new
one.
G5M0391

EB-14
EXTERIOR BODY PANELS REAR DOOR PANEL
6. Rear Door Panel
A: REMOVAL
CAUTION:
•During removal and installation of doors, do
not damage body.
•Doors are heavy. Be careful not to drop and
damage them.
1) Disconnect ground cable from battery.
2) Remove rear door trim. <Ref. to EI-21, REMOV-
AL, Rear Door Trim.>
3) Remove rear door regulator and motor assem-
bly. <Ref. to GW-34, REMOVAL, Rear Regulator
and Motor Assembly.>
4) Remove rear door latch. <Ref. to SL-34, RE-
MOVAL, Rear Door Latch Assembly.>
5) Remove rear outer handle. <Ref. to SL-33, RE-
MOVAL, Rear Outer Handle.>
6) Remove center pillar lower trim. <Ref. to EI-29,
REMOVAL, Lower Inner Trim.>
7) Disconnect connector of door harness.
8) Put a wooden block on the jack and place the
jack under the door. Support the door with the jack
to protect it.
9) Remove checker bolts.
10) Remove door-side bolts for upper and lower
hinges to remove door.
11) Using special tool, remove body-side bolts for
upper and lower hinges, and remove door hinges.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Apply grease to sliding area of door hinges.
BO0154
BO0261
S5M0183
G5M0385

EB-15
EXTERIOR BODY PANELS
REAR DOOR PANEL
C: ADJUSTMENT
1) Using special tool, loosen body-side bolts of up-
per and lower hinges to align the position of rear
door panel longitudinally and vertically.
2) Loosen door-side bolts of upper and lower hing-
es to align the position of rear door panel vertically
and laterally at front-end.
3) Loosen screw (A) and tap striker (B) using plas-
tic hammer to adjust striker.
CAUTION:
Do not usean impact wrench. The welding area
on the striker nut plate is easily broken.
B5M0933A
G5M0385
B5M0934A

EB-16
EXTERIOR BODY PANELS REAR SEALING COVER
7. Rear Sealing Cover
A: REMOVAL
1) Remove rear door trim. <Ref. to EI-21, REMOV-
AL, Rear Door Trim.>
2) Remove rear speaker. <Ref. to ET-12, REMOV-
AL, Rear Speaker.>
3) Using a spatula, remove sealer.
CAUTION:
•Carefully remove sealer. Excessive force will
easily break the cover.
•If cover gets broken, replace it with a new
one.
B: INSTALLATION
1) Install in the reverse order of removal.
2) When replacing sealing cover, use CEMEDINE
5430L sealer.
3) Press sealer-applied area firmly to prevent any
floating on surface.
Sealer:
CEMEDINE 5430L or equivalent
CAUTION:
•Apply an uniform bead of sealer.
•Attach sealing cover, keeping it from becom-
ing wrinkled.
•Breaks in the bead will allow water leakage
and contamination.
C: INSPECTION
If sealing cover gets damaged, replace it with a
new one.
G5M0391

EB-17
EXTERIOR BODY PANELS
TRUNK LID PANEL
8. Trunk Lid Panel
A: REMOVAL
1. TRUNK LID
1) Open trunk lid.
2) Disconnect trunk lid connector.
3) Loosen trunk lid mounting bolts to remove trunk
lid from hinges.
2. TORSION BAR
1) Open trunk lid.
2) Using special tool, remove torsion bar from
hinge link.
ST 927780000 REMOVER
CAUTION:
During removal and installation, carefully han-
dle torsion bar. It will generate reactive force.
3) Remove right/left torsion bars.
CAUTION:
After the torsion bar is removed, the trunk lid
will slam shut. Be careful not to get hit by the
trunk lid.
B: INSTALLATION
1. TRUNK LID
1) Install in the reverse order of removal.
2) Install trunk lid with uniform clearance.
2. TORSION BAR
1) Install in the reverse order of removal.
2) Apply grease to rotating area of hinges and mat-
ing surface of torsion bar.
G5M0144
G5M0145

EB-18
EXTERIOR BODY PANELS REAR GATE PANEL
9. Rear Gate Panel
A: REMOVAL
1. REAR GATE PANEL
1) Open rear gate.
2) Remove rear gate outer handle. <Ref. to SL-36,
REMOVAL, Rear Gate Outer Handle.>
3) Remove rear gate latch assembly. <Ref. to SL-
37, REMOVAL, Rear Gate Latch Assembly.>
4) Remove rear gate key lock cylinders. <Ref. to
SL-43, REAR GATE, REPLACEMENT, Key Lock
Cylinders.>
5) Remove rear wiper. <Ref. to WW-21, REMOV-
AL, Rear Wiper Motor.>
6) Disconnect connectors of rear wiper, rear defog-
ger, and other lighting devices.
7) Disconnect washer hose.
8) Remove rubber duct (A) connection, and pull out
harness and washer hose from rear gate.
9) Using a support, support the rear gate while re-
moving gas stay mounting bolts.
CAUTION:
When the rear gate is released, it may hit and
damage the body. To prevent this, place a shop
cloth between body and gate.
10) Loosen rear gate bolts to remove rear gate.
2. GAS STAY
1) Open rear gate. Using a support jack to support
the rear gate.
CAUTION:
•After gas stay is removed, rear gate cannot
stay open. Supporting the rear gate with a jack,
remove the bolts.
•Do not damage piston rods and oil seals.
•Never disassemble cylinders: They contain
gas.
B5M0733A
BO0262
BO0155
BO0278
BO0262