Subaru 2001 IMPREZA User manual

FUJI HEAVY INDUSTRIES LTD. G1830GE2
2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
ENGINE 1 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.
FUEL INJECTION (FUEL SYSTEMS) FU(SOHC)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES) EC(SOHC)
INTAKE (INDUCTION) IN(SOHC)
MECHANICAL ME(SOHC)
EXHAUST EX(SOHC)
COOLING CO
LUBRICATION LU
SPEED CONTROL SYSTEMS SP
IGNITION IG(SOHC)
STARTING/CHARGING SYSTEMS SC
ENGINE (DIAGNOSTICS) EN(SOHC)

SPEED CONTROL SYSTEMS SP
Page
1. General Description ....................................................................................2
2. Accelerator Pedal........................................................................................4
3. Accelerator Control Cable...........................................................................9

SP-2
SPEED CONTROL SYSTEMS GENERAL DESCRIPTION
1. General Description
A: SPECIFICATION
B: COMPONENT
1. LHD MODEL
Accelerator pedal Free play At pedal pad 1 —4 mm (0.04 —0.16 in)
Stroke At pedal pad 52 —57 mm (2.05 —2.24 in)
B2M4176A
(1) Accelerator bracket (7) Accelerator pedal lever (13) Kick-down switch (AT model)
(2) Stopper (8) Spring pin
(3) Bushing (9) Accelerator pedal Tightening torque: N·m (kgf-m, ft-lb)
(4) Clip (10) Accelerator stopper T: 18 (1.8, 13.0)
(5) Accelerator spring (11) Accelerator plate
(6) Accelerator pedal spring (12) Clip

SP-3
SPEED CONTROL SYSTEMS
GENERAL DESCRIPTION
2. RHD MODEL
C: CAUTION
•Wear work clothing, including a cap, protective
goggles, and protective shoes during operation.
•Remove contamination, including dirt and corro-
sion, before removal, installation or disassembly.
•Keep the disassembled parts in order and pro-
tect them from dust and 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 in the vehicle is hot after running.
•Be sure to tighten fasteners including bolts and
nuts to the specified torque.
•Place shop jacks or safety stands at the specified
points.
•Before disconnecting electrical connectors of
sensors or units, be sure to disconnect negative
terminal from battery.
B2M4177A
(1) Accelerator bracket (6) Spring pin (11) Kick-down switch (AT model).
(2) Stopper (7) Accelerator spring
(3) Accelerator pedal lever (8) Bushing Tightening torque: N·m (kgf-m, ft-lb)
(4) Accelerator pedal spring (9) Clip T: 18 (1.8, 13.0)
(5) Accelerator pedal (10) Accelerator stopper

SP-4
SPEED CONTROL SYSTEMS ACCELERATOR PEDAL
2. Accelerator Pedal
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove lock nut from accelerator cable bracket.
3) Separate accelerator cable from bracket.
4) Remove accelerator cable end from throttle cam.
5) Disconnect accelerator cable from throttle body.
CAUTION:
Be careful not to kink accelerator cable.
•SOHC model
•DOHC TURBO model
6) Remove clip inside engine compartment.
•LHD SOHC model
•RHD SOHC model
•LHD DOHC TURBO model
•RHD DOHC TURBO model
7) Remove instrument panel lower cover from in-
strument panel, and connector.
8) Disconnect connector from kick-down switch.
(AT model)
9) Remove brake and clutch pedal bracket. (LHD
MT model) <Ref. to BR-73, REMOVAL, Brake
Pedal.>
10) Remove accelerator pedal connecting bolt from
accelerator pedal bracket.
(A) Lock nut
(B) Accelerator cable bracket
(C) Accelerator cable
(D) Throttle cam
(B) (D) (C)
(A)
EN0918
(B)
(D)
(C)
(A)
EN0919
EN0920
(A)
(B)
(C)
(D)
(E)
(E)
(A) Toe board
(B) Accelerator cable
(C) To accelerator pedal
(D) Brake booster
(E) Clip
EN0921
(A)
(B) (C)
(E)
(E)
(E)
(E)
(D)
(A)
(D)
(E)
(E)
(E)
(C)
(B)
(E)
EN0922
(A)
(D)
(E)
(E)
(B) (C)
EN0923

SP-5
SPEED CONTROL SYSTEMS
ACCELERATOR PEDAL
•LHD model
•RHD model
11) Disconnect grommet from toe board.
NOTE:
From inside compartment, push grommet into hole.
12) Pull out the cable from the toe board hole.
13) Disconnect accelerator cable bushing from ac-
celerator pedal lever.
14) Disconnect accelerator cable stopper from
bracket.
15) Separate accelerator cable and bracket.
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
•If cable clamp is damaged, replace it with a
new one.
•Never fail to cover outer cable end with boot.
•Be careful not to kink accelerator cable.
•Always use new clevis pins.
EN0924
EN0925
B4M1740A
B4M1741A
B4M1742A

SP-6
SPEED CONTROL SYSTEMS ACCELERATOR PEDAL
C: DISASSEMBLY
1) Remove the clip, and then remove the accelera-
tor pedal from the bracket.
2) Pull out the spring pin, and then remove the ac-
celerator pedal from the accelerator pedal lever.
•LHD model
•RHD model
D: ASSEMBLY
Assemble in the reverse order of disassembly.
CAUTION:
Clean and apply grease to spacer and inside
bore of a accelerator pedal.
E: INSPECTION
1. ACCELERATOR PEDAL
Lightly move pedal pad in lateral the direction toen-
sure pedal deflection is in specified range.
CAUTION:
If excessive deflection is noted, replace bush-
ing and clip with new ones.
(A) Accelerator bracket
(B) Stopper
(C) Bushing
(D) Clip
(E) Accelerator spring
(F) Accelerator pedal spring
(G) Accelerator pedal lever
(H) Spring pin
(I) Accelerator pedal
(J) Kick-down switch (AT model)
EN0926
(A) Accelerator bracket
(B) Stopper
(C) Bushing
(D) Clip
(E) Accelerator spring
(F) Accelerator pedal spring
(G) Accelerator pedal lever
(H) Spring pin
(I) Accelerator pedal
(J) Kick-down switch (AT model)
EN0927

SP-7
SPEED CONTROL SYSTEMS
ACCELERATOR PEDAL
Deflection of accelerator pedal:
Service limit
5.0 mm (0.197 in) or less
2. KICK-DOWN SWITCH
If kick-down switch does not operate properly (or if
it does not stop at the specified position), replace
with a new one.
Specified position: A
2+1.5/0mm (0.079 +0.059/0in)
F: ADJUSTMENT
1) Check pedal stroke and free play by operating
accelerator pedal by hand.
If it is not within specified value, adjust it by turning
nut connecting accelerator cable to throttle body.
Free play at pedal pad: L
1 —4 mm (0.04 —0.16 in)
Stroke at pedal pad: A
52 —57 mm (2.05 —2.24 in)
Accelerator cable lock nut tightening torque:
12 N·m (1.2 kgf-m, 9 ft-lb)
G4M0333
B4M0155A
(A) Accelerator pedal
(B) Accelerator pedal bracket
B4M1739A

SP-8
SPEED CONTROL SYSTEMS ACCELERATOR PEDAL
2) Check to ensure the kick-down switch operates
at the specified value in relation to the stroke of the
accelerator pedal.
If it is not in specified value, adjust it by adjusting
position of kick-down switch.
CAUTION:
Be careful not to rotate kick-down switch.
Kick-down switch stroke: A
48
±
±±
±
1 mm (1.89
±
±±
±
0.04 in)
Kick-down switch tightening torque:
12 N·m (1.2 kgf-m, 9 ft-lb)
B4M1758A

SP-9
SPEED CONTROL SYSTEMS
ACCELERATOR CONTROL CABLE
3. Accelerator Control Cable
A: REMOVAL
1) Remove accelerator pedal. <Ref. to SP-4, RE-
MOVAL, Accelerator Pedal.>
2) Separate accelerator cable and accelerator ped-
al.
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
•If cable clamp is damaged, replace it with a
new one.
•Never fail to cover outer cable end with boot.
•Be careful not to kink accelerator cable.
•Do not apply grease to the throttle cable on
the engine side.
2) Adjustment after pedal installation <Ref. to SP-5,
INSTALLATION, Accelerator Pedal.>
C: INSPECTION
1) Make sure the inner cable is not twisted or
frayed.
2) Make sure the outer cable is not cracked.