Subaru 2002 Impreza User manual

I
2002 IMPREZA SERVICE MANUAL
a
QUICK REFERENCEINDEX
~~
CHASSIS SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessaryinformationand 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 experiencedmechanics.
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.
c- .
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
G18306E5

FRONT SUSPENSION
FSr
1 .
2 .
3 .
4.
5 .
6 .
7 .
8 .
9 .
....................................................................................
.........................................................................................
GeneralDescription 2
Wheel Alignment
8
Sub Frame ................................................................................................ 16
FrontTransverseLink
............................................................................... 17
Front BallJoint .......................................................................................... 19
Front Crossmember .................................................................................. 25
GeneralDiagnosticTable
.......................................................................... 26
.................................................................................................
..........................................................................................
Front Strut 20
Front Stabilizer 24
c- .

GENERAL DESCRIPTION
I
FRONT SUSPENSION
Model
1. General Description
A: SPECIFICATIONS
1. STABILIZER
Bardiameter.
ALL MODEL
2. WHEEL ALIGNMENT
20 mm (0.79 in)
Model Sedan Wagon
Caster (commondifference:
f0'45')
I I I I
. ~-
0+3 mm (Of0.12 in)
Eachtoe anale:
kO"O7'30 (Totaltoe anale: fO"15')
Toe-in
3'35' I 3'25' I 3'35' I 3'25' I 3'25'
I Kingpinangle (tolerance: +0"45') I 14"35' I 14"20' I 13"45' I 13"30' I 13'20'
Wheel arch height
[tolerance:
f12 mm (f0.47 in)]
402 mm 396 mm 406 mm 387 mm 397 mm
(15.59 in) (15.98 in) (15.24 in) (15.63 in) (1 5.83 in)
AOTE:
Front and rear toe-ins and front camber can be
adjusted.
If the toe-inor cambertoleranceexceeds
specifications,adjusttoe-in andcamber
to the mid-
dle value of specification.
The other items indicatedin the specificationta-
blecannot be adjusted.
If the other items exceeds
specifications, check suspension parts and con-
nectionsfor deformities; replacewith new ones as
required.
B4M2250B
(1) Front
A
- B = Positive: Toe-in, Negative:Toe-out
a = Eachtoe angle
FS-2

I
GENERAL DESCRIPTION FRONT
SUSPENSION
c- .
FS-3

GENERAL DESCRIPTION
FRONT SUSPENSION
B: COMPONENT
FS-4

GENERAL DESCRIPTION
FRONT SUSPENSION
Frontcrossmember (1 7)
BoltASSY (1 8)
Housing
(1 9)
Washer (20)
Stopper rubber (Rear) (21)
Rear bushing (22)
Stopper rubber (Front) (23)
Balljoint (24)
Transverselink (25)
Cotterpin (26)
Front bushing
(27)
model) (29)
Clamp (30)
Bushing (31
1
Stabilizer (32)
Stabilizerlink (Exceptsedanturbo (28)
Jack-upplate
Dustseal
Strut mount
Spacer
Upperspringseat
Rubberseat
Dustcover
Helper
Coilspring
Damperstrut
Adjusting bolt
Castlenut
Self-lockingnut
Sub frame
Tightening torque: N.m (kgf-m, ft-lb)
TI: ZO(2.0, 14.5)
T3:
30 (3.1,22)
T4: 34 (3.5,25)
T5: 40 (4.1,30)
T6: 45 (4.6,33)
T7: 50 (5.1, 37)
T8: 55 (5.6, 41)
T9: 71
(7.2, 52)
T10: 100(10.2, 74)
T11: <Ref. toFS-17, INSPECTION,
Sub Frame.>
T2: 25(2.5, 18.1)
1
Cover
T12: 175 (17.8, 129)
Clip
T13: 190(19.4, 140)
Stabilizerlink (Sedanturbo model) T14: 250(25.5, 184)
.-
I
FS-5

GENERAL DESCRIPTION
FRONT SUSPENSION
C: CAUTION
Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
Remove contamination including dirt and corro-
sion beforeremoval, installationor 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.
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 specifiedtorque.
Placeshopjacksorsafetystandsat thespecified
points.
Apply grease onto sliding or revolutionsurfaces
before installation.
c- - BeforeinstallingO-ringsor snap rings,apply suf-
ficient amount of grease to avoid damage and de-
formation.
Before securing a part on a vice, place cushion-
ing materialsuch as wood blocks,aluminum plate,
or shop cloth betweenthe partand the vice.
FS-6

GENERAL DESCRIPTION FRONT
SUSPENSION
D: PREPARATIONTOOL
1. SPECIAL TOOLS
ILLUSTRATION TOOL NUMBER
927380002
84M2385
TOOL NAME
Alignment gauge
Turning radiusgauge
Toe-in gauge
Dial gauge
927680000
927760000
REMARKS
Usedfor wheel alignmentmeasurement.
Usedfor wheel alignment measurement.
Usedfor toe-in measurement.
Usedfor damper strut measurement.
2. GENERAL PURPOSETOOLS
~ NSTALLER
&
3EMOVER SET
STRUT MOUNT
SOCKET
REMARKS
sed as an adapter for camber
& caster gauge
,henmeasuringcamber andcaster.
I ) 28199AC000 PLATE
2) 28199AC010 BOLT
Jsed for replacingtransverse link bushing.
Usedfor disassemblingandassemblingstrut
andshock mount.
FS-7

I
WHEEL ALIGNMENT
FRONT SUSPENSION
2. Wheel Alignment
A: INSPECTION
Check, adjust and/or measurewheel alignment in accordance with procedures indicatedinfigure:
WHEEL ARCH HEIGHT (FRONT AND REAR)
1
CAMBER (FRONT AND REAR)
FRONT TOE-IN
REAR TOE-IN
THRUST ANGLE (REAR)
WHEEL STEERING ANGLE
B4M1 OBBA
FS-8

I
~ ~~
Front
Rear
Front
Rear
Front
-
-
Rear
396k12 mm (15.59k0.47 in)
376k12 mm (14.80k0.47 in)
387k12 mm (1 5.24k0.47 in)
376+12 mm (14.80k0.47 in)
Sedan
Wagon
OUTBACK
I
c
406kl2 mm (15.98k0.47 in)
381532 mm (15.0k0.47 in)
397k12 mm (1 5.63k0.47 in)
381332 mm (15.0k0.47 in)
402k12 mm (15.83k0.47 in)
386k12 mm (1 5.20k0.47 in)
FRONTSUSPENSION
WHEEL ALIGNMENT
1. WHEEL ARCH HEIGHT
1) Adjust the tire pressureto specifications.
2) Set the vehicle under “curb weight” conditions.(Emptyluggage compartment,installsparetire,jack, ser-
vice tools, and top up fuel tank.)
3) Set the steeringwheel in a wheel-forwardposition.
4) Suspendathreadfrom wheel arch (point “A infigure below)to determinethe point directlyabove center
of spindle.
5) Measurethe distance betweenmeasuringpoint “A and centerof spindle.
t
m
.-
E
m
a, a,
.c c
2
2
.-
c
m
a,
a,
c
a,
c
-
5
3
C m
LL
L
c
a,
e a
7
E
m
.-
a,
.c
c
2
a,
c
-
3
C
LL
c
e
E
m
.-
c a,
a,
a,
.c
2 m
f
-
End of spindle;,y//,/
suo009
I
Specifiedwheel arch height Non-turbo
Turbo
Model
I
FS-9

I WHEEL ALIGNMENT
FRONT SUSPENSION
2. CAMBER
Inspection
1) Place the front wheel on turning radius gauge.
Makesure the ground contactingsurfacesof front
and rearwheels are set at the same height.
2) Setthe ST intothe center of the wheel, andthen
installthe wheel alignment gauge.
ST
927380002 ADAPTER
c- ~ (1) Alignment gauge
(2) Turningradius gauge
NOTE:
Refer to the ‘SPECIFICATIONS” for the camber
va
I ues.
Front: <Ref. to FS-2, SPECIFICATIONS, General
Description.>
Rear: <Ref. to RS-2, SPECIFICATIONS, General
Description.>
Frontcamber adjustment
1) Loosen the two self-locking nuts located at the
lowerfront portionof strut.
CAUTION:
When the adjusting bolt needs to be loos-
ened or tightened, holdits headwith a wrench
and turn the self-lockingnut.
Discardthe loosened self-locking nut and re-
place with a new one.
2) Turn the camber adjustingbolt so that the cam-
ber is set at the specification.
NOTE:
Movingthe adjusting bolt by one scale graduation
changesthe camber by approximately
0’10’.
(1) Strut
(2) Adjusting bolt
(3) Housing
(4) Outer
(5) Inner
(6) Camber is increased.
(7) Camberis decreased.
J
FS-10

I
FRONT SUSPENSION
WHEEL ALIGNMENT
I
Camber is increased.
Camber is decreased.
Leftside
I
J @) ;hte counterclock-
u
04M0190
@ Rotateclockwise.
B4M0350
~
Rightside
@ Rotateclockwise.
B4M03Gn
I
‘@ ;?:e counterclock-
W
B4M0190
3) Tighten the two self-lockingnuts.
4. FRONT WHEEL TOE-IN
-- Tightening torque:
175N.m (17.8 kgf-m, 129
ft-lb)
3. CASTER
Inspection
1) Place the front wheel on turning radius gauge.
Makesure the ground contactingsurfaces of front
and rearwheels are set at the same height.
2) Setthe ST intothe center
of thewheel, and then
installthe wheel alignment gauge.
ST 927380002 ADAPTER
(1) Alignment gauge
(2) Turningradiusgauge
NOTE:
Referto the ‘SPECIFICATIONS’for the casterval-
ues. <Ref. to
FS-2, SPECIFICATIONS, General
Description.>
Inspection
1) Usinga toe gauge, measurethe frontwheel toe-
in.
Toe-in:
2) Markthe rearsidesof leftandrighttiresat height
corresponding to the center of spindles and mea-
sure distance
“A between marks.
3) Move the vehicleforward
so that the marks line
up with front sides at height corresponding to the
center of spindles.
4) Measure the distance “6 between left and the
rightmarks. Toe-incan then beobtainedbythefol-
lowing equation:
A - B = Toe-in
Of3 mm (OdU. 12 in)
B A
i i
Adjustment
1) Loosen the left and right side steering tie-rods
lock nuts.
FS-11

I WHEEL ALIGNMENT
FRONT SUSPENSION
2) Turnthe leftand righttie rodsequalamountsun-
til the toe-in is at the specification.
Both the left and right tie-rods are right-hand
threaded.
To increase toe-in, turn both tie-rods
clockwise equal amounts (as viewed from the in-
side of the vehicle).
-
S4M0348A
(1) Lock nut
3) Tightenthe tie-rod lock nut.
Tighteningtorque:
CAUTION:
Correct the tie-rod boot,
if it is twisted.
NOTE:
Checkthatthe leftandrightwheel steeringangle is
within specifications.
Inspection
1) Using a toe-in gauge, measure the rear wheel
toe-in.
Toe-in:
2) Markthe rearsidesof leftand righttiresat height
corresponding to the center of spindlesand mea-
sure distance
“A” betweenmarks.
3) Move the vehicle forward so the that marks line
up with front sides at height corresponding to the
center of spindles.
83 N-m (8.5 kgf-m, 61.5 ff-lb)
5. REAR WHEEL TOE-IN
-132 mm (-0.039fo.079 in)
4) Measurethe distance “B” betweenleft and right
marks.Toe-in can then be obtainedby the follow-
ing equation:
A - B = Toe-in
I
Adjustment
1) Loosen the self-locking nut on inner side of link
rear.
CAUTION:
When loosening or tightening the adjusting
bolt, hold the bolt head and turn self-locking
nut.
Discardthe loosenedself-lockingnutand re-
placewith a new one.
(1) Adjusting bolt
(2) Link rear
2) Turn the adjusting bolt head untiltoe-in is at the
specification.
FS-12

I
FRONT SUSPENSION
WHEEL ALIGNMENT
NOTE:
When the left and right wheels are adjustedfor toe-inat the same time, the movement
of one scale gradu-
ationchanges toe-inby approximately
1.5 mm (0.1 2 in).
c
~~
Toe-inis increased.
~~
Toe-in is decreased.
Left side
Rotateclockwise.
B4M0192
Rotatecounterclock-
wise.
B4M0352
1) Tightenthe self-lockingnut. Adjus
Tighteningtorque:
100 N-m (10.2 kgf-m, 74 ft-lb)
6. STEERINGANGLE
Inspection
1) Placethe vehicle on a turning radiusgauge.
2) Whiledepressingthe brakepedal,turnthesteer-
ingwheel fully to the left and right. With the steer-
ing wheel held at each fully turned position,
measure both the inner and outer wheel steering
angle.
Steering angle:
Others
Turbo,sedanand
OUTBACK
Model
~~
Outerwheel I 29"35"f1.5" I 31"35Y1.5"
Rightside
Rotatecounterclock-
wise.
B4M0352
Rotateclockwise.
84M0192
ment
Turnthetie-rodto adjustthe steeringangleof both
innerand outer wheels.
CAUTION:
Checkthe toe-in.
Correct the boot if it istwisted.
-
S4M0348A
(1) Locknut
FS-13

WHEEL ALIGNMENT
FRONT SUSPENSION
I
7. THRUST ANGLE
Inspection
1) Positionthe vehicle on a levelsurface.
2) Movethe vehicle
3 to 4 meters directlyforward.
3) Determinethe locusof both front and rear axles.
4) Measurethe distance
“L” betweencenter lineof
loci
of the axles.
Thrustangle:
Less than
20‘ when “L” is equal to or less
than
15 mm (59 in).
c- .
T S4M0350B
(1) Center line of loci (frontaxle)
(2) Center lineof loci (rear axle)
Adjustment
1) Make the thrust angle adjustments by turning
toe-inadjustingboltsof rear suspension equallyin
the same direction.
2) When one rear wheel is adjusted in a toe-in di-
rection,adjust the other rearwheel equally in toe-
out direction,in order to make the thrust angle ad-
justment.
3) Whenthe leftandrightadjustingboltsareturned
incrementallybyone graduation in the same direc-
tion, the thrust angle will change approximately
16’
[‘I“ isalmost equal to 12 mm (0.472 in)].
Thrustangle:
O”f20’
S4M0350B
M
(1) Center line of loci (frontaxle)
(2) Centerlineof loci(rearaxle)
NOTE:
Thrust angle refersto a meanvalue of leftandright
rear wheel toe angles in relation to the vehicle
body center line. Vehicle is driven straight in the
thrust angle directionwhile swinging inthe oblique
direction depending on the degree of the mean
thrust angle.
(1 1
t
(1) Front
(2) Thrust angle
(3) Bodycenter line
FS-14

I
FRONT SUSPENSION
WHEEL ALIGNMENT
I
Thrust angle: r = (a - p)/2
a: Rightrear wheel toe-in angle
p: Left rear wheel toe-in angle
NOTE:
Here, use only positive toe-in values from each
wheel to substitutefor
a and p inthe equation.
B4M01948
(1) Front
(2) Body center line
c.
FS-15

SUB FRAME
FRONT SUSPENSION
3. Sub Frame
A: REMOVAL
1) Lift-upthe vehicle.
2) Removethe under cover.
3) Remove the bolt cover.
4) Removethe clip.
5) Removethe sub frame.
NOTE:
Loosen bolt (1) and leave a few threads caught,
then remove the bolts in the order
of (2), (3), (4),
(51, and (6).
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Replacethe M12 bolt with a new one.
Tighteningtorque:
T1:34 N.m (3.5 kgf-m,
25 ff-lb)
T2:55N-m (5.6 kgf-m, 41 ff-lb)
T3: 71 N.m (7.2 kgf-m, 52 ff-lb)
T4: 105N-m(10.7 kgf-m, 77 ff-lb)
(1) M8 bolt
(2) M12bolt (with
max)
(3) M12bolt (withoil)
(4) M10bolt
FS-16

SUB FRAME
FRONT SUSPENSION
C: INSPECTION
1) Check that there is no damage and distortion at
the sub frame.
2) Check that the bolts are tightened with the spec-
ified torque.
If there is looseness, tighten to the
specified torque.
NOTE:
The tightening torque differs by the color for bolt
(3). Always verify the bolt color before checking
tightening torque.
Tighteningtorque:
TI:34 N-m(3.5 kgf-m, 25 ff-lb)
T2:55 N.m (5.6 kgf-m,41 ff-lb)
T3: 71 N-m(7.2 kgf-m, 52 ff-lb)
T4: Dark green bolt
T4:Except dark green bolt
105Nom(10.7 kgf-m, 77ff-lb)
55 N-m(5.6 kgf-m,41 ff-lb)
FS-17

SUB FRAME
FRONT SUSPENSION
3. Sub Frame
A: REMOVAL
1) Lift-upthe vehicle.
2) Removethe undercover.
3) Removethe boltcover.
4) Removethe clip.
5) Removethe sub frame.
NOTE:
Loosen bolt
(1) and leave a few threads caught,
then remove the bolts in the order of
(2), (3), (4),
(5), and (6).
B: INSTALLATION
Installinthe reverseorder of removal.
NOTE:
Replacethe M12 boltwith a new one.
Tightening
torque:
T1:34 N-m(3.5 kgf-my25 ft-16)
T2: 55 N-m (5.6 kgf-my41 ft-16)
T3: 71 N-m(7.2kgf-my 52 ft-16)
(1) M8 bolt
(2) M12 bolt
(3) MlObolt
C: INSPECTION
Checkthatthereisnodamageanddistortionat the
sub frame.
FS-16