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