Subaru Impreza 2004 User manual

FUJI HEAVY INDUSTRIES LTD. G1870GE6
2004 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(diag)
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTICS) AB(diag)
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
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF) SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANELS EB

2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G1870GE6
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTICS) CC(diag)
IMMOBILIZER (DIAGNOSTICS) IM(diag)

SEAT BELT SYSTEM
SB
Page
1. General Description ....................................................................................2
2. Pretensioner Connector ..............................................................................6
3. Seat Belt Warning System ..........................................................................7
4. Inspection Locations After a Collision .......................................................10
5. Front Seat Belt ..........................................................................................11
6. Rear Seat Belt...........................................................................................13
7. Disposal of Pretensioner ...........................................................................16

SB-2
SEAT BELT SYSTEM
General Description
1. General Description
A: COMPONENT
1. FRONT SEAT BELT
(1) Adjuster anchor ASSY (3) Outer belt ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Anchor cover (4) Inner belt ASSY T1: 7.5 (0.76, 5.5)
T2: 30 (3.1, 22)
T3: 53 (5.4, 39)
SB-00111
T3
(1)
(2)
(3)
(4)
T2
T2
T2
T1

SB-3
SEAT BELT SYSTEM
General Description
2. REAR SEAT BELT (SEDAN MODEL)
(1) Outer seat belt RH ASSY (4) Center seat belt LH ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Shoulder seat belt CTR ASSY (5) Case center ELR T: 30 (3.1, 22)
(3) Outer seat belt LH ASSY
SB-00113
T
T
T
(5)
(3)
(4)
(2)
(1)
T
T

SB-4
SEAT BELT SYSTEM
General Description
3. REAR SEAT BELT (WAGON MODEL)
(1) Outer seat belt RH ASSY (4) Center seat belt RH ASSY Tightening torque: N·m (kgf-m, ft-lb)
(2) Shoulder seat belt CTR ASSY (5) Center seat belt LH ASSY T: 30 (3.1, 22)
(3) Outer seat belt LH ASSY
SB-00115
(3)
(2)
(1)
(4)
(5)
T
T
T
T
T
T
T

SB-5
SEAT BELT SYSTEM
General Description
B: CAUTION
•Before starting, turn the ignition switch to OFF,
disconnect the battery ground cable and wait for 20
seconds or more.
•The pretensioner system has a backup power
source. The pretensioner might deploy if you do not
wait for 20 seconds or more before starting work.
•Do not drop or apply any impact to the preten-
sioner.
•If oil, grease, or water gets on the pretensioner,
wipe it off immediately with a dry cloth.
•Do not expose the pretensioner to high tempera-
ture or flame.
•Do not allow current to flow through or voltage to
reach the pretensioner. Do not use a circuit tester
to check resistance of the pretensioner.
•Do not disassemble or attempt to repair the pre-
tensioner. If it is dented, cracked, or deformed, re-
place it with a new one.
•Do not use the airbag or pretensioner parts from
other vehicles. Always replace parts with new
parts.
•When handling a seat belt with a deployed pre-
tensioner, wear gloves and goggles. Wash your
hands afterwards.
•Do not re-use a seat belt with a deployed preten-
sioner again.
•Be sure to deploy pretensioner before disposal.
<Ref. to SB-16, OPERATION, Disposal of Preten-
sioner.>
•If the material gets in your eyes or on your skin
during deployment, wash it away with clean water,
and then consult a doctor.
C: PREPARATION TOOL
1. SPECIAL TOOLS
2. GENERAL PURPOSE TOOLS
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
98299SA010 ADAPTER D
(DEPLOYMENT)
•Used for deploying the pretensioner.
•Used with DEPLOYMENT TOOL
(98299PA030).
98299PA030 DEPLOYMENT
TOOL
•Used for deploying the pretensioner.
•Used with ADAPTER D (DEPLOYMENT)
(98299SA010).
TOOL NAME REMARKS
Circuit tester Used for measuring resistance and voltage.
ST98299SA010
ST98299PA030

SB-6
SEAT BELT SYSTEM
Pretensioner Connector
2. Pretensioner Connector
A: OPERATION
1) How to disconnect:
(1) Using a flat tip screwdriver, pull the push
lock upward to unlock.
(2) Pull the connector to disconnect from retrac-
tor assembly.
2) How to connect:
Connect the connector in reverse order of discon-
necting. At this time, be sure to insert the push lock
in until connecting sound is heard.
CAUTION:
•Be sure to insert the connector in until it
locks. Then pull on it gently to make sure that it
is locked.
•At this time, be sure to insert the push lock in.
AB-00478
AB-00479
AB-00480

SB-7
SEAT BELT SYSTEM
Seat Belt Warning System
3. Seat Belt Warning System
A: WIRING DIAGRAM
1. LHD MODEL
<Ref. to WI-248, LHD FOR EUROPE MODEL, WIRING DIAGRAM, Seat Belt Warning System.>
2. RHD MODEL
<Ref. to WI-249, RHD FOR EUROPE MODEL, WIRING DIAGRAM, Seat Belt Warning System.>
B: INSPECTION
TROUBLE SYMPTOM:
•Seat belt warning light does not come on or go off.
•Buzzer does not beep.
Step Check Yes No
1 CHECK HARNESS BETWEEN SEAT BELT
TIMER MODULE AND CHASSIS GROUND.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from seat belt
timer module.
3)Measure the resistance between seat belt
timer module harness connector and chassis
ground.
Connector & terminal
(B44) No. 3 —Chassis ground:
Is the resistance less than 1
Ω?
Go to step 2. Repair the open
circuit of harness
between seat belt
timer module and
chassis ground.
2 CHECK POWER SUPPLY OF SEAT BELT
TIMER MODULE.
1)Turn the ignition switch to ON.
2)Measure the voltage between seat belt timer
module connector and chassis ground.
Connector & terminal
(B44) No. 9 (+) —Chassis ground (–):
Is the voltage more than 10 V? Go to step 3. Repair the open
harness, short cir-
cuit and poor con-
tact of connector
between seat belt
timer module and
battery.
3 CHECK HARNESS AND SEAT BELT
SWITCH.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from seat belt
timer module.
3)Hold the tang plate disconnected from seat
belt buckle.
4)Measure the resistance between seat belt
timer module harness connector and chassis
ground.
Connector & terminal
(B44) No. 6 —Chassis ground:
Is the resistance less than 1
Ω?
Go to step 4. Repair the short
circuit of harness
between seat belt
timer module con-
nector and chassis
ground.
4 CHECK SEAT BELT SWITCH AND HAR-
NESS.
1)Turn the ignition switch to OFF.
2)Insert the tang plate into seat belt buckle.
3)Measure the resistance between seat belt
timer module connector and chassis ground.
Connector & terminal
(B44) No. 6 —Chassis ground:
Is the resistance more than 1
MΩ?
Go to step 7. Go to step 5.
5 CHECK HARNESS BETWEEN SEAT BELT
TIMER MODULE AND SEAT BELT SWITCH.
Measure the resistance of harness between
seat belt timer module connector and seat belt
switch.
Connector & terminal
(B44) No. 6 —(R8) No. 1:
Is the resistance less than 1
Ω?
Go to step 6. Repair the open
circuit of harness
and poor contact
of connector
between seat belt
timer module con-
nector and seat
belt switch.

SB-8
SEAT BELT SYSTEM
Seat Belt Warning System
6 CHECK HARNESS BETWEEN SEAT BELT
SWITCH AND CHASSIS GROUND.
Measure the resistance of harness between
seat belt switch and chassis ground.
Connector & terminal
(R8) No. 2 —Chassis ground:
Is the resistance more than 1
MΩ?
Go to step 7. Repair the open
circuit of harness
between seat belt
switch and chas-
sis ground.
7 CHECK SEAT BELT SWITCH.
1)Hold the tang plate disconnected from seat
belt buckle.
2)Measure the resistance between seat belt
switch terminals.
Terminals
No. 1 —No. 2:
Is the resistance less than 1
Ω?
Go to step 8. Replace the inner
belt assembly.
8 CHECK SEAT BELT SWITCH.
1)Insert the tang plate into seat belt buckle.
2)Measure the resistance between seat belt
switch terminals.
Terminals
No. 1 —No. 2:
Is the resistance more than 1
Ω?
Go to step 9. Replace the inner
belt assembly.
9 CHECK OPERATION OF SPEEDOMETER IN
COMBINATION METER.
Check the speedometer indicates vehicle
speed correctly.
Does the speedometer operate
correctly?
Go to step 10. Check the speed-
ometer circuit.
10 CHECK VEHICLE MODEL.
Check the model of vehicle.
Is the vehicle MT model? Go to step 11. Go to step 13.
11 CHECK HARNESS BETWEEN VEHICLE
SPEED SENSOR AND SEAT BELT TIMER
MODULE.
1)Turn the ignition switch to OFF.
2)Disconnect the connector of vehicle speed
sensor.
3)Measure the resistance between vehicle
speed sensor harness connector and seat belt
timer module connector.
Connector & terminal
(B17) No. 1 —(B44) No. 7:
Is the resistance less than 10
Ω?
Go to step 12. Repair the open
harness between
vehicle speed sen-
sor and seat belt
timer module.
12 CHECK HARNESS BETWEEN VEHICLE
SPEED SENSOR AND SEAT BELT TIMER
MODULE.
Measure the resistance between seat belt
timer module harness connector and chassis
ground.
Connector & terminal
(B44) No. 7 —Chassis ground:
Is the resistance more than 1
MΩ?
Go to step 15. Repair the short of
harness.
13 CHECK HARNESS BETWEEN TCU AND
SEAT BELT TIMER MODULE.
1)Turn the ignition switch to OFF.
2)Disconnect the connector of TCU.
3)Measure the resistance of harness between
TCU harness connector and seat belt timer
module harness connector
Connector & terminal
(B56) No. 17 —(B44) No. 7:
Is the resistance less than 10
Ω?
Go to step 14. Repair the open
harness between
TCU and seat belt
timer module.
Step Check Yes No