Subaru Impreza 2004 User manual

FUJI HEAVY INDUSTRIES LTD. G1870GE5
2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX
CHASSIS 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.
FRONT SUSPENSION FS
REAR SUSPENSION RS
WHEEL AND TIRE SYSTEM WT
DIFFERENTIALS DI
TRANSFER CASE TC
DRIVE SHAFT SYSTEM DS
ABS ABS
ABS (DIAGNOSTICS) ABS(diag)
BRAKE BR
PARKING BRAKE PB
POWER ASSISTED SYSTEM
(POWER STEERING) PS

POWER ASSISTED SYSTEM
(POWER STEERING)
PS
Page
1. General Description ....................................................................................2
2. Steering Wheel..........................................................................................23
3. Universal Joint...........................................................................................24
4. Tilt Steering Column..................................................................................26
5. Steering Gearbox [LHD MODEL] ..............................................................29
6. Steering Gearbox [RHD MODEL] .............................................................47
7. Pipe Assembly [LHD MODEL] ..................................................................64
8. Pipe Assembly [RHD MODEL]..................................................................72
9. Oil Pump ...................................................................................................80
10. Reservoir Tank..........................................................................................85
11. Power Steering Fluid.................................................................................86
12. General Diagnostic Table..........................................................................87

PS-47
POWER ASSISTED SYSTEM (POWER STEERING)
Steering Gearbox [RHD MODEL]
6. Steering Gearbox [RHD MOD-
EL]
A: REMOVAL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Loosen the front wheel nut.
4) Lift-up the vehicle, and then remove the front
wheels.
5) Remove the under cover.
6) Remove the sub frame.
7) Remove the front exhaust pipe assembly. (Non-
turbo model)
<Ref. to EX(H4SO)-6, REMOVAL, Front Exhaust
Pipe.>
WARNING:
Be careful, the exhaust pipe is hot.
8) Using a puller, remove the tie-rod end from
knuckle arm after pulling off cotter pin and remov-
ing castle nut.
9) Remove the jack-up plate and front stabilizer.
10) Remove the one pipe joint at center of gearbox,
and connect vinyl hose to pipe and joint. Discharge
fluid by turning the steering wheel fully clockwise
and counterclockwise. Discharge fluid similarly
from the other pipe.
11) Remove the universal joint. <Ref. to PS-24,
REMOVAL, Universal Joint.>
12) Disconnect the lower pipe C from gear box first,
and upper pipe D second.
13) Remove the clamp bolts securing the gearbox
to crossmember, and then remove the gearbox.
(1) Castle nut
(2) Tie-rod end
(3) Knuckle arm
(1) Jack-up plate
PS-00043
PS-00044
(1) Pipe A
(2) Pipe B
(1) Pipe C
(2) Pipe D
(1) Clamp
PS-00045
PS-00046
PS-00047

PS-48
POWER ASSISTED SYSTEM (POWER STEERING)
Steering Gearbox [RHD MODEL]
B: INSTALLATION
1) Insert the gearbox into crossmember, being
careful not to damage the gearbox boot.
2) Tighten the gearbox to crossmember bracket via
clamp with bolts to specified torque.
Tightening torque:
60 N·m (6.1 kgf-m, 44.1 ft-lb)
3) Connect the pipe D first to gear box, and pipe C
second.
Tightening torque:
T: 15 N·m (1.5 kgf-m, 10.8 ft-lb)
4) Install the universal joint. <Ref. to PS-24, IN-
STALLATION, Universal Joint.>
5) Connect the tie-rod end and knuckle arm, and
tighten with castle nut.
Castle nut tightening torque:
27 N·m (2.75 kgf-m, 19.9 ft-lb)
CAUTION:
When connecting, do not hit the cap at bottom
of tie-rod end with hammer.
6) After tightening the castle nut to the specified
tightening torque, tighten it further within 60° until
cotter pin hole is aligned with slot in the nut. Fit the
cotter pin into nut, and then bend the pin to lock.
7) Install the front stabilizer to vehicle.
8) Install the front exhaust pipe assembly.
9) Install the sub frame.
10) Install the under cover.
11) Align the center of roll connector. <Ref. to AB-
18, ADJUSTMENT, Roll Connector.>
12) Install the steering wheel. <Ref. to PS-23, IN-
STALLATION, Steering Wheel.>
13) Install the front wheels.
14) Tighten the wheel nuts to specified torque.
Tightening torque:
90 N·m (9.1 kgf-m, 65.8 ft-lb)
15) Connect the battery ground cable to battery.
16) Pour fluid into the oil tank, and bleed air.
<Ref. to PS-86, Power Steering Fluid.>
17) Check for fluid leaks.
18) Install the jack-up plate.
19) Lower the vehicle.
20) Check the fluid level in oil tank.
(1) Clamp
(1) Pipe C
(2) Pipe D
PS-00047
PS-00049
(A) Cotter pin
(B) Castle nut
(C) Tie-rod
DS-00042
(C)
(B)
(A)

PS-49
POWER ASSISTED SYSTEM (POWER STEERING)
Steering Gearbox [RHD MODEL]
21) After adjusting the toe-in and steering angle,
tighten the lock nut on tie-rod end.
Tightening torque:
83 N·m (8.5 kgf-m, 61.5 ft-lb)
NOTE:
When adjusting the toe-in, hold boot as shown to
prevent it from being rotated or twisted. If twisted,
straighten it.
C: DISASSEMBLY
1) Secure the gearbox removed from vehicle in
vise using the ST.
ST 926200000 STAND
CAUTION:
Secure the gearbox assembly in a vise using
the ST as shown. Do not attempt to secure it
without this ST.
2) Remove the tie-rod end and lock nut from gear-
box.
3) Remove the clip on outside of boot using pliers,
and then slide the boot to tie-rod end side.
4) Using flat tip screwdriver, remove the band from
boot.
NOTE:
Check the boot for crack, damage or deterioration.
Replace the boot with a new one if necessary.
5) Using the ST, loosen lock nut.
ST 926230000 SPANNER
(1) Clamp
PS-00051
PS-00052
(1) Clip
(1) Band
(1) Lock nut
PS-00053
PS-00054
PS-00056

PS-50
POWER ASSISTED SYSTEM (POWER STEERING)
Steering Gearbox [RHD MODEL]
6) Tighten the adjusting screw until it no longer
tightens.
7) Using a wrench (32 mm (1.26 in) width across
flats) or adjustable wrench with cinching boot, re-
move the tie-rod.
8) Loosen the adjusting screw, and then remove
the spring and sleeve.
9) Disconnect the pipes A and B from steering body
and control valve housing.
10) Clean the dirt of input shaft. Remove the dust
cover taking care not to scratch the housing or in-
put shaft and allow foreign matter to enter gear box
interior.
11) Align the ST pin to plug hole to install. Rotate
the ST counterclockwise to remove plug.
ST 34199AE090 PLUG WRENCH
(1) Adjusting screw
(1) Tie-rod
(1) Pipe A
(2) Pipe B
PS-00057
PS-00058
PS-00059
(1) Dust cover
(1) Plug
PS-00060
PS-00061

PS-51
POWER ASSISTED SYSTEM (POWER STEERING)
Steering Gearbox [RHD MODEL]
12) Remove the valve assembly taking care not to
scratch seal ring and valve housing inner surface.
13) Remove the holder using a wrench (32 mm
(1.26 in) width across flats) or adjustable wrench.
14) Install the ST on valve side of rack and press
outer side oil seal out taking care not to contact
rack with steering body inner surface.
ST 34099FA030 INSTALLER & REMOVER
NOTE:
Block the pipe connection of steering body to pre-
vent fluid from flowing out.
(1) Valve ASSY
(2) Seal ring
PS-00062
PS-00063
(1) Rack piston
(2) Outer side oil seal
PS-00064

PS-52
POWER ASSISTED SYSTEM (POWER STEERING)
Steering Gearbox [RHD MODEL]
15) Insert the ST from valve side and press back-
up ring and oil seal out.
ST 927580000 REMOVER
16) Using the ST1 and ST2, repair the cylinder’s
clinched sections.
ST1 34099FA080 PUNCH
ST2 34099FA070 BASE
17) If the cylinder edge is deformed in a convex
shape, repair using an oil stone.
18) Remove the oil seal using ST and press from
plug.
ST 34199AE100 PLUG OIL SEAL REMOVER
NOTE:
Do not apply force on the plug edge surface.
19) Set the ST on drawing dimension.
ST 34199AE120 GEARBOX OIL SEAL RE-
MOVER
(1) Cylinder
PS-00065
PS-00066
(1) Oil seal
(2) O-ring
(1) 70 mm (2.76 in)
PS-00067
PS-00068
PS-00069

PS-53
POWER ASSISTED SYSTEM (POWER STEERING)
Steering Gearbox [RHD MODEL]
20) Set the stopper to gear box, and then insert the
tip of ST to gear box.
21) By fixing the 2-surface width, press in by rotat-
ing the rod and attach to oil seal.
22) While fixing the 2-surface width, pull out the oil
seal by rotating nut.
CAUTION:
Take care not to scratch the gear box inner sur-
face.
D: ASSEMBLY
1) Apply a coat of grease to inside and outside of
new oil seal.
Specified steering grease:
VALIANT GREASE M2 (Part No. 003608001)
2) Verify the oil seal direction and installation posi-
tion. Using the ST and press, press fit the oil seal to
gear box.
ST 34199AE130 GEARBOX OIL SEAL IN-
STALLER
(1) Stopper
(2) Oil seal
(1) Rod
(2) 2-surface width
PS-00070
PS-00071
(1) 2-surface width
(2) Nut
(1) Oil seal
PS-00072
PS-00073

PS-54
POWER ASSISTED SYSTEM (POWER STEERING)
Steering Gearbox [RHD MODEL]
3) Attach the steering body to ST as shown in the
figure. Apply a coat of grease to needle bearing.
ST 926200000 STAND
CAUTION:
Ensure the needle bearing is free from defects.
If it is faulty, replace the steering body with a
new one.
4) Using the ST·B and ST·C, attach the oil seal to
ST·A.
ST 927490000 INSTALLER A, B, C
NOTE:
Face the oil seal in direction shown in the figure.
5) Insert the ST·A with oil seal assembled, through
gear side of rack. Remove the oil seal from ST·A
near piston, and then remove the ST·A from rack.
6) Install the back-up washer from gear side of
rack.
(1) Steering body
(A) Oil seal
PS-00074
PS-00075
ST A
ST B
ST C
(A)
(A) Oil seal
(B) Rack
(C) Piston
(1) Oil seal
(2) Back-up washer
(3) Rack
PS-00076
ST A
(A)
(B)
(C)
PS-00077