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

FRONT SUSPENSION
FS
Page
1. General Description ....................................................................................2
2. Wheel Alignment .........................................................................................6
3. Front Transverse Link ...............................................................................15
4. Front Ball Joint ..........................................................................................18
5. Front Strut .................................................................................................19
6. Front Stabilizer ..........................................................................................23
7. Front Crossmember ..................................................................................24
8. Sub Frame ................................................................................................25
9. Front Support Arm.....................................................................................27
10. General Diagnostic Table..........................................................................28

FS-2
FRONT SUSPENSION
General Description
1. General Description
A: SPECIFICATIONS
*1 WRX: 20 mm (0.79 in)
STi: 19 mm (0.75 in)
*2 TS, GX: None
RS: 10 mm (0.39 in)
NOTE:
•Front and rear toe-ins and front camber can be
adjusted. If toe-in or camber tolerance exceeds
specifications, adjust toe-in and camber to the
specification.
•The other items indicated in the specification ta-
ble cannot be adjusted. If the other items exceeds
specifications, check suspension parts and con-
nections for deformities, and replace with new ones
as required.
Model Sedan Wagon OUTBACK
Non-turbo Turbo Non-turbo Turbo
Front
Camber (tolerance: ±0°45′)−0°15′−0°25′−0°10′−0°20′−0°05′
Caster 3°25′3°30′3°25′3°30′3°25′
Toe-in mm (in) 0±3 (0±0.12) Each toe angle: ±0°07′30″
Kingpin angle 14°20′14°35′13°30′13°45′13°20′
Wheel arch height
[tolerance:+12 -24 mm
(+0.47 -0.94 in)]
mm (in) 406
(15.98)
396
(15.59)
397
(15.28)
387
(15.24)
402
(15.83)
Diameter of stabilizer mm (in) 20 (0.79) *1 20 (0.79)
Rear
Camber (tolerance: ±0°45′)−1°25′−1°30′−1°15′−1°20′−1°10′
Toe-in mm (in) 0±3 (0±0.12) Each toe angle: ±0°09′
Thrust angle (Tolerance: ±0°30′) 0°
Wheel arch height
[tolerance:+12 −24 mm
(+0.47 −0.94 in)]
mm (in) 381
(15.0)
376
(14.80)
381
(15.0)
376
(14.80)
386
(15.20)
Diameter of stabilizer mm (in) *2 *1 —17
(0.67) —
(1) Front
A −B = Positive: Toe-in, Negative: Toe-out
α= Each toe angle
FS-00001
B
A
(1)

FS-3
FRONT SUSPENSION
General Description
B: COMPONENT
FS-00137
T8
T9
T3
(16)
(33)
(34)
(15)
(11)
(28)
(28)
(26)
(25)
(24)
(23)
(22)
(21)
(20)
(19)
(18)
(17)
(28)
(1) (2)
(5)
(4)
(3)
(6)
(28)
(7)
(8)
(9)
(27)
(10)
(28)
(28)
(28)
(4)
(11)
(8)
(31)
(9)
(27)
(28) (10)
(12)
(15)
(30)
(32)
(29)
(28)
(14)
(13) (12)
T11
T15
T14
T5 T12
T6
T6 T3
T9
T9
T10
T4
T13
T8
T1
T3
T3
T2
T2
T7
(28)
T10

FS-4
FRONT SUSPENSION
General Description
C: CAUTION
•Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
•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.
•Before securing a part on a vise, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vise.
•Be sure to tighten fasteners including bolts and
nuts to the specified torque.
•Place shop jacks or rigid racks at the specified
points.
(1) Front crossmember (18) Strut mount Tightening torque: N·m (kgf-m, ft-lb)
(2) Bolt ASSY (19) Spacer T1: 20 (2.0, 14.5)
(3) Housing (20) Upper spring seat T2: 25 (2.5, 18.1)
(4) Washer (21) Rubber seat T3: 30 (3.1, 22)
(5) Stopper rubber (Rear) (22) Dust cover T4: 34 (3.5, 25)
(6) Rear bushing (23) Helper T5: 40 (4.1, 30)
(7) Stopper rubber (Front) (24) Coil spring T6: 45 (4.6, 33)
(8) Ball joint (25) Damper strut T7: 50 (5.1, 37)
(9) Transverse link (26) Adjusting bolt T8: 55 (5.6, 41)
(10) Cotter pin (27) Castle nut T9: 70 (7.1, 52)
(11) Front bushing (28) Self-locking nut T10: 95 (9.7, 70)
(12) Stabilizer link (29) Sub frame T11: 105 (10.7, 77)
(13) Clamp (30) Cover T12: 155 (15.8, 114)
(14) Bushing (31) Boss T13: 175 (17.8, 129)
(15) Stabilizer (32) Clip T14: 186 (19.0, 137)
(16) Jack-up plate (33) Front support arm T15: 250 (25.5, 184)
(17) Dust seal (34) Sedan turbo model