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)

EXTERIOR/INTERIOR TRIM
EI
Page
1. General Description ....................................................................................2
2. Front Grille ................................................................................................18
3. Hood Grille ................................................................................................19
4. Front Under Cover ....................................................................................21
5. Front Bumper ............................................................................................22
6. Rear Bumper.............................................................................................28
7. Mud Guard ................................................................................................31
8. Cowl Panel ................................................................................................32
9. Roof Spoiler ..............................................................................................33
10. Rear Spoiler ..............................................................................................35
11. Side Sill Spoiler .........................................................................................36
12. Front Door Trim.........................................................................................37
13. Rear Door Trim .........................................................................................38
14. Glove Box..................................................................................................39
15. Roof Rail ...................................................................................................40
16. Roof Molding .............................................................................................41
17. Console Box..............................................................................................42
18. Instrument Panel Assembly ......................................................................43
19. Upper Inner Trim .......................................................................................46
20. Lower Inner Trim .......................................................................................47
21. Rear Quarter Trim .....................................................................................48
22. Sun Visor...................................................................................................49
23. Roof Trim ..................................................................................................50
24. Rear Gate Trim .........................................................................................52
25. Rear Shelf Trim .........................................................................................53
26. Trunk Trim.................................................................................................54
27. Floor Mat ...................................................................................................55
28. Luggage Floor Mat ....................................................................................56
29. Trunk Room Mat .......................................................................................57
30. Heat Shield Cover .....................................................................................58

EI-2
EXTERIOR/INTERIOR TRIM
General Description
1. General Description
A: COMPONENT
1. FRONT GRILLE
2. UNDER COVER
(1) Front grille (2) Front grille emblem (3) Clip
(1) Under cover (2) Clip (side) Tightening torque: N·m (kgf-m, ft-lb)
T: 14 (1.42, 10.3)
EI-00413
(1)
(2)
(3)
EI-00414
(2)
T
(1)

EI-3
EXTERIOR/INTERIOR TRIM
General Description
3. HOOD GRILLE
(1) Hood grille (4) Grille duct lower Tightening torque: N·m (kgf-m, ft-lb)
(2) Packing (5) Intercooler water spray (STi
model)
T: 4.5 (0.46, 3.32)
(3) Grille duct upper
EI-00842
(1) (3)
(2)
(2)
T
T(5)
(4)

EI-4
EXTERIOR/INTERIOR TRIM
General Description
4. FRONT BUMPER
(1) Bumper face (6) Air spoiler side bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) Fog light cover (7) Air spoiler upper bracket T1: 32 (3.3, 24)
(3) Fog light cover (STi model) (8) Bumper bracket side lower T2: 69 (7.0, 51)
(4) Air dam skirt ASSY (9) Energy absorber form
(5) Bumper bracket side upper (10) Bumper beam ASSY
T2
(3)
(8)
(1)
(7)
(2)
(4)
(9)
(10)
(6)
(5)
T2
T2
T1
EI-00848
T1

EI-5
EXTERIOR/INTERIOR TRIM
General Description
5. REAR BUMPER
(1) Bumper face (6) Energy absorber form (model with
bumper beam)
Tightening torque: N·m (kgf-m, ft-lb)
(2) Bumper upper beam T1: 33 (3.4, 24)
(3) Bumper corner bracket (7) Back beam ASSY (model with
bumper beam)
T2: 34 (3.5, 25)
(4) Bumper side bracket T3: 95 (9.7, 70)
(5) Bumper side cover
EI-00849
T2
T3
T1
(4)
(5)
(3)
(2)
(6)
(7)
(1)

EI-6
EXTERIOR/INTERIOR TRIM
General Description
6. MUD GUARD
7. COWL PANEL
(1) Mud guard (3) Sub frame cover (5) Mud guard plate
(2) Clip (4) Front air flap plate (6) Rear air flap plate
(1) Cowl panel (3) Protector (4) Seal
(2) Cowl side panel
EI-00419
(5)
(4)
(3)
(1)
(2)
(6)
EI-00420
(2)
(1)
(4)
(3)
(2)

EI-7
EXTERIOR/INTERIOR TRIM
General Description
8. ROOF SPOILER
9. REAR SPOILER
(1) Roof spoiler (3) Clip Tightening torque: N·m (kgf-m, ft-lb)
(2) Cap T: 7.4 (0.75, 5.46)
(1) Rear spoiler (4) Grommet Tightening torque: N·m (kgf-m, ft-lb)
(2) Protector (5) Seal (RH) T: 7.4 (0.75, 5.46)
(3) Clip (6) High mount stop lamp
EI-00421
T
(2)
(1)
(3)
EI-00422
(1)
(2)
(3)
(6)
(5)
(4)
T

EI-8
EXTERIOR/INTERIOR TRIM
General Description
10.SIDE SILL SPOILER
11.ROOF RAIL
(1) Side sill spoiler (3) Protector (5) Clip (Side sill spoiler)
(2) End cover (4) Rivet clip (6) Clip
(1) Roof rail Tightening torque: N·m (kgf-m, ft-lb)
T: 7.4 (0.75, 5.46)
EI-00423
(4)
(6)
(3) (5)
(1)
(4)
(2)
EI-00424
T
T
(1)

EI-9
EXTERIOR/INTERIOR TRIM
General Description
12.ROOF MOLDING
(A) For sedan model (B) For wagon model (C) For wagon model (with roof rail)
(1) Roof molding (3) Clip B (5) Clip D
(2) Clip A (4) Clip C
EI-00443
(1)
(A)
(3)
(4)
(2)
(5)
(B)
(1)
(1)
(C)
(3)
(2)
(3)
(1)
(2)

EI-10
EXTERIOR/INTERIOR TRIM
General Description
13.DOOR TRIM
(A) Front door trim (B) Rear door trim (C) Rear gate trim
(1) Gusset cover (4) Clip (6) Power window switch cover
(2) Bracket (5) Trim panel (7) Lower trim
(3) Weather strip upper
EI-00425
(A)
(B)(C)
(1)
(2)
(3)
(4)
(5)
(6)
(2)
(4)
(3)
(5)
(6)
(7)

EI-11
EXTERIOR/INTERIOR TRIM
General Description
14.CONSOLE BOX
(1) Console cover (6) Lid hinge (11) Lower bracket
(2) Cup holder (7) Rear lid (12) Lock
(3) Bracket (8) Console box (13) Front cover (AT model)
(4) Strip (9) Console pocket (14) Front cover (MT model)
(5) Upper lid (10) Upper bracket (15) Boot
EI-00533
(1)
(2)
(5)
(6)
(7)
(9)
(8)
(3)
(14)
(12)
(11)
(10)
(15)
(13)
(4)

EI-12
EXTERIOR/INTERIOR TRIM
General Description
15.INSTRUMENT PANEL
(1) Pad & frame (9) Air vent grille (side) (16) Glove box lid
(2) Center upper panel (10) Instrument panel lower cover (17) Glove box panel
(3) Air vent grille (defroster) (11) Console cover (18) Console reinforcement
(4) Grille cover (12) Center panel (19) Coin box
(5) Meter visor (13) Center pocket
(6) Defroster grille (14) Ash tray Tightening torque: N·m (kgf-m, ft-lb)
(7) Cup holder (15) Audio bracket T: 7 (0.71, 5.2)
(8) Air vent grille (center)
EI-00427
(6)
(2)
T
T
T
T
(8)
(7)
(5)
(10)
(19)
(13)
(12)
(14)
(15)
(11)
(18)
(17)
(9)
(1)
(4)
(4)
(3)
(16)

EI-13
EXTERIOR/INTERIOR TRIM
General Description
16.INNER TRIM (SEDAN MODEL)
(1) Front pillar upper trim (6) Trunk rear trim (10) Center pillar lower trim
(2) Center pillar upper trim (7) Trunk side trim (11) Side sill front cover
(3) Rear pillar upper trim (8) Rear pillar lower trim (12) Front garnish
(4) Rear shelf trim (9) Side sill rear cover (13) Rear garnish
(5) Rear bulk trim
EI-00429
(1)
(2)
(8)
(9)
(10)
(12)
(13)
(11)
(5)
(6)
(7)
(3)
(4)

EI-14
EXTERIOR/INTERIOR TRIM
General Description
17.INNER TRIM (WAGON MODEL)
(1) Front pillar upper trim (6) Rear quarter lower trim (11) Side sill front cover
(2) Center pillar upper trim (7) Hook (12) Front garnish
(3) Rear pillar upper trim (8) Rear skirt trim (13) Rear garnish
(4) Rear rail trim (9) Side sill rear cover
(5) Rear pillar lower trim (10) Center pillar lower trim
EI-00430
(6)
(5)
(9)
(10)
(1)
(2)
(3)
(4)
(11)
(12)
(13)
(7)
(8)

EI-15
EXTERIOR/INTERIOR TRIM
General Description
18.ROOF TRIM (SEDAN MODEL)
19.ROOF TRIM (WAGON MODEL)
(1) Roof trim
(1) Roof trim (2) Roof trim (Model with sun roof) (3) Sun roof garnish
EI-00431
(1)
EI-00432
(1)
(2)
(3)

EI-16
EXTERIOR/INTERIOR TRIM
General Description
20.LUGGAGE FLOOR MAT
21.HEAT SHIELD COVER
(1) Front floor mat (3) Side floor mat (RH) (5) Side floor mat (LH)
(2) Floor box (4) Center floor mat
(1) Front heat shield cover (2) Center heat shield cover (3) Rear heat shield cover
EI-00433
(3)
(2)
(4)
(5)
(1)
EI-00089
(1)
(2)
(3)

EI-17
EXTERIOR/INTERIOR TRIM
General Description
22.INNER ACCESSORIES
B: PREPARATION TOOL
(1) Hook (3) Assist grip (4) Center visor
(2) Sun visor
TOOL NAME REMARKS
Clip remover Used for removal of trim.
Clip clamp pliers Used for removal of various clips and clamps.
EI-00434
(1)
(4)
(2)
(3)

EI-18
EXTERIOR/INTERIOR TRIM
Front Grille
2. Front Grille
A: REMOVAL
1) Open the front hood.
2) Remove the four clips (A).
3) Remove the right and left hooks on the lower
side.
B: INSTALLATION
Install in the reverse order of removal.
: (A) EI-00407
EI-00476