Subaru Impreza 2012 Workshop Manual
Subaru Impreza: Experience a blend of power, efficiency, and versatility. With its rugged build, spacious interior, and advanced safety features, Impreza is your perfect companion for daily commutes, outdoor adventures, and family road trips. Its intuitive infotainment system keeps you connected and entertained, while its responsive handling and confidence-inspiring all-wheel drive provide a thrilling driving experience in all conditions.
advertisement
2001 IMPREZA SERVICE MANUAL
BODY SECTION
QUICK REFERENCE INDEX
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, reassembling, inspection and adjustment of components and diagnostics for guidance 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 specifications contained in this manual are based on the latest product information available at the time of publication approval.
FUJI HEAVY INDUSTRIES LTD.
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTICS)
AIRBAG SYSTEM
AC
AC
AB
AB AIRBAG SYSTEM (DIAGNOSTICS)
SEAT BELT SYSTEM SB
LI LIGHTING SYSTEM
WIPER AND WASHER SYSTEMS WW
ET ENTERTAINMENT
COMMUNICATION SYSTEM COM
GW GLASS/WINDOWS/MIRRORS
BODY STRUCTURE BS
IDI INSTRUMENTATION/DRIVER INFO
SEATS SE
SL SECURITY AND LOCKS
IMMOBILIZER (DIAGNOSTICS) IM
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
EXTERIOR/INTERIOR TRIM EI
G1830GE6
2001 IMPREZA SERVICE MANUAL
BODY SECTION
QUICK REFERENCE INDEX
CRUISE CONTROL SYSTEM
CRUISE CONTROL SYSTEM
(DIAGNOSTICS)
CC
CC
G1830GE6
EXTERIOR BODY PANELS
EB
Page
EXTERIOR BODY PANELS
1. General Description
A: SPECIFICATIONS
GENERAL DESCRIPTION
Front hood
SECTION A
Front fender
Front fender
SECTION B
Front door
Rear door
SECTION D
Rear quarter
Section
A
B
C
D
E, F
Part
Front hood to Front fender
Front fender to Front door
Front door to Rear door
Rear door to Rear quarter
Door panel to Side sill
Front door
SECTION C
Rear door
Door panel
SECTION E,F
Side sill
BO0260
Specification
NA: 4.0 ± 1.0 (0.16 ± 0.04 in)
TURBO: 3.7 ± 1.0 (0.15 ± 0.04 in)
4.7 ± 1.0 (0.19 ± 0.04 in)
5.1 (0.20 in)
4.6 (0.18 in)
5.9 (0.23 in)
EB-2
B: COMPONENT
1. FRONT HOOD
GENERAL DESCRIPTION
EXTERIOR BODY PANELS
(1) Front hood
(2) Seal (Front hood)
(3) Hinge
(4) Hood grille
(5) Packing
(6) Clip
(7) Locking piece
BO0248
Tightening torque: N·m (kg-m, ft-lb)
T: 7.35 (0.75, 5.4)
T1: 24.5 (2.5, 18.1)
EB-3
EXTERIOR BODY PANELS
2. FRONT DOOR PANEL
GENERAL DESCRIPTION
(1) Gusset
(2) Weatherstrip (Outer)
(3) Clip (Weatherstrip, outer)
(4) Stabilizer (Lifter)
(5) Stabilizer (Outer)
(6) Stabilizer (Inner)
(7) Sealing cover
(8) Checker
(9) Lower hinge
(10) Upper hinge
(11) Door panel
BO0249
Tightening torque: N·m (kg-m, ft-lb)
T1: 7.35 (0.75, 5.4)
T2: 18 (1.8, 13)
T3: 30 (3.1, 2.2)
EB-4
3. REAR DOOR PANEL
GENERAL DESCRIPTION
EXTERIOR BODY PANELS
(1) Weatherstrip (Outer)
(2) Clip (Weatherstrip, outer)
(3) Stabilizer (Outer)
(4) Stabilizer (Inner)
(5) Door panel
(6) Bracket
(7) Sealing cover
(8) Checker
(9) Lower hinge
(10) Upper hinge
BO0250
Tightening torque: N·m (kg-m, ft-lb)
T1: 7.35 (0.75, 5.4)
T2: 18 (1.8, 13)
T3: 30 (3.1, 2.2)
EB-5
EXTERIOR BODY PANELS
4. TRUNK LID PANEL
GENERAL DESCRIPTION
(1) Torsion bar
(2) Trunk lid
(3) Weatherstrip
(4) Hinge ASSY
(5) Cover
BO0251
Tightening torque: N·m (kg-m, ft-lb)
T1: 7.5 (0.76, 5.5)
T2: 14 (1.8, 13)
EB-6
5. REAR GATE PANEL
GENERAL DESCRIPTION
EXTERIOR BODY PANELS
(1) Gas stay
(2) Hinge
(3) Rear gate
C: CAUTION
• Exterior body panels are heavy. Do not drop and damage the panels. During removal and installation, do not damage the panel painting surface.
• While removing mounting bolts, using assistance devices such as a support jack will help support the panel.
• Be careful not to lose small parts.
EB-7
BO0252
Tightening torque: N·m (kg-m, ft-lb)
T: 25 (2.5, 18.1)
EXTERIOR BODY PANELS
D: PREPARATION TOOL
1. SPECIAL TOOLS
GENERAL DESCRIPTION
ILLUSTRATION TOOL NUMBER
925610000
DESCRIPTION
WRENCH
REMARKS
Used for removing and installing door hing.
B5M1117
927780000 REMOVER Used for removing and installing trunk torsion bar.
B5M1118
2. GENERAL TOOL
TOOL NAME
Support Jack
REMARKS
Used for supporting door panel.
EB-8
2. Front Hood
A: REMOVAL
1) Open front hood to remove washer nozzles.
2) Release clips to remove hood insulator.
FRONT HOOD
EXTERIOR BODY PANELS
3) Rotate hood buffer to adjust lateral height.
B5M0750
B5M1090
3) Remove bolts to disconnect hood from hinges.
B5M0747
B: INSTALLATION
1) Install in the reverse order of removal.
2) Adjust clearance between hood and fender.
Clearance must be equal at both sides.
C: ADJUSTMENT
1) Use hinge mounting holes to align front hood longitudinally and laterally.
B5M0747
2) Adjust height at front end of hood. <Ref. to SL-
40, ADJUSTMENT, Front Hood Lock Assembly.>
EB-9
FENDER PANEL
EXTERIOR BODY PANELS
3. Fender Panel
A: REMOVAL
1) Disconnect ground (
−
) cable from battery.
2) Remove side sill spoilers. <Ref. to EI-19, Side
Sill Spoiler.> (If fitted)
3) Remove front bumper face. <Ref. to EI-8, RE-
MOVAL, Front Bumper.>
4) Remove mud guard. <Ref. to EI-16, REMOVAL,
Mud Guard.>
5) Loosen bolts to remove front fender.
BO0153
B: INSTALLATION
1) Install in the reverse order of removal.
2) When fender panel is installed, clearance between fender panel and hood or front fender must be equal.
EB-10
4. Front Door Panel
FRONT DOOR PANEL
EXTERIOR BODY PANELS
10) Remove door-side bolts for upper and lower hinges to remove door.
A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove front door trim. <Ref. to EI-20, REMOV-
AL, Front Door Trim.>
3) Remove outer mirror assembly. <Ref. to GW-46,
REMOVAL, Outer Mirror Assembly.>
4) Remove front door regulator and motor. <Ref. to
GW-31, REMOVAL, Front Regulator and Motor Assembly.>
5) Remove front door latch assembly. <Ref. to SL-
30, REMOVAL, Front Door Latch Assembly.>
6) Remove front outer handle. <Ref. to SL-29, RE-
MOVAL, Front Outer Handle.>
7) Remove front pillar lower trim to disconnect connector from body harness.
G5M0385
11) Using special tool, remove body-side bolts for upper and lower hinges, and remove door hinges.
ST 925610000 DOOR HINGE WRENCH
B5M0726
8) Put wooden block on jack and place jack under door. Support door with a support jack to protect it from damage.
B5M0933A
CAUTION:
• During removal and installation of doors, do not damage body.
• Doors are heavy. Be careful not to drop and damage them.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Apply grease to sliding area of door hinges.
BO0261
9) Remove checker bolts.
S5M0183
EB-11
FRONT DOOR PANEL
EXTERIOR BODY PANELS
C: ADJUSTMENT
1) Using special tool, loosen body-side bolts of upper and lower hinges to align the position of front door panel longitudinally and vertically.
ST 925610000 DOOR HINGE WRENCH
B5M0933A
2) Loosen door-side bolts of upper and lower hinges to align the position of front door panel vertically and laterally at the front end.
G5M0385
3) Loosen screw (A) and tap striker (B) using plastic hammer to adjust striker.
CAUTION:
Do not use impact wrench. Welding area on striker nut plate is easily broken.
B5M0934A
EB-12
FRONT SEALING COVER
5. Front Sealing Cover
A: REMOVAL
1) Remove front door trim. <Ref. to EI-20, REMOV-
AL, Front Door Trim.>
2) Remove front speaker. <Ref. to ET-10, REMOV-
AL, Front Speaker.>
3) Using a spatula, remove sealer.
CAUTION:
• Carefully remove sealer. Excessive force will easily break the cover.
• If cover gets broken, replace it with a new one.
EXTERIOR BODY PANELS
G5M0391
B: INSTALLATION
1) Install in the reverse order of removal.
2) When replacing sealing cover, use CEMEDINE
5430L sealer.
3) Press sealer-applied area firmly to prevent any floating on surface.
Sealer:
CEMEDINE 5430L or equivalent
CAUTION:
• Apply a uniform bead of sealer.
• Attach sealing cover, keeping it from becoming wrinkled.
• Breaks in the bead will allow water leakage and contamination.
C: INSPECTION
If sealing cover is damaged, replace it with a new one.
EB-13
REAR DOOR PANEL
EXTERIOR BODY PANELS
6. Rear Door Panel
A: REMOVAL
CAUTION:
• During removal and installation of doors, do not damage body.
• Doors are heavy. Be careful not to drop and damage them.
1) Disconnect ground cable from battery.
2) Remove rear door trim. <Ref. to EI-21, REMOV-
AL, Rear Door Trim.>
3) Remove rear door regulator and motor assembly. <Ref. to GW-34, REMOVAL, Rear Regulator and Motor Assembly.>
4) Remove rear door latch. <Ref. to SL-34, RE-
MOVAL, Rear Door Latch Assembly.>
5) Remove rear outer handle. <Ref. to SL-33, RE-
MOVAL, Rear Outer Handle.>
6) Remove center pillar lower trim. <Ref. to EI-29,
REMOVAL, Lower Inner Trim.>
7) Disconnect connector of door harness.
9) Remove checker bolts.
S5M0183
10) Remove door-side bolts for upper and lower hinges to remove door.
G5M0385
11) Using special tool, remove body-side bolts for upper and lower hinges, and remove door hinges.
B: INSTALLATION
1) Install in the reverse order of removal.
2) Apply grease to sliding area of door hinges.
BO0154
8) Put a wooden block on the jack and place the jack under the door. Support the door with the jack to protect it.
BO0261
EB-14
REAR DOOR PANEL
C: ADJUSTMENT
1) Using special tool, loosen body-side bolts of upper and lower hinges to align the position of rear door panel longitudinally and vertically.
EXTERIOR BODY PANELS
B5M0933A
2) Loosen door-side bolts of upper and lower hinges to align the position of rear door panel vertically and laterally at front-end.
G5M0385
3) Loosen screw (A) and tap striker (B) using plastic hammer to adjust striker.
CAUTION:
Do not use an impact wrench. The welding area on the striker nut plate is easily broken.
B5M0934A
EB-15
REAR SEALING COVER
EXTERIOR BODY PANELS
7. Rear Sealing Cover
A: REMOVAL
1) Remove rear door trim. <Ref. to EI-21, REMOV-
AL, Rear Door Trim.>
2) Remove rear speaker. <Ref. to ET-12, REMOV-
AL, Rear Speaker.>
3) Using a spatula, remove sealer.
CAUTION:
• Carefully remove sealer. Excessive force will easily break the cover.
• If cover gets broken, replace it with a new one.
G5M0391
B: INSTALLATION
1) Install in the reverse order of removal.
2) When replacing sealing cover, use CEMEDINE
5430L sealer.
3) Press sealer-applied area firmly to prevent any floating on surface.
Sealer:
CEMEDINE 5430L or equivalent
CAUTION:
• Apply an uniform bead of sealer.
• Attach sealing cover, keeping it from becoming wrinkled.
• Breaks in the bead will allow water leakage and contamination.
C: INSPECTION
If sealing cover gets damaged, replace it with a new one.
EB-16
8. Trunk Lid Panel
TRUNK LID PANEL
A: REMOVAL
1. TRUNK LID
1) Open trunk lid.
2) Disconnect trunk lid connector.
3) Loosen trunk lid mounting bolts to remove trunk lid from hinges.
EXTERIOR BODY PANELS
B: INSTALLATION
1. TRUNK LID
1) Install in the reverse order of removal.
2) Install trunk lid with uniform clearance.
2. TORSION BAR
1) Install in the reverse order of removal.
2) Apply grease to rotating area of hinges and mating surface of torsion bar.
G5M0144
2. TORSION BAR
1) Open trunk lid.
2) Using special tool, remove torsion bar from hinge link.
ST 927780000 REMOVER
CAUTION:
During removal and installation, carefully handle torsion bar. It will generate reactive force.
G5M0145
3) Remove right/left torsion bars.
CAUTION:
After the torsion bar is removed, the trunk lid will slam shut. Be careful not to get hit by the trunk lid.
EB-17
REAR GATE PANEL
EXTERIOR BODY PANELS
9. Rear Gate Panel
A: REMOVAL
1. REAR GATE PANEL
1) Open rear gate.
2) Remove rear gate outer handle. <Ref. to SL-36,
REMOVAL, Rear Gate Outer Handle.>
3) Remove rear gate latch assembly. <Ref. to SL-
37, REMOVAL, Rear Gate Latch Assembly.>
4) Remove rear gate key lock cylinders. <Ref. to
SL-43, REAR GATE, REPLACEMENT, Key Lock
Cylinders.>
5) Remove rear wiper. <Ref. to WW-21, REMOV-
AL, Rear Wiper Motor.>
6) Disconnect connectors of rear wiper, rear defogger, and other lighting devices.
7) Disconnect washer hose.
8) Remove rubber duct (A) connection, and pull out harness and washer hose from rear gate.
CAUTION:
When the rear gate is released, it may hit and damage the body. To prevent this, place a shop cloth between body and gate.
10) Loosen rear gate bolts to remove rear gate.
BO0278
2. GAS STAY
1) Open rear gate. Using a support jack to support the rear gate.
B5M0733A
9) Using a support, support the rear gate while removing gas stay mounting bolts.
BO0262
CAUTION:
• After gas stay is removed, rear gate cannot stay open. Supporting the rear gate with a jack, remove the bolts.
• Do not damage piston rods and oil seals.
• Never disassemble cylinders: They contain gas.
BO0262
BO0155
EB-18
REAR GATE PANEL
2) Loosen bolts to remove gas stay from rear gate.
EXTERIOR BODY PANELS
1) Cover with a vinyl case as shown in the figure.
Gas stay
BO0156
B: INSTALLATION
1. REAR GATE PANEL
1) Install in the reverse order of removal.
2) Install rear gate panel with uniform clearance to body.
CAUTION:
Do not damage painted surfaces of body and rear gate.
2. GAS STAY
Install in the reverse order of removal.
CAUTION:
After supporting rear gate with a jack, start operation.
C: DISPOSAL
1. GAS STAY
CAUTION:
Gas is colorless, odorless, and harmless. However, gas pressure may spray cutting powder or oil. Be sure to wear dust-resistant goggles.
Vinyl sack
BO0264
CAUTION:
Prevent the vinyl case from being caught by drill cutting edge
2) Lift body side slightly with piston rods fully extended, and secure body side on vise stand.
Drill a hole in 2 to 3 mm (0.08 to 0.12 in) diameter at a point 10 to 200 mm (0.39 to 7.87 in) from door side, and bleed gas stay completely.
Body side Door side
190mm
(7.48 in)
10mm
(0.39 in)
Piston rod Cylinder
Portion to be drilled
BO0263
EB-19
EXTERIOR BODY PANELS
REAR GATE PANEL
EB-20
advertisement