SONY 00035071 Service Manual

http://listado.mercadolibre.com.mx/_CustId_67027869

rodcasti@gmail.com

I

3

2002

IMPREZA SERVICE MANUAL

GENERAL INFOMATION 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

c-

.

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

repair work is needed, be sure SUBARU genuine parts.

of

parts during

to

QUICK REFERENCE INDEX

use

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.

G1830BE1

I

FOREWORD

1

.

Foreword

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..

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FWa

Page

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.2

FOREWORD

~

1.

Foreword

A:

FOREWORD

These manuals are used when performing mainte-

nance, repair or diagnosis of the Subaru IMPREZA.

2001

Applied model: GG***** and GD***** from The additional manuals below are also available:

AUTOMATIC TRANSMISSION SERVICE MANUAL (Pub. No. G0853ZE)

The manuals contain the latest information at the time

of

publication. Changes in the specifications,

methods, etc. may be made without notice.

MY.

FW-2

HOW

TO

USE

How

1.

THIS MANUALS

to

Use

This

Manuals

...........................................................................

HU

Paae

--

2

I

HOW TO USE THIS MANUALS

HOW

TO

USE

THIS

MANUALS

1.

How

A:

HOW

1.

STRUCTURE

Each section consists of SCT that are broken down into

SC

ponent. The specification, maintenance and other

information for the components are included, and the diagnosis information has also been added where necessary.

2.

INDEX

The first page has an index with tabs. And at the end of each section is an alphabetical index.

3.

COMPONENTS

For each component, a composition drawing is included.

4.

SPECIFICATIONS

to

Use

TO

that are divided into sections for each com-

This

Manuals

USE THIS MANUALS

ff

necessary, specifications are also included

5.

INSPECTION

Inspections are included to be carried out before and after maintenance.

6.

MAINTENANCE

Maintenance instructions are provided for each

component. When multiple components comprise one process, refer to the instructions for that process for each component.

7.

DIAGNOSIS

Tables showing a step-by-step process make it easy to conduct diagnosis.

8.

SI

UNITS

Measurements in these manuals are according to

the

SI

units. Metric and yard/pound measurements

are also included.

H

U-2

SPECIFICATIONS

SPC

1

.

lmpreza

...

.

. .

. . . . . .

. . .

,

. . .

. .

.

. .

.

. . . . , . . . .

. . .

,

. . .

. . . . . . . . .

. .

,

.

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. . , .

. . . . . . . ..

. . . .

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.

. . ..

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...

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Page

.2

a

SPECIFICATIONS

1.

lmpreza

A:

DIMENSIONS

IMPREZA

Model Overall lennth mm (in) Overall width mm (in) Overall height (at CW)

Compartment Length mm (in)

Width mm (in)

I

Height

Tread

Minimum road clearance mm (in)

B:

ENGINE

Model

I

valve arranqement Bore x Stroke mm (in)

Displacement cm3 (cu in) ComDression ratio

I

Firinq order Idle speed at Park/Neutral

I

position (NC OFF) Maximum output Maximum torque

I

Front mm (in) Rear mm (in)

N.m (kgf-m, ft-lb)/rpm 294

mm (in)

mm

rpm

kW (HP)/rpm 169 (227)/6,000

(in)

\I

Sedan Waaon OUTBACK

I

1,730 (68.1) 1,695 (66.7) 1,710 (67.3) 1,440 (56.7) 1,890 (74.4) 1,845 (72.6)

I

1

,I

80 (46.5)

I

1.485 (58.5)

,\,

1,475 (58.1

1,480 (58.3)*1

150 (5.9), 150 (5.9),

155 (6.1)*1 155 (6.1)*1

),

Turbo 2.0

L

I

92

x

75

(3.62

x

2.95)

1,994 (121.67)

8.0

I

(30.0,

750

217)/4,000

I

4,405 (173.4)

1,465 (57.7), 1,475 (58.1),

1,485 (58.5)*2 1,495 (58.9)*2

1,380 (54.3)

1,200 (47.2), 1,200 (47.2),

I

1,150 (45.3)*3

1.465 (57.7) 1.460 (57.5)

.\,

1,455 (57.3) 1,455 (57.3)

Overhead camshaft tvDe

1-3-2-4

I

2.5

99.5

(3.91 7

2,457

10.0

650 (MT)

700 (AT)

123 (165)/5,600

226 (23.0, 166)/4,000

1,150 (45.3)*3

I\,

160 (6.3)

L

x

79.0

x

3.1

IO)

(1

49.9)

-1

1

SPC-2

C:

ELECTRICAL

IMPREZA

I

SPECIFICATIONS

Model Turbo 2.0 L Ignition timing at idling speed BTDC/rpm

Spark plug

Generator Battery Type

Reserve capacity min

Cold cranking amp amperes

rMm

Transmission type Clutch type

-'

Gear ratio

I

'

Reduction gear

,

(Front drive) Gear ratio

I

Reduction gear (Rear drive)

~

1

st

reduction Type

Final reduction Type

I I

Transfer reduction Type

Final reduction Type

I

1st 3.454 2.785

L

1

3rd

L

14th

5th 0.738 Reverse

of

Gear ratio

of

Gear ratio 1.100

of

Gear ratio 3.545 4.111

I

12"+10"/750

NGK: PFR6G NGK: BKR5E-11

-

12V

MT: 12V

AT: 12V

-

48AH (55D23L)

-

52AH (65D23L)

MT: 99 MT: 99

AT:

MT: 356 MT: 356

AT: 420 AT: 520

I

5MTSrl 4ATlr2

DSPD TCC

I

gear

gear Hypoid Hypoid

I

gear Helical

gear Hypoid Hypoid

1.366

0.972

3.333 2.272

-

3.900

75A

111

I

CHAMPION: RCI OYC4(Standard)

MT: 12V

AT: 12V

Turbo

2.0

L

I

I I

2.5

MT: 1 O"k1 0°/650

AT: 1 O"k1 0"/700

NGK: BKR6E-11

12V

-

48AH (55D23L)

-

52AH (75D23L)

AT: 118

1

.ooo

0.694

-

Helical

1.000

I

4.1

11

-

L

90A

I

4

I

SPC-3

IM

PREZA

SPECIFICATIONS

Model

Transmission type Clutch type

I

1st

2nd 3rd 4th 5th

I

Reverse Dual range

1

st

reduction Reduction gear

(Front drive)

Final reduction

r

Reduction gear (Rear drive)

r

I

5MTM : 5 forward speeds with synchromesh and I -reverse 4AT+2: Electronically controlled fully-automatic, 4-forward speeds and DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch

Transfer reduction

Final reduction

Type of gear Gear ratio

Type of gear Gear ratio Type

of

gear Gear ratio Type of gear Gear ratio

5MT*1 4ATlr2 5MTlrl 4AT*2

DSPD TCC DSPD TCC

I

3.454

2.062 1.619 2.062 1.545

1.448

1.088 0.694 1.088 1.694

0.780

I

3.333

- - - -

-

Hypoid Hypoid Hypoid

11

4.1

I

ical

He

1

.ooo

Hypoid Hypoid

11

4.1

RS

I

2.5

L

3.027

1

.ooo

-

2.272

Helical

1

.ooo

4.444 3.900

I

-

4.444 3.900

1

-reverse

Others

3.454

1.448

0.780

3.333

-

He I ical

1.000

Hypoid Hypoid

I

2.785

~~~

1

.ooo

-

2.272

Helical

1

.ooo

...

Hypoid

11

4.1

-

11

4.1

I

1

E: STEERING

Type Turns, lock

Minimum turning circle m

Front Rear

Model Service brake system

Front Rear Parking brake

H:

to

TIRE

lock

(ft)

Curb

Wall

to

curb wall

Rack and Pinion

3.2 3

10.2 (33.5)

11

.I

(36.3) 11.7 (38.3)

Macpherson strut type, Independent, Coil spring

Dual-link strut type, Independent, Coil spring

SEDAN WAGON

Dual circuit hydraulic with vacuum suspended power unit

Ventilated disc brake

Disc brake Drum brake, Disc brakelrl

Mechanical on rear brakes

I

10.8

(35.4)

Rim size Tire size

Type

15 x 6JJ

PI 95/60R15 87H P205/55R16 89V

Steel belted radial, Tubeless

16

x

6’/2JJ

SPC-4

I:

CAPACITY

IMPREZA

SPECIFICATIONS

Fuel tank Engine oil Upper level

Lower level

Transmission gear oil

Automatic transmission fluid AT differential gear oil AWD rear differential gear oil

Power steering fluid Engine coolant

Model

Q

t-

Curb weight

I

Gross vehicle weight

.V.

W.)

(G

(C.W.)

Front kg (Ib) Rear

I

Total ka (Ib) I 1,395 (3,075)

Front Rear

Total

(US gal, Imp gal)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

Q

(US qt, Imp qt)

I

826 (1,820) 851 (1,875)

ka

(Ibl

w.

kg (Ib) kg (Ib) kg (Ib)

569 (1.255) 569 (1.255)

I1

998 (2,200) 998 (2,200) 857 (1,890) 857 (1,890)

1,837 (4,050) 1,795 (4,050)

I

5MTlrl 4ATJrl

5MT

3.5

(3.7, 3.1) (3.7, 3.1)

-

7.7 (8.1, 6.8)

Turbo 2.0

WRX

..

I

60 (1 5.9, 13.2)

4.5 (4.8, 4.0)

3.5 (3.7, 3.1)

4AT

-

9.3 (9.8, 8.2)

1.2 (1.3, 1 .I)

I

7.6 (8.0, 6.7)

L

I I

I

I. I I.

1,420 (3,130)

I

0.8 (0.8, 0.6)

0.7 (0.7, 0.6)

I

AWD

1

1,345 (2,965)

1,778 (3,920) 1,837 (4,050)

5MT

3.5

-

7.0 (7.4, 6.2)

5MT 4AT 778 (1,715) 803 (1,770) 567 (1.250) 567 (1,250)

939 (2,070) 939 (2,070) 857 (1,890) 857 (1,890)

I

60 (1 5.9, 13.2)

4.0 (4.2, 3.5)

3.0 (3.2, 2.6)

9.5 (10.0, 8.4)

1.2 (1.3, 1.1)

1

6.9 (7.3, 6.1)

2.5 L RS

.

I

1,370 (3,020)

4AT

-

I

SPC-5

SPECIFICATIONS

IM

PREZA

I

Model

Curb weight (C.W.) Front kg (Ib)

Rear ka (Ib)

~~

~

Gross vehicle weight

.

V.

W.

)

(G

Curb weight (C.W.) Front kg (Ib)

Gross vehicle weight Front kg (Ib)

-(

G

.

v.

w.

)

tl:

Excludes weight

t2: Excludes weight

htai ka ob)

Front kg (Ib) Rear kg (Ib) 925 (2,040)

Total kg (Ib) 1,901 (4,190)

Rear kg (Ib)

Total

Rear kg (Ib) Total kg (Ib) [ 1,833 (4,040)

of

ABS,

of

side air bag.

kg

(Ib)

-

cruise control.

AWD

Xirbo 2.0

5MTt2 4ATt2

825 (1,820) 851 (1,875)

606

(1.335) 605 (1,335)

1

-

5MTtl 4ATt 773 (1,705) 603 (1,330)

1,376 (3,035) 1,402 (3,090) 1,384 (3,050)

939 (2,070) 939 (2,070) 925 (2,040)

1,431 (3,155)

998 (2,200)

TS

796 (1,755) 783 (1,725) 606 (1,335) 601 (1,325)

925 (2,040) 925 (2,040)

I

1,833 (4,040)

1

WRX

I

2.5

I

L

939 (2,070)

1,833 (4,040)

1,458 (3,210)

998 (2,200) 925 (2,040)

1,901 (4,190)

OUTBACK

5MT 4AT

805 (1,775) 603 (1,330)

1,408 (3,l 05)

939 (2,070) 925 (2,040)

I

1,833 (4,040)

SPC-6

2.

CANADA SPEC. VEHICLE

Sedan

Model

Curb weight

Gross vehicle weight

.V.

W.

(G

(C.W.)

)

Front

Rear Total Front

Rear Total

Wagon

.-

IMPREZA

5MT

kg (Ib) kg (Ib) 573 (1,265) kg (Ib) kg (Ib) kg (Ib) kg Ob)

826 (1,820)

1,399 (3,085)

998 (2,200) 998 (2,200) 857 (1,890) 857 (1,890)

1,837 (4,050) 1,837 (4,050)

Turbo 2.0

WRX

SPECIFICATIONS

2.5

L

4AT 5MT 851 (1,875) 778 (1,715) 803 (1,770) 573 (1,265) 567 (1,250)

1,424 (3,140) 1,345 (2,965) 1,370 (3,020)

939 (2,070) 939 (2,070) 857 (1,890)

1,778 (3,920) 1,778 (3,920)

L

RS

4AT

567 (1,250)

857 (1,890)

I

*1: Excludes weight

of

air conditioner

SPC-7

SPECIFICATIONS

IMPREZA

c-

.

SPC-8

PRECAUTION

Precaution

1

.

...........

..................

PC

Page

......................................................................

I

2

PRECAUTION

1.

Precaution

A:

PRECAUTION

Please clearly understand and adhere to the following general precautions. They must be strictly followed to avoid minor or serious injury to the person

doing the work or people in the area.

1. ABS

Handle the ABS as a total system. Do not disas-

semble or attempt to repair individual parts. Doing

so

could prevent the ABS system from operating when needed or cause it to operate incorrectly and result in injury.

2.

BRAKE FLUID

If

brake fluid gets in your eyes or on your skin, do

the following:

Wash out your eyes and seek immediate medical

attention.

Wash your skin with soap and then rinse thor-

oughly with water.

3.

ELECTRIC FAN

The electric fan may rotate without warning, even when the engine is not on. Do not place your hand, cloth, tools or other items near the fan at any time.

7.

AIRBAG MODULE

Adhere to the following when handing and storing the airbag module to prevent bodily injury from unexpected deployment:

Do

not hold the harnesses or connectors to carry

the module.

Do not face the bag in the direction that it opens

towards yourself or other people.

Do not face the bag in the direction that it opens

towards the floor or walls.

8.

AIRBAG SPECIAL TOOLS

To

prevent unexpected deployment, only use spe-

cial tools.

9.

WINDOW

Always wear safety glasses when working around any glass to prevent glass fragments from damaging your eyes.

1O.WINDOW ADHESIVE

Atways use the specified urethane adhesive when attaching glass to prevent it from coming loose and falling, resulting in accidents and injury.

4.

ROADTESTS

Always conduct road tests in accordance with traffic rules and regulations to avoid bodily injury and interrupting traffic.

5.

AIRBAG

To prevent bodily injury from unexpected deployment of airbags and unnecessary maintenance, follow the instructions in this manual when performing maintenance on the airbag components or nearby, and the airbag wiring harnesses or nearby. To

prevent unexpected deployment, perform one of the steps below and then wait at least to discharge electricity before beginning work.

Step

1

:

Turn the ignition switch OFF.

Step

2:

Remove the negative battery terminal.

6.

AIRBAG DISPOSAL

To prevent bodily injury from unexpected airbag deployment, do not dispose the airbag modules in the same way as other refuse. Follow instructions of SOA (distributor) service for disposal of airbag module. Follow all government regulations concerning the disposal of refuse.

20

seconds

PC-2

NOTE

1

.

NT

Note

.............................................................................................................

I

Page

2

NOTE

1.

Note

A:

NOTE

This is the information that can improve the effi-

ciency of maintenance and assure the sound work.

1.

FASTENER NOTICE

Fasteners are used to prevent the parts from damage and dislocation due to looseness. Fasteners must be tightened to the specified torque. Do not apply paint, lubricant, rust retardant or other

substances to the surface around bolts, fasteners,

etc. Doing rect torque and result in looseness and other problems.

2.

STATIC ELECTRICITY DAMAGE

Do

not touch the and other such parts when there is a risk of static electricity. Always use a static electricity prevention cord or touch grounded metal before conducting work.

so

will make it difficult to obtain the cor-

ECM,

connectors, logic boards

NOTE

3.

IGNITION

When removing the battery cables, always be sure to turn the ignition off to prevent electrical damage to the

4.

mance and maintenance, when conducting repairs. Subaru/FHI will not be responsible for poor performance resulting from the use of parts not specified by a genuine dealer.

ECM

SERVICE PARTS

Use authentic service parts for maximum perfor-

OFF

BATTERY

from rush current.

NT-2

NOTE

5.

LIFTS

When using a lift or jack-ridged rack to raise a vehicle, always follow the instructions concerning jack-up points and weight limits to prevent the vehicle from falling, which could result in injury. Be especially careful

to make sure the vehicle is balanced before raising it.

AND

JACKS

Support locations

Pantograph jack

A

Without side sill cover

I

With-ver

fi.w

I

Lift

Safety stand

GI0166

NT-3

NOTE

I

Front

Rear

nt

cross member

Rear differential

GI0121

NT-4

NOTE

6.

TIE

DOWNS

Tie downs are used when transporting vehicles and when using the chassis dynamo. Attach tie downs only

to the specified points on the vehicle.

Hook

for

tie-down

3

Hook

for

1-

towing

Hook

for

tie-down

Hook

for

towing

and tie-down

GI0122

NT-5

I

NOTE

I

20 20’

20 20”

20 20” 20

7.

TOWING

Avoid towing vehicles except when the vehicle cannot be driven. For vehicles with AWD, AT or VTD, use a loader instead of towing. When towing other vehicles, to prevent excessive weight from damaging the hook or vehicle:

Do not tow other vehicles with a front towing

hook.

Make sure the vehicle towing is heavier than the

vehicle being towed.

8.

TRAINING

For an information about training, contact a dealer or agent.

20”

9. GENERAL SCAN TOOL

Using general scan tools will greatly improve the ef-

ficiency of repairing engine electronic controls. The

Subaru Select Monitor can be used to diagnose the engine and also the ABS, the air conditioner and other parts.

NT-6

IDENTIFICATION

Identification

1

.

....

. ... .

....

.. . .

...

. .

... . ...

....

.

...

. . .. . . .. . .. . .

...

.

....

. .. . .. .

. .. . . .

...

ID

. ..

...

... .

.. . ..

Page

.....

.

.2

IDENTIFICATION

I

DE

NTI

F I CAT1 0 N

1.

Identification

A:

IDENTIFICATION

1.

IDENTIFICATION NUMBER AND LABEL LOCATIONS

The VIN (Vehicle Identification Numbers) is used to classify the vehicle.

Positioning of the plate label for identification

Vacuum hose piping label

/

..

I

number plate

pressure label

Vehicle

Engine sdrial number G l0007A

'

Model number plate

I

Transmission serial number

o.

G10008A

GI0161

I

D-2

I

DENTI FlCATlON

I

IDENTIFICATION

Model number

plate

U

/

b

'I

L3

F

trim code engine

9+#L2-F

2

3

0

r'z"'!it

sv53>w

type

E

J

2

0

ENMABA~

GlOOllA

I

D-3

IDENTIFICATION

2.

MEANING

The meaning

North

America

of

OF

the

V.I.N.

VIN

is

as

follows:

]JF1 GD255X2G500001[

The starting and ending brackets

(

I[

IDENTIFICATION

)

are

stop

marks.

Digits Code

1

to3

4 G

5

JFI

ID

6

7

8

9

10

11

12

to

17

2 Displacement

5

X Check digit 2 Model year

G

500001

Meaning Manufacturer body area Car line

Grade

Restraint

Transmission type

Manufacture number

Details

JFI: Passenger car, FHI made

G: IMPREZA D: 4 Door Sedan

G: Waaon

2: 2.0 L AWD Turbo

6:

2.5 LAWD

5:

TS

7:

RS

8:

OUTBACK

9:

WRX

5:

Manual belts, dual airbag.

6:

Manual belts, dual airbag, side airbag.

0-9

&

x

2: 2002MY 3:

2003MY

G:

Full-time AWD 5-speed MT

H:

Full-time AWD 4-speed AT

From

500001

800001 : Waaon

From

:

4 Door Sedan

I

D-4