Subaru Impreza 2002 thru 2005, repair e-manual

Content

General information

• Foreword
• How to use this manual
• Specifications
• Precaution
• Note
• Identification
• Recommended materials
• Pre-delivery inspection

Periodic maintenance services

• General description
• Schedule
• Engine oil
• Engine oil filter
• Spark plugs
• Drive belt(s)
• Camshaft drive
• Fuel line
• Fuel filter
• Air cleaner element
• Cooling system
• Coolant
• Idle mixture
• Clutch system
• Transmission oil
• ATF
• Front and rear differential oil
• Brake line
• Brake fluid
• Disc brake pads and discs
• Brake linings and drums
• Suspension
• Wheel bearing
• Axle boots and joints
• Steering system
• Supplemental restraint system

Fuel injection

• General description
• Throttle body
• Intake manifold
• Engine coolant temperature sensor
• Crankshaft position sensor
• Camshaft position sensor
• Knock sensor
• Throttle position sensor
• Intake air temperature and pressure sensor
• Atmospheric pressure sensor
• Idle air control solenoid valve
• Air assist injector solenoid valve
• Fuel injector
• Front oxygen (a/f) sensor
• Rear oxygen sensor
• Engine control module
• Main relay
• Fuel pump relay
• Fuel
• Fuel tank
• Fuel filler pipe
• Fuel pump
• Fuel level sensor
• Fuel sub level sensor
• Fuel filter
• Fuel cut valve
• Fuel damper valve
• Fuel delivery, return and evaporation lines
• Fuel system trouble in general

Emission control

• General description
• Front catalytic converter
• Rear catalytic converter
• Canister
• Purge control solenoid valve
• Two-way valve

Intake

• General description
• Air cleaner element
• Air cleaner case
• Air intake duct
• Resonator chamber

Mechanical

• General description
• Compression
• Idle speed
• Ignition timing
• Intake manifold vacuum.
• Engine oil pressure
• Fuel pressure
• Valve clearance
• Engine assembly
• Engine mounting
• Preparation for overhaul
• V-belt
• Crankshaft pulley
• Belt cover
• Timing belt assembly.
• Camshaft sprocket
• Crankshaft sprocket
• Valve rocker assembly
• Camshaft
• Cylinder head assembly
• Cylinder block
• Engine trouble in general
• Engine noise

Exhaust

• General description
• Front exhaust pipe
• Center exhaust pipe
• Rear exhaust pipe
• Muffler

Cooling

• General description
• Radiator main fan system
• Radiator sub fan system
• Engine coolant
• Water pump
• Thermostat
• Radiator
• Radiator cap
• Radiator main fan and fan motor
• Radiator sub fan and fan motor
• Reservoir tank
• Coolant filler tank
• Engine cooling system trouble in general

Lubrication

• General description
• Oil pressure system
• Engine oil
• Oil pump
• Oil pan and strainer
• Oil pressure switch
• Engine oil cooler
• Engine oil filter
• Engine lubrication system trouble in general

Speed control systems

• General description
• Accelerator pedal
• Accelerator control cable

Ignition

• General description
• Spark plug
• Ignition coil and ignitor assembly
• Spark plug cord

Starting / charging systems

• General description
• Starter
• Generator
• Battery

Engine

• Basic diagnostic procedure
• Check list for interview
• General description
• Electrical components location
• Engine control module (ECM) I/O signal
• Engine condition data
• Transmission control module (TCM) I/O signal
• Data link connector
• OBD-II general scan tool
• Subaru select monitor
• Read diagnostic trouble code (DTC)
• Inspection mode
• Drive cycle
• Clear memory mode
• Compulsory valve operation check mode
• Engine malfunction indicator lamp (MIL)
• Diagnostics for engine starting failure
• List of diagnostic trouble code (DTC)
• Diagnostic procedure with diagnostic trouble code (DTC)
• General diagnostic table

Fuel injection

• General description
• Throttle body
• Intake manifold
• Engine coolant temperature sensor
• Crankshaft position sensor
• Camshaft position sensor
• Knock sensor
• Throttle position sensor
• Intake air temperature and pressure sensor
• Idle air control solenoid valve
• Fuel injector
• Oxygen sensor
• Engine control module
• Main relay
• Fuel pump relay
• Fuel
• Fuel tank
• Fuel filler pipe
• Fuel pump
• Fuel level sensor
• Fuel sub level sensor
• Fuel filter
• Fuel cut valve
• Fuel damper valve
• Fuel delivery, return and evaporation lines
• Fuel system trouble in general

Emission control

• General description
• Front catalytic converter
• Rear catalytic converter.
• Canister
• Purge control solenoid valve
• Two-way valve

Exhaust

• General description
• Front exhaust pipe
• Center exhaust pipe
• Rear exhaust pipe
• Muffler

Ignition

• General description
• Spark plug
• Ignition coil and ignitor assembly
• Spark plug cord

Engine

• Basic diagnostic procedure
• Check list for interview
• General description
• Electrical components location
• Engine control module (ECM) I/O signal
• Subaru select monitor
• Read diagnostic trouble code (DTC)
• Inspection mode
• Clear memory mode
• Compulsory valve operation check mode
• Engine malfunction indicator lamp (MIL)
• Diagnostics for engine starting failure
• List of diagnostic trouble code (DTC)
• Diagnostic procedure with diagnostic trouble code (DTC)
• General diagnostic table

Control systems

• General description
• Select lever
• Select cable
• MT gear shift lever
• MT drive select lever
• Drive select cable
• General diagnostic

Automatic transmission

• General description
• Automatic transmission fluid
• Differential gear oil
• Road test
• Stall test
• Time lag test
• Line pressure test
• Transfer clutch pressure test
• Automatic transmission assembly
• Transmission mounting system
• Extension case oil seal
• Inhibitor switch
• Front vehicle speed sensor
• Rear vehicle speed sensor
• Torque converter turbine speed sensor
• Control valve body
• Shift solenoids, duty solenoids and atf temperature sensor
• Atf filter
• Transmission control module (TCM)
• ATF cooler pipe and hose
• Basic diagnostic procedure
• Check list for interview
• Electrical components location
• Transmission control module (TCM) I/O signal
• Subaru select monitor
• Read diagnostic trouble code (DTC)
• Inspection mode
• Clear memory mode
• Power indicator light display
• List of diagnostic trouble code (DTC)
• Diagnostic procedure for power indicator light
• Diagnostic procedure for select monitor communication
• Diagnostic procedure with diagnostic trouble code (DTC)
• Diagnostic procedure for no-diagnostic trouble code (DTC)
• Symptom related diagnostic

Manual transmission and differential

• General description
• Transmission gear oil
• Manual transmission assembly
• Transmission mounting system
• Oil seal
• Switches and harness
• Vehicle speed sensor
• Preparation for overhaul
• Transfer case and extension case assembly
• Transfer drive gear
• Transfer driven gear
• Center differential
• Reverse check sleeve
• Transmission case
• Main shaft assembly for single-range
• Main shaft assembly for dual-range
• nput shaft assembly
• Drive pinion shaft assembly
• Front differential assembly
• Speedometer gear
• Reverse idler gear
• Shifter fork and rod
• Counter gear
• General diagnostic

Clutch system

• General description
• Clutch disc and cover
• Flywheel
• Release bearing and lever
• Operating cylinder
• Master cylinder
• Clutch pipe and hose
• Clutch fluid
• Clutch fluid air bleeding
• Clutch pedal
• Clutch cable
• Clutch switch
• General diagnostic table

Front suspension

• General description
• Wheel alignment
• Front transverse link
• Front ball joint
• Front strut
• Front stabilizer
• Front crossmember
• Sub frame
• General diagnostic table

Rear suspension

• General description
• Wheel alignment
• Rear stabilizer
• Rear trailing link
• Rear strut
• Lateral link
• Rear crossmember
• General diagnostic table

Wheel and tire system

• General description
• Tire
• Steel wheel
• Aluminum wheel
• Wheel balancing
• “T-type” tire
• Full wheel cap
• General diagnostics table

Differentials

• General description
• Differential gear oil
• Front differential
• Rear differential for T-type
• Rear differential for VA-type
• Rear differential front oil seal
• Rear differential side oil seal
• Rear differential member
• General diagnostic table

Transfer case

• General description
• Transfer case and extension for MT
• Transfer clutch and extension for AT
• Oil seal
• Transfer drive gear (MT)
• Transfer driven gear (MT)
• Reduction drive gear without VTD
• Reduction drive gear with VTD
• Reduction driven gear without VTD
• Reduction driven gear with VTD
• Center differential
• Transfer clutch pressure test
• Transfer duty solenoid and valve body

Drive shaft system

• General description
• Propeller shaft
• Front axle
• Rear axle
• Front drive shaft
• Rear drive shaft
• General diagnostic table

ABS

• General description
• ABS control module and hydraulic control unit (ABSCM and H/U)
• ABS sequence control
• Front ABS sensor
• Rear ABS sensor
• Front tone wheel
• Rear tone wheel
• G sensor
• Basic diagnostic procedure
• Check list for interview
• General description
• Electrical components location
• Control module I/O signal
• Subaru select monitor
• Read diagnostic trouble code (DTC)
• Inspection mode
• Clear memory mode
• ABS warning light illumination pattern
• List of diagnostics trouble code (DTC)
• Diagnostics chart with diagnosis connector
• Diagnostics chart with subaru select monitor
• General diagnostics table

Brake

• General description
• Front brake pad
• Front disc rotor
• Front disc brake assembly
• Rear brake pad
• Rear disc rotor
• Rear disc brake assembly
• Rear drum brake shoe
• Rear drum brake drum
• Rear drum brake assembly
• Master cylinder
• Brake booster
• Proportioning valve
• Brake fluid
• Air bleeding
• Brake hose
• Brake pipe
• Hill holder
• Brake pedal
• Stop light switch
• General diagnostics

Parking brake

• General description
• Parking brake lever
• Parking brake cable
• Parking brake assembly (rear disc brake)
• General diagnostic table

Power assisted system

• General description
• Steering wheel
• Universal joint
• Tilt steering column
• Steering gearbox
• Pipe assembly
• Oil pump
• Reservoir tank
• Power steering fluid
• General diagnostic table

HVAC system

• General description
• Refrigerant pressure with manifold gauge set
• Refrigerant recovery procedure
• Refrigerant charging procedure
• Refrigerant leak check
• Compressor oil
• Blower motor unit assembly
• Power transistor (auto A/C model)
• Blower resistor (manual A/C model)
• Heater core
• Control unit
• Compressor
• Condenser
• Heater and cooling unit
• Evaporator
• Hose and tube
• Relay and fuse
• Pressure switch (dual switch)
• Ambient sensor (auto A/C model)
• Sun-load sensor (auto A/C model)
• Air vent grille
• Heater duct
• Heater vent duct.
• General diagnostics

Airbag system

• General description
• Airbag connector
• Inspection locations after a collision
• Driver's airbag module
• Passenger's airbag module
• Side airbag module
• Airbag control module
• Side airbag sensor
• Roll connector
• Front sub sensor
• Disposal of airbag module (deploying while installed in vehicle)
• Disposal of airbag module (deploying after removal from vehicle)

Seat belt system

• General description
• Inspection locations after a collision
• Front seat belt
• Rear seat belt
• Disposal of pretensioner

Lighting system

• General description
• Headlight and tail light system
• Front fog light system
• Rear fog light system
• Turn signal and hazard light system
• Back-up light system
• Stop light system
• Interior light system
• Headlight beam leveler system
• Combination switch (light)
• Headlight assembly
• Headlight bulb
• Front turn signal light bulb
• Clearance/parking light bulb
• Front fog light assembly
• Front fog light bulb
• Rear combination light assembly
• Brake/tail light bulb
• Back-up light bulb
• Rear turn signal light bulb
• Rear fog light bulb
• License plate light
• High-mounted stop light
• Side turn signal light
• Spot light
• Room light
• Luggage room light
• Trunk room light
• Glove box light

Wiper and washer systems

• General description
• Wiper and washer system
• Combination switch (wiper)
• Wiper blade
• Washer tank and motor
• Front wiper arm
• Front wiper motor and link
• Front washer nozzle
• Rear wiper arm
• Rear wiper motor
• Rear washer
• Wiper control relay

Entertainment

• General description
• Radio system
• Cigarette lighter system
• Radio body
• Front speaker
• Tweeter
• Rear speaker
• Antenna
• Antenna amplifier
• Noise suppressor
• Cigarette lighter

Communication system

• General description
• Horn system
• Horn
• Horn switch

Body structure

• General description
• Datum points
• Datum dimensions

Instrumentation

• General description
• Combination meter system
• Combination meter assembly
• Speedometer
• Tachometer
• Fuel gauge
• Water temperature gauge
• Ambient sensor

Security and locks

• General description
• Door lock control system
• Keyless entry system
• Front inner remote
• Front outer handle
• Front door latch assembly
• Front door lock actuator
• Rear inner remote
• Rear outer handle
• Rear door latch assembly
• Rear door lock actuator
• Rear gate outer handle
• Rear gate latch assembly
• Rear gate latch lock actuator
• Trunk lid lock assembly
• Front hood lock assembly
• Remote openers
• Ignition key lock
• Key lock cylinders
• Immobilizer control module
• Immobilizer antenna
• Keyless entry control module
• Keyless transmitter

Immobilizer

• Basic diagnostic procedure
• General description
• Electrical components location
• Immobilizer control module I/O signal
• Subaru select monitor
• Read diagnostic trouble code (DTC)
• Clear memory mode
• Diagnostics chart for immobilizer indicator light
• List of diagnostic trouble code (DTC)
• Diagnostics chart with diagnostic trouble code

Exterior / interior trim

• General description
• Front grille
• Hood grille
• Front under cover
• Front bumper
• Rear bumper
• Mud guard
• Cowl panel
• Roof spoiler
• Rear spoiler
• Side sill spoiler
• Front door trim
• Rear door trim
• Glove box
• Roof rail
• Console box
• Instrument panel assembly
• Upper inner trim
• Lower inner trim
• Rear quarter trim
• Sun visor
• Roof trim
• Rear gate trim
• Rear shelf trim
• Trunk trim
• Floor mat
• Luggage floor mat
• Trunk room mat

Cruise control system

• General description
• Actuator
• Cruise control module
• Cruise control main switch
• Cruise control command switch
• Stop and brake switch
• Clutch switch
• Inhibitor switch

Wiring system

• Basic diagnostics procedure
• Working precautions
• Super multiple junction (SMJ)
• Power supply routing
• Ground distribution
• Airbag system
• Air conditioning system
• Anti-lock brake system
• A/T control system
• Audio system
• Charging system
• Combination meter
• Cruise control system
• Door lock system
• Engine coolant temperature gauge system
• Engine electrical system
• Fuel gauge system
• Full-time dual-range system
• Front accessory power supply system
• Headlight beam leveler system
• Horn system
• Immobilizer system
• Keyless entry system
• Back-up light system
• Clearance light and illumination light system
• Front fog light system
• Headlight system
• In compartment light system
• Stop light system
• Turn signal light and hazard light system
• Oil pressure warning light system
• Outside temperature display system
• Parking brake and brake fluid level warning system
• Power window system
• Radiator fan system
• Rear fog light system
• Rear window defogger system
• Remote controlled rearview mirror system
• Seat belt warning system
• Starter system
• Sunroof system
• Wiper and washer system (front)
• Wiper and washer system (rear)
• Overall systems
• Front wiring harness
• Bulkhead wiring harness (in engine room)
• Bulkhead wiring harness (in compartment)
• Engine wiring harness and transmission cord
• Instrument panel wiring harness
• Rear wiring harness, bulkhead wiring harness, roof cord and fuel tank cord
• Door cord
• Rear wiring harness and trunk lid cord
• Rear wiring harness and rear gate cord

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