2004-2005 Subaru Impreza WRX & WRX STI Service & Repair Manual

I 2002 IMPREZA SERVICE MANUAL 3 QUICK REFERENCE INDEX 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 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. c- . 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

FOREWORD FWa ~~~~ Page Foreword .... .... ... ........ .... ......... ... . ... .. ... ..... ... ........................... . .... ...... ...... ... . .2 1 .

FOREWORD FOREWORD ~ 1. Foreword A: FOREWORD These manuals are used when performing maintenance, repair or diagnosis of the Subaru IMPREZA. Applied model: GG***** and GD***** from 2001 MY. The additional manuals below are also available: AL (Pub. No. G0853ZE) AUTOMATIC TRANSMISSION SERVICE MANU- The manuals contain the latest information at the time of publication. Changes in the specifications, methods, etc. may be made without notice. FW-2

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I HOW TO USE THIS MANUALS HOW TO USE THIS MANUALS 1. How to Use This Manuals A: HOW TO USE THIS MANUALS 1. STRUCTURE Each section consists of SCT that are broken down into SC that are divided into sections for each component. 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 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 ... . . . .. . . .. . . . . . . . , . . . .. . . . .. . . .. . . ,. . .. . . . ,. . . .. . ... . .. . . . . ,. . . . . .. , . ... . .. . .. .. . . . . . .. .. . ... .. . . ... .2 Page a

IMPREZA SPECIFICATIONS Model 1. lmpreza A: DIMENSIONS Sedan Waaon OUTBACK Overall width mm (in) Overall height (at CW) mm (in) Compartment Length mm (in) Width mm (in) Overall lennth mm (in) I 4,405 (173.4) 1,730 (68.1) 1,695 (66.7) 1,710 (67.3) 1,465 (57.7), 1,475 (58.1), 1,485 (58.5)*2 1,495 (58.9)*2 1,440 (56.7) 1,890 (74.4) 1,845 (72.6) 1,380 (54.3) Tread I Front mm (in) I 1.485 (58.5) I Height 1.465 (57.7) 1.460 (57.5) 1,200 (47.2), 1,200 (47.2), I 1,150 (45.3)*3 I 1,150 (45.3)*3 I 1 ,I 80 (46.5) mm (in) \ I Rear mm (in) , \ , . \ , I \ , 1,455 (57.3) 1,455 (57.3) 1,475 (58.1 ), 1,480 (58.3)*1 Minimum road clearance mm (in) 160 (6.3) 150 (5.9), 150 (5.9), 155 (6.1)*1 155 (6.1)*1 B: ENGINE Model Turbo 2.0 L 2.5 L I valve arranqement I Overhead camshaft tvDe 1 Bore x Stroke mm (in) Displacement cm3 (cu in) ComDression ratio 92 x 75 (3.62 x 2.95) 99.5 x 79.0 (3.91 7 x 3.1 IO) 1,994 (121.67) 2,457 (1 49.9) 8.0 10.0 I Firinq order I 1-3-2-4 -1 Maximum output kW (HP)/rpm 169 (227)/6,000 Maximum torque N.m (kgf-m, ft-lb)/rpm 294 (30.0, 217)/4,000 Idle speed at Park/Neutral I position (NC OFF) 123 (165)/5,600 226 (23.0, 166)/4,000 rpm I 750 650 (MT) 700 (AT) SPC-2

IMPREZA SPECIFICATIONS Model Turbo 2.0 L I 2.5 L C: ELECTRICAL Spark plug Generator Battery Type Reserve capacity min Cold cranking amp amperes CHAMPION: RCIOYC4(Standard) NGK: PFR6G NGK: BKR5E-11 NGK: BKR6E-11 12V - 90A MT: 12V - 48AH (55D23L) AT: 12V - 52AH (75D23L) 12V - 75A MT: 12V - 48AH (55D23L) AT: 12V - 52AH (65D23L) MT: 99 MT: 99 AT: 111 AT: 118 MT: 356 MT: 356 AT: 420 AT: 520 I I MT: 1 O"k10°/650 AT: 1 O"k10"/700 12"+10"/750 Ignition timing at idling speed BTDC/rpm -' Transmission type 5MTSrl 4ATlr2 Clutch type DSPD TCC Gear ratio I 1st 3.454 2.785 rMm ~ I Turbo 2.0 L I - 5th 0.738 Reverse 3.333 2.272 ' Reductiongear 1 st reduction Type of gear - Helical Final reduction Type of gear Hypoid Hypoid , (Front drive) Gear ratio - 1.000 I I I Gear ratio I 3.900 I 4.1 11 I Reductiongear (Rear drive) I L I I 4 Transfer reduction Type of gear Helical - - Gear ratio 1.100 Gear ratio 3.545 4.111 Final reduction Type of gear Hypoid Hypoid I 1 3rd I 1.366 I 1 .ooo I I L I I 14th I 0.972 I 0.694 I SPC-3

IM PREZA SPECIFICATIONS Model Transmission type Clutch type I 2.5 L 5MT*1 4ATlr2 5MTlrl 4AT*2 DSPD TCC DSPD TCC RS Others 2nd Reductiongear (Rear drive) r 2.062 1.619 2.062 1.545 I 1st 3rd I 3.454 I 3.027 I 3.454 I 2.785 I 1.448 1 .ooo 1.448 1 .ooo 4th 5th ~~~ 1.088 0.694 1.088 1.694 0.780 - 0.780 - I Reverse I 3.333 I 2.272 I 3.333 I 2.272 1 1 st reduction Reductiongear (Front drive) r Dual range - - - - Type of gear - Helical - Helical 1 .ooo - 1 .ooo Gear ratio - Final reduction Transfer reduction ... Type of gear Hypoid Hypoid Hypoid Hypoid Gear ratio 4.1 11 4.444 3.900 4.1 11 Type of gear He I ical - He I ical - Final reduction I 5MTM : 5 forward speeds with synchromesh and I -reverse 4AT+2: Electronically controlled fully-automatic, 4-forward speeds and 1 -reverse DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch E: STEERING Gear ratio 1 .ooo - 1.000 - Type of gear Hypoid Hypoid Hypoid Hypoid Gear ratio 4.1 11 4.444 3.900 4.1 11 Type Turns, lock to lock Minimum turning circle m (ft) Curb to curb Wall to wall I Rack and Pinion 3.2 3 10.2 (33.5) 10.8 (35.4) 11 .I (36.3) 11.7 (38.3) Front Rear Macpherson strut type, Independent, Coil spring Dual-link strut type, Independent, Coil spring Model Service brake system Front H: TIRE SEDAN WAGON Dual circuit hydraulic with vacuum suspended power unit Ventilated disc brake Rear Parking brake Disc brake Drum brake, Disc brakelrl Mechanical on rear brakes SPC-4 Rim size Tire size Type 15 x 6JJ 16 x 6’/2JJ P I95/60R15 87H P205/55R16 89V Steel belted radial, Tubeless

2004-2005 Subaru Impreza WRX & WRX STI Service & Repair Manual

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