2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

BODY SECTION

HVAC SYSTEM AC
(HEATER, VENTILATOR AND A/C)

HVAC SYSTEM (AUTO A/C) AC

(DIAGNOSTICS)

AIRBAG SYSTEM AB

AIRBAG SYSTEM (DIAGNOSTICS) AB

This service manual has been prepared
to provide SUBARU service personnel
SEAT BELT SYSTEM SB
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. LIGHTING SYSTEM LI
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of WIPER AND WASHER SYSTEMS WW
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual ENTERTAINMENT ET
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. COMMUNICATION SYSTEM COM
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts. GLASS/WINDOWS/MIRRORS GW

BODY STRUCTURE BS

INSTRUMENTATION/DRIVER INFO IDI

SEATS SE

SECURITY AND LOCKS SL

IMMOBILIZER (DIAGNOSTICS) IM

SUNROOF/T-TOP/CONVERTIBLE TOP SR
(SUNROOF)
All information, illustration and specifi-
cations contained in this manual are EXTERIOR/INTERIOR TRIM EI
based on the latest product information
available at the time of publication
approval.

FUJI HEAVY INDUSTRIES LTD. G1830GE6

2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

BODY SECTION

EXTERIOR BODY PANELS EB

CRUISE CONTROL SYSTEM CC

CRUISE CONTROL SYSTEM CC

(DIAGNOSTICS)

G1830GE6
EXTERIOR BODY PANELS

EB
Page
1. General Description ....................................................................................2
2. Front Hood ..................................................................................................9
3. Fender Panel.............................................................................................10
4. Front Door Panel.......................................................................................11
5. Front Sealing Cover ..................................................................................13
6. Rear Door Panel .......................................................................................14
7. Rear Sealing Cover...................................................................................16
8. Trunk Lid Panel .........................................................................................17
9. Rear Gate Panel .......................................................................................18
 GENERAL DESCRIPTION
EXTERIOR BODY PANELS

1. General Description
A: SPECIFICATIONS

Front hood

Front fender

Front fender
Front door

SECTION A SECTION B

Front door Rear door

SECTION C

Door panel

Rear door Side sill

Rear quarter

SECTION D SECTION E,F

BO0260

Section Part Specification

NA: 4.0 ± 1.0 (0.16 ± 0.04 in)
A Front hood to Front fender
TURBO: 3.7 ± 1.0 (0.15 ± 0.04 in)
B Front fender to Front door 4.7 ± 1.0 (0.19 ± 0.04 in)
C Front door to Rear door 5.1 (0.20 in)
D Rear door to Rear quarter 4.6 (0.18 in)
E, F Door panel to Side sill 5.9 (0.23 in)

EB-2
 GENERAL DESCRIPTION
EXTERIOR BODY PANELS

B: COMPONENT
1. FRONT HOOD

BO0248

(1) Front hood (5) Packing Tightening torque: N·m (kg-m, ft-lb)
(2) Seal (Front hood) (6) Clip T: 7.35 (0.75, 5.4)
(3) Hinge (7) Locking piece T1: 24.5 (2.5, 18.1)
(4) Hood grille

EB-3
 GENERAL DESCRIPTION
EXTERIOR BODY PANELS

2. FRONT DOOR PANEL

BO0249

(1) Gusset (7) Sealing cover Tightening torque: N·m (kg-m, ft-lb)
(2) Weatherstrip (Outer) (8) Checker T1: 7.35 (0.75, 5.4)
(3) Clip (Weatherstrip, outer) (9) Lower hinge T2: 18 (1.8, 13)
(4) Stabilizer (Lifter) (10) Upper hinge T3: 30 (3.1, 2.2)
(5) Stabilizer (Outer) (11) Door panel
(6) Stabilizer (Inner)

EB-4
 GENERAL DESCRIPTION
EXTERIOR BODY PANELS

3. REAR DOOR PANEL

BO0250

(1) Weatherstrip (Outer) (7) Sealing cover Tightening torque: N·m (kg-m, ft-lb)
(2) Clip (Weatherstrip, outer) (8) Checker T1: 7.35 (0.75, 5.4)
(3) Stabilizer (Outer) (9) Lower hinge T2: 18 (1.8, 13)
(4) Stabilizer (Inner) (10) Upper hinge T3: 30 (3.1, 2.2)
(5) Door panel
(6) Bracket

EB-5
 GENERAL DESCRIPTION
EXTERIOR BODY PANELS

4. TRUNK LID PANEL

BO0251

(1) Torsion bar (4) Hinge ASSY Tightening torque: N·m (kg-m, ft-lb)
(2) Trunk lid (5) Cover T1: 7.5 (0.76, 5.5)
(3) Weatherstrip T2: 14 (1.8, 13)

EB-6
 GENERAL DESCRIPTION
EXTERIOR BODY PANELS

5. REAR GATE PANEL

BO0252

(1) Gas stay Tightening torque: N·m (kg-m, ft-lb)

(2) Hinge T: 25 (2.5, 18.1)
(3) Rear gate

C: CAUTION
• Exterior body panels are heavy. Do not drop and
damage the panels. During removal and installa-
tion, 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
 GENERAL DESCRIPTION
EXTERIOR BODY PANELS

D: PREPARATION TOOL
1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

925610000 WRENCH Used for removing and installing door hing.

B5M1117
927780000 REMOVER Used for removing and installing trunk torsion
bar.

B5M1118

2. GENERAL TOOL

TOOL NAME REMARKS

Support Jack Used for supporting door panel.

EB-8
 FRONT HOOD
EXTERIOR BODY PANELS

2. Front Hood 3) Rotate hood buffer to adjust lateral height.

A: REMOVAL
1) Open front hood to remove washer nozzles.
2) Release clips to remove hood insulator.

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 be-
tween fender panel and hood or front fender must
be equal.

EB-10
 FRONT DOOR PANEL
EXTERIOR BODY PANELS

4. Front Door Panel 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 As-
sembly.>
5) Remove front door latch assembly. <Ref. to SL- G5M0385
30, REMOVAL, Front Door Latch Assembly.> 11) Using special tool, remove body-side bolts for
6) Remove front outer handle. <Ref. to SL-29, RE- upper and lower hinges, and remove door hinges.
MOVAL, Front Outer Handle.> ST 925610000 DOOR HINGE WRENCH
7) Remove front pillar lower trim to disconnect con-
nector from body harness.

B5M0933A

B5M0726
CAUTION:
8) Put wooden block on jack and place jack under • During removal and installation of doors, do
door. Support door with a support jack to protect it not damage body.
from damage. • 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 up-
per 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 hing-
es 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 plas-
tic 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
EXTERIOR BODY PANELS

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.

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 becom-
ing 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 9) Remove checker bolts.

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.> S5M0183
3) Remove rear door regulator and motor assem- 10) Remove door-side bolts for upper and lower
bly. <Ref. to GW-34, REMOVAL, Rear Regulator hinges to remove door.
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.

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
EXTERIOR BODY PANELS

C: ADJUSTMENT
1) Using special tool, loosen body-side bolts of up-
per and lower hinges to align the position of rear
door panel longitudinally and vertically.

B5M0933A
2) Loosen door-side bolts of upper and lower hing-
es to align the position of rear door panel vertically
and laterally at front-end.

G5M0385
3) Loosen screw (A) and tap striker (B) using plas-
tic 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 becom-
ing 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
 TRUNK LID PANEL
EXTERIOR BODY PANELS

8. Trunk Lid Panel B: INSTALLATION

A: REMOVAL 1. TRUNK LID
1) Install in the reverse order of removal.
1. TRUNK LID
2) Install trunk lid with uniform clearance.
1) Open trunk lid.
2) Disconnect trunk lid connector. 2. TORSION BAR
3) Loosen trunk lid mounting bolts to remove trunk 1) Install in the reverse order of removal.
lid from hinges. 2) Apply grease to rotating area of hinges and mat-
ing 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 han-
dle 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 CAUTION:

When the rear gate is released, it may hit and
A: REMOVAL damage the body. To prevent this, place a shop
cloth between body and gate.
1. REAR GATE PANEL
10) Loosen rear gate bolts to remove rear gate.
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.>
BO0278
6) Disconnect connectors of rear wiper, rear defog-
ger, and other lighting devices. 2. GAS STAY
7) Disconnect washer hose.
8) Remove rubber duct (A) connection, and pull out 1) Open rear gate. Using a support jack to support
harness and washer hose from rear gate. the rear gate.

BO0262
B5M0733A
9) Using a support, support the rear gate while re- CAUTION:
moving gas stay mounting bolts. • 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
EXTERIOR BODY PANELS

2) Loosen bolts to remove gas stay from rear gate. 1) Cover with a vinyl case as shown in the figure.

Gas stay

Vinyl sack

BO0264

CAUTION:
Prevent the vinyl case from being caught by
drill cutting edge
2) Lift body side slightly with piston rods fully ex-
tended, 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

BO0156

B: INSTALLATION 190mm
(7.48 in)
10mm
(0.39 in)
1. REAR GATE PANEL
1) Install in the reverse order of removal.
2) Install rear gate panel with uniform clearance to Portion to be drilled
body. Piston rod Cylinder
BO0263
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 op-
eration.
C: DISPOSAL
1. GAS STAY
CAUTION:
Gas is colorless, odorless, and harmless. How-
ever, gas pressure may spray cutting powder or
oil. Be sure to wear dust-resistant goggles.

EB-19
 REAR GATE PANEL
EXTERIOR BODY PANELS

EB-20