2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

CHASSIS SECTION

FRONT SUSPENSION FS

REAR SUSPENSION RS

WHEEL AND TIRE SYSTEM WT

DIFFERENTIALS DI
This service manual has been prepared
to provide SUBARU service personnel
TRANSFER CASE TC
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. DRIVE SHAFT SYSTEM DS
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of ABS ABS
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual ABS (DIAGNOSTICS) ABS
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. BRAKE BR
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts. PARKING BRAKE PB

POWER ASSISTED SYSTEM PS

(POWER STEERING)

All information, illustration and specifi-

cations contained in this manual are
based on the latest product information
available at the time of publication
approval.

FUJI HEAVY INDUSTRIES LTD. G1830GE5

REAR SUSPENSION

RS
Page
1. General Description ....................................................................................2
2. Wheel Alignment .......................................................................................10
3. Rear Stabilizer...........................................................................................11
4. Rear Trailing Link ......................................................................................12
5. Rear Strut..................................................................................................16
6. Lateral link.................................................................................................18
7. Rear Crossmember...................................................................................22
8. General Diagnostic Table..........................................................................24
 GENERAL DESCRIPTION
REAR SUSPENSION

1. General Description
A: SPECIFICATIONS
Sedan Wagon
Item OUTBACK
Turbo Non-turbo Turbo Non-turbo
Camber (tolerance: ±0°45′) −1°30′ −1°25′ −1°20′ −1°15′ −1°10′
-1±2 mm (-0.039±0.079 in)
Toe-in
Each toe-in angle: ±0°07′30”
Wheel arch height 376 mm 381 mm 376 mm 381 mm 386 mm
[tolerance: ±12 mm (±0.47 in)] (14.80 in) (15.0 in) (14.80 in) (15.0 in) (15.20 in)
Thrust angle 0°±20′
20 mm 17 mm
Diameter of stabilizer — —
(0.79 in) (0.67 in)
NOTE:
• Front and rear toe-ins and front camber can be
adjusted. If toe-in or camber tolerance exceeds
specifications, adjust toe-in and camber to the mid-
dle value of specification.
• The other items indicated in the specification ta-
ble cannot be adjusted. If the other items exceeds
specifications, check suspension parts and con-
nections for deformities; replace with new ones as
required.

B4M2250C

(1) Front
A − B = Positive: Toe-in, Negative: Toe-out
α1, α2: Each toe-in angle

RS-2
GENERAL DESCRIPTION
REAR SUSPENSION

RS-3
 GENERAL DESCRIPTION
REAR SUSPENSION

B: COMPONENT
1. REAR SUSPENSION
• AWD model

SU0013

RS-4
 GENERAL DESCRIPTION
REAR SUSPENSION

(1) Stabilizer (Turbo model) (16) Trailing link bracket Tightening torque: N·m (kgf-m, ft-lb)
(2) Stabilizer bracket (Turbo model) (17) Cap (Protection) T1: 20 (2.0, 14.5)
(3) Stabilizer bushing (Turbo model) (18) Washer T2: 25 (2.5, 18.1)
(4) Clamp (Turbo model) (19) Rear crossmember T3: 45 (4.6, 33.2)
(5) Floating bushing (20) Strut mount cap T4: 55 (5.6, 41)
(6) Stopper (21) Strut mount T5: 70 (7.1, 52)
(7) Stabilizer link (Turbo model) (22) Rubber seat upper T6: 90 (9.2, 66)
(8) Rear lateral link (Turbo model) (23) Dust cover T7: 100 (10.2, 74)
(9) Bushing (C) (24) Coil spring T8: 115 (11.7, 85)
(10) Bushing (A) (25) Helper T9: 130 (13.3, 96)
(11) Front lateral link (26) Rubber seat lower T10: 135 (13.8, 100)
(12) Bushing (B) (27) Damper strut T11: 220 (22.4, 162)
(13) Trailing link rear bushing (28) Self-locking nut
(14) Trailing link (29) Rear differential member rear
(15) Trailing link front bushing (30) Rear lateral link (Non-turbo
model)

RS-5
 GENERAL DESCRIPTION
REAR SUSPENSION

• FWD model

SU0020

(1) Adjusting bolt (12) Trailing link front bushing Tightening torque: N·m (kgf-m, ft-lb)
(2) Adjusting wheel (13) Trailing link bracket T1: 20 (2.0, 14.5)
(3) Rear lateral link (14) Crossmember T2: 55 (5.6, 41)
(4) Bushing (D) (15) Cap T3: 90 (9.2, 66)
(5) Bushing (A) (16) Strut mount T4: 100 (10.2, 74)
(6) Front lateral link (17) Dust cover T5: 115 (11.7, 85)
(7) Self-locking nut (18) Coil spring T6: 130 (13.3, 96)
(8) Washer (19) Helper T7: 135 (13.8, 100)
(9) Cap (20) Rubber seat lower T8: 220 (22.4, 162)
(10) Trailing link rear bushing (21) Damper strut
(11) Trailing link

RS-6
 GENERAL DESCRIPTION
REAR SUSPENSION

C: CAUTION
• Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
• Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
• Keep the disassembled parts in order and pro-
tect them from dust or dirt.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
• Use SUBARU genuine grease etc. or the equiv-
alent. Do not mix grease etc. with that of another
grade or from other manufacturers.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or safety stands at the specified
points.
• Apply grease onto sliding or revolution surfaces
before installation.
• Before installing O-rings or snap rings, apply suf-
ficient amount of grease to avoid damage and de-
formation.
• Before securing a part on a vice, place cushion-
ing material such as wood blocks, aluminum plate,
or shop cloth between the part and the vice.
• Before disposing shock absorbers, be sure to
bleed gas completely. Also, do not throw away in
fire.

RS-7
 GENERAL DESCRIPTION
REAR SUSPENSION

D: PREPARATION TOOL
1. SPECIAL TOOLS

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

927380002 ADAPTER Used as an adapter for camber & caster gauge
when measuring camber and caster.
(1) 28199AC000 PLATE
(2) 28199AC010 BOLT

B4M2378A
927720000 INSTALLER & Used for replacing front bushing.
REMOVER

SU0014
927730000 INSTALLER & Used for replacing rear bushing.
REMOVER

SU0015
28099PA100 REMOVER Used for removing DOJ.

SU0016

RS-8
 GENERAL DESCRIPTION
REAR SUSPENSION

ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS

927710000 INSTALLER & Used for replacing lateral link bushing.
REMOVER

SU0015
92770000 INSTALLER & Used for replacing lateral link bushing.
REMOVER

SU0015
927690000 HELPER SOCKET Used for replacing lateral link bushing.
WRENCH

SU0015

2. GENERAL PURPOSE TOOLS

TOOL NAME REMARKS

Alignment gauge Used for wheel alignment measurement.
Turning radius gauge Used for wheel alignment measurement.
Toe-in gauge Used for toe-in measurement.
Transmission jack Used for suspension assembly/disassembly.
Bearing puller Used for removing bushings.

RS-9
 WHEEL ALIGNMENT
REAR SUSPENSION

2. Wheel Alignment
A: INSPECTION
NOTE:
The front and rear wheel alignment must be mea-
sured and/or adjusted at once to obtain accuracy.
Measure and/or adjust the rear wheel alignment to-
gether with the front. Follow the procedure in "FS"
section "Wheel Alignment" for measurement and/or
adjustment of wheel alignment. <Ref. to FS-8, IN-
SPECTION, Wheel Alignment.>

RS-10
 REAR STABILIZER
REAR SUSPENSION

3. Rear Stabilizer 2) Always tighten rubber bushing location when

wheels are in full contact with the ground and vehi-
A: REMOVAL cle is curb weight.
1) Jack-up the rear part of the vehicle, support it Tightening torque:
with safety stands (rigid racks). Stabilizer link to rear lateral link
2) Remove bolts which secure stabilizer link to rear 45 N·m (4.6 kgf-m, 33.2 ft-lb)
lateral link. Stabilizer to stabilizer bracket
25 N·m (2.5 kgf-m, 18.1 ft-lb)
C: INSPECTION
1) Check bushing for cracks, fatigue or damage.
2) Check stabilizer links for deformities, cracks, or
damage, and bushing for protrusions from the hole
of stabilizer link.

SU0017
3) Remove bolt and nut which secure stabilizer to
stabilizer bracket.

SU0018

B: INSTALLATION
1) Install in the reverse order of removal.
NOTE:
• Install bushing while aligning it with paint mark on
stabilizer.
• Ensure that bushing and stabilizer have the
same identification colors when installing.

SU0012

(1) Mark stamped on stabilizer

(2) Bushing identification color

RS-11
 REAR TRAILING LINK
REAR SUSPENSION

4. Rear Trailing Link B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
CAUTION:
1) Loosen rear wheel nuts.
Always tighten rubber bushing location when
2) Jack-up vehicle, support it with safety stands wheels are in full contact with the ground and
(rigid racks) and remove rear wheels. vehicle is at curb weight condition.
3) Remove both rear parking brake clamp and ABS
sensor harness. (Models equipped with ABS) NOTE:
4) Remove bolt which secure trailing link to trailing Check wheel alignment and adjust if necessary.
link bracket.

S4M0103B

(1) Trailing link

5) Remove bolt which secure trailing link to rear

housing.

RS-12
 REAR TRAILING LINK
REAR SUSPENSION

C: DISASSEMBLY 2. REAR BUSHING

1. FRONT BUSHING 1) Remove housing. <Ref. to DS-24, REMOVAL,
Rear Axle.>
Using ST, press front bushing out of place. 2) Using ST, press rear bushing out of place.
ST 927720000 INSTALLER & REMOVER ST 927730000 INSTALLER & REMOVER
SET SET

S4M0358A S4M0359A

(1) Press (1) Press

(2) Trailing link (2) Housing

RS-13
 REAR TRAILING LINK
REAR SUSPENSION

D: ASSEMBLY 2. REAR BUSHING

1. FRONT BUSHING 1) Using ST, press bushing into trailing link.
ST 927730000 INSTALLER & REMOVER
Using ST, press bushing into trailing link. SET
ST 927720000 INSTALLER & REMOVER
SET NOTE:
If it is difficult to press bushing into trailing link, ap-
CAUTION: ply water-diluted TIRE LUBE to the inner surface of
When installing bushing, turn ST plunger up- ST as a lubricant.
side down and press it until plunger end sur-
face contacts trailing link end surface. SPECIFOED lubricant:
TIRE LUBE : water = 1 : 3

S4M0360A
B4M0224B
(1) Press
(2) Front bushing (1) Press
(3) Trailing link

CAUTION:
Install front bushing in the proper direction, as
shown in figure.

S4M0361A

(1) Front

RS-14
 REAR TRAILING LINK
REAR SUSPENSION

2) Press ST pluger until bushing flange protrudes 3) Turn trailing link upside down. Press ST plunger
beyond trailing link. in the direction opposite that outlines in the former
ST 927730000 INSTALLER & REMOVER procedure until bushing is correctly positioned in
SET trailing link.
ST 927730000 INSTALLER & REMOVER
SET

B4M0195B

(1) Plunger
B4M0196B
(2) Flange
(1) Press
(2) Plunger

4) Install housing. <Ref. to DS-27, INSTALLA-

TION, Rear Axle.>
E: INSPECTION
Check trailing links for bends, corrosion or damage.

RS-15
 REAR STRUT
REAR SUSPENSION

5. Rear Strut 9) Remove nuts securing strut mount to body.

A: REMOVAL
1) Depress brake pedal and secure it in that posi-
tion using a wooden block, etc. (FWD only)
2) Remove rear seat cushion and backrest. (Sedan
model)
3) Remove strut cap of quarter trim. (Wagon mod-
el)
4) Loosen rear wheel nuts.
5) Jack-up vehicle, support it with safety stands
(rigid racks) and remove rear wheels.
6) FWD models:
Remove brake hose clip.
Disconnect brake hose from brake pipe from strut,
and disconnect brake pipe from drum brake.

G4M0399
7) AWD models:
Remove brake hose clip and remove brake hose
from rear strut.

SU0019

(1) Brake hose clip

(2) Brake hose

8) Remove bolts which secure rear strut to hous-

ing.

H4M1070

RS-16
 REAR STRUT
REAR SUSPENSION

B: INSTALLATION E: INSPECTION
1) Tighten self-locking nut used to secure strut Refer to Front Strut as a guide for inspection proce-
mount to car body. dures.
CAUTION: <Ref. to FS-22, INSPECTION, Front Strut.>
Discard loosened self-locking nut, and replace F: DISPOSAL
with a new one. Refer to Front Strut as a guide for disposal proce-
Tightening torque: dures.<Ref. to FS-22, DISPOSAL, Front Strut.>
20 N·m (2.0 kgf-m, 14.5 ft-lb)
2) Tighten bolts which secure rear strut to housing.
Tightening torque:
220 N·m (22.4 kgf-m, 162 ft-lb)
CAUTION:
Discard loosened self-locking nut, and replace
with a new one.
3) AWD model
Install brake hose to lower side of strut, then insert
brake hose clip.
FWD model
Connect brake hose to brake pipe.
Tightening torque:
15 N·m (1.5 kgf-m, 10.8 ft-lb)
Insert brake hose clip between brake hose and low-
er side of strut.
CAUTION:
• Check that hose clip is positioned properly.
• Check brake hose for twisting, or excessive
tension.
• (Model equipped with ABS)
Do not subject ABS sensor harness to exces-
sive tension.
4) Be sure to bleed air from brake system.
5) Lower vehicle and tighten wheel nut.
Tightening torque:
90 N·m (9.2 kgf-m, 66 ft-lb)
6) (Sedan model)
Install rear seat backrest and rear seat cushion.
(Wagon model)
Install strut cap to rear quarter trim.
NOTE:
Check wheel alignment and adjust if necessary.
C: DISASSEMBLY
For disassembly of rear strut, refer to procedures
outlined under front strut as a guide. <Ref. to FS-
20, DISASSEMBLY, Front Strut.>
D: ASSEMBLY
Refer to Front Strut as a guide for assembly proce-
dures.
<Ref. to FS-21, ASSEMBLY, Front Strut.>

RS-17
 LATERAL LINK
REAR SUSPENSION

6. Lateral link 6) Remove DOJ from rear differential using ST.

(2.0 L MT model)
A: REMOVAL ST 28099PA100 DRIVE SHAFT REMOVER
1) Loosen wheel nuts. Lift-up vehicle and remove NOTE:
wheel. The side spline shaft circlip comes out together
2) Remove stabilizers. (Turbo model) with the shaft.
3) Remove ABS sensor harness from trailing link.
(Models eqipped with ABS)
4) Remove bolt securing trailing link to housing.

S4M0362A

(1) Bolt
B4M0573B (2) DOJ

(1) Rear housing CAUTION:

(2) Trailing link Be careful not to damage side bearing retainer.
Always use bolt shown in figure, as supporting
5) Remove bolts which secure lateral link assembly point for ST during removal.
to rear housing.
7) Remove DOJ from rear differential using tire le-
ver.
(Except for 2.0 L MT model)
NOTE:
The side spline shaft circlip comes out together
with the shaft.

S4M0363A

(1) Tire lever

CAUTION:
When removing the DOJ from the rear differen-
tial, fit tire lever to the bolt as shown in figure so
as not to damage the axle shaft holder.

RS-18
 LATERAL LINK
REAR SUSPENSION

S4M0364A

(1) Axle shaft holder

8) Scribe an alignment mark on rear lateral link ad-

justing bolt and crossmember.
9) Remove bolts securing front and rear lateral
links to crossmember, detach lateral links.
CAUTION:
To loosen adjusting bolt, always loosen nut
while holding the head of adjusting bolt.
B: INSTALLATION S4M0100B
Install in the reverse order of removal. Observe the
following instructions. (1) Bushing A
• Installation of DOJ to differential:<Ref. to DS-37, (2) FWD: Bushing A, AWD: Bushing B
INSTALLATION, Rear Drive Shaft.> (3) FWD: Bushing D, AWD: Bushing C
(4) Front
CAUTION:
(5) Outside of body
• Do not allow DOJ splines to damage side oil
seal.
• Always tighten rubber bushing location when
wheels are in full contact with the ground and
vehicle is curb weight.
• Tighten nut when installing adjusting bolt.
• Replace self-locking nut and DOJ circlip with
new ones.
NOTE:
Check wheel alignment and adjust if necessary.
C: DISASSEMBLY
Using ST, press bushing out of place.
NOTE:
• Using the following table as a guide, verify the
type of bushings.
• Select ST according to the type of bushings
used.
Bushing ST:INSTALLER & REMOVER SET
Bushing A 927700000
Bushing B 927690000
Bushing C 927700000 S4M0365A
Bushing D 927710000
(1) Press
(2) Lateral link

RS-19
 LATERAL LINK
REAR SUSPENSION

D: ASSEMBLY 2) Press ST plunger until bushing flange protrudes

1) Using ST, press bushing into place. beyond lateral link.
CAUTION: NOTE:
Select ST according to the type of bushings Using the same ST as that used during disassem-
used. bly.
NOTE:
• Using the same ST as that used during disas-
sembly.
• If it is difficult to press bushing into trailing link,
apply water-diluted TIRE LUBE to the inner surface
of ST as a lubricant.
Specified lubricant:
TIRE LUBE : water = 1 : 3

B4M0197B

(1) Press
(2) Plunger
(3) Lateral link
(4) Flange

S4M0366A

(1) Press
(2) Bushing
(3) Lateral link

RS-20
 LATERAL LINK
REAR SUSPENSION

3) Turn lateral link upside down. Press ST plunger

in the direction opposite that outlined in the former
procedure until bushing is correctly positioned in
trailing link.
NOTE:
Using the same ST as that used during dissassem-
bly.

B4M0198B

(1) Press
(2) Plunger
(3) Lateral link

E: INSPECTION
Visually check lateral links for damage or bends.

RS-21
 REAR CROSSMEMBER
REAR SUSPENSION

7. Rear Crossmember 2. FWD MODEL

1) Disconnect lateral links from housing.
A: REMOVAL 2) Remove rear exhaust pipe and muffler.
1. AWD MODEL 3) Remove heat-shield cover.
4) Remove four bolts securing crossmember to
CAUTION: body.
Do not subject ABS sensor harness to exces-
sive tension. (Models equipped with ABS)
1) Separate front exhaust pipe and rear exhaust
pipe.
2) Remove rear exhaust pipe and muffler.
3) Remove rear differential.
T-type
<Ref. to DI-25, REMOVAL, Rear Differential for T-
type.>
VA-type
G4M0542
<Ref. to DI-40, REMOVAL, Rear Differential for
VA-type.>
4) Place transmission jack under rear crossmem-
ber.

G4M0544
5) Remove bolts securing crossmember to vehicle
body, and remove crossmember.

G4M0545
6) Scribe an alignment mark on rear lateral link cam
bolt and crossmember.
7) Remove front and rear lateral links by loosening
nuts.

RS-22
 REAR CROSSMEMBER
REAR SUSPENSION

B: INSTALLATION
1. AWD MODEL
1) Install in the reverse order of removal.
2) For installation and tightning torque of rear differ-
ential;
T-type
<Ref. to DI-27, INSTALLATION, Rear Differential
for T-type.>
VA-type
<Ref. to DI-42, INSTALLATION, Rear Differential
for VA-type.>
3) Always tighten rubber bushing when wheels are
in full contact with the ground and vwhicle is curb
weight.
NOTE:
Check wheel alignment and adjust if necessary.
2. FWD MODEL
Install in the reverse order of removal.
CAUTION:
• Discard loosened self-locking nut and re-
place with a new one.
• Always tighten nut (not adjusting bolt), when
tightening adjusting bolt.
• Always tighten rubber bushing when wheels
are in full contact with the ground and vehicle is
curb weight.
NOTE:
Check wheel alignment and adjust if necessary.
C: INSPECTION
Check removed parts for wear, damage and
cracks, and correct or replace if defective.

RS-23
 GENERAL DIAGNOSTIC TABLE
REAR SUSPENSION

8. General Diagnostic Table

A: INSPECTION
1. IMPROPER VEHICLE POSTURE OR IMPROPER WHEEL ARCH HEIGHT
Possible causes Countermeasures
(1) Permanent distortion or breakage of coil spring Replace.
(2) Unsmooth operation of damper strut and/or shock absorber Replace.
(3) Installation of wrong strut and/or shock absorber Replace with proper parts.
(4) Installation of wrong coil spring Replace with proper parts.

2. POOR RIDE COMFORT

1) Large rebound shock
2) Rocking of vehicle continues too long after running over bump and/or hump.
3) Large shock in bumping

Possible causes Countermeasures

(1) Breakage of coil spring Replace.
(2) Overinflation pressure of tire Adjust.
(3) Improper wheel arch height Adjust or replace coil springs with new ones.
(4) Fault in operation of damper strut and/or shock absorber Replace.
(5) Damage or deformation of strut mount and/or shock absorber mount Replace.
(6) Unsuitability of maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
(7) Deformation or loss of bushing Replace.
(8) Deformation or damage of helper in strut assembly and/or shock Replace.
absorber
(9) Oil leakage of damper strut and/or shock absorber Replace.

3. NOISE
Possible causes Countermeasures
(1) Wear or damage of damper strut and/or shock absorber component Replace.
parts
(2) Loosening of suspension link installing bolt Retighten to the specified torque.
(3) Deformation or loss of bushing Replace.
(4) Unsuitability of maximum and/or minimum length of damper strut and/or Replace with proper parts.
shock absorber
(5) Breakage of coil spring Replace.
(6) Wear or damage of ball joint Replace.
(7) Deformation of stabilizer clamp Replace.

RS-24