Subaru Impreza Service Repair Manual 2002-2006

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Generation: 2nd Generation (GD/GG) Codes Chassis Codes: GD (Sedan), GG (Wagon) Production Years Covered: 2002, 2003, 2004, 2005, 2006 👋 Introduction Market Position Segment: Compact/Small Family Car, Rally-inspired Sedan/Hatchback Usp: Symmetrical All-Wheel Drive, turbocharged WRX and STI performance variants, practical and durable. Competitive Analysis Key Competitors: Mitsubishi Lancer Evolution, Honda Civic Si, Mazda3, Toyota Corolla. Key Features AWD System: Standard Symmetrical All-Wheel Drive on most models, providing excellent traction and handling. Performance Variants: Iconic WRX and WRX STI models with turbocharged engines and enhanced performance features. Body Styles: Available as a 4-door sedan and a 5-door wagon (classified as GG chassis). 📋 Manual Details Coverage Areas Diagnostic Procedures: Comprehensive diagnostic procedures for all systems. Repair Procedures: Detailed step-by-step repair procedures for all components. Maintenance Schedules: Scheduled maintenance intervals and recommended services. Wiring Diagrams: Complete electrical wiring diagrams. Troubleshooting Guides: Extensive troubleshooting guides for common and complex issues. Technical Specifications: In-depth technical specifications for all vehicle systems. Special Tools: Listing and usage of specialized tools required for repairs. Page Count Estimated Pages: Over 2000 pages (typical for a complete factory manual). Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Digital (Printable PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshaft, timing belt/chain, lubrication system, cooling system. Engine Performance: Fuel injection system, ignition system, emissions control system, turbocharger system (if applicable). Transmission Manual: Clutch system, manual transmission assembly, disassembly, gears, bearings, seals. Transmission Automatic: Automatic transmission assembly, disassembly, torque converter, valve body, hydraulic control. Drivetrain: All-Wheel Drive (AWD) system, viscous coupling, center differential, rear differential, driveshafts, CV joints. Suspension: Front and rear suspension components, struts, shocks, control arms, sway bars, bushings. Steering: Power steering system, steering rack, tie rods, steering column. Brakes: Brake system components (master cylinder, calipers, pads, rotors), ABS system, parking brake. Electrical System: Battery, charging system (alternator), starting system, lighting, accessories, fuses, relays. Body And Frame: Body panel removal/installation, interior trim, exterior trim, glass, sunroof. HVAC: Heating, ventilation, and air conditioning system components, refrigerant, controls. Safety Systems: Airbag system, seat belt system. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs. Component Replacement: Replacement of worn or failed parts like alternators, starters, water pumps, fuel pumps, etc. Engine Rebuild: Complete engine disassembly and reassembly procedures. Transmission Overhaul: Detailed procedures for overhauling both manual and automatic transmissions. Brake Service: Brake pad and rotor replacement, brake fluid flush, caliper service. Suspension And Steering Repair: Replacement of struts, shocks, ball joints, bushings, and steering components. Electrical Diagnostics: Troubleshooting electrical faults using diagrams and test procedures. Drivetrain Service: Service and repair of AWD system components, CV joints, and differentials. HVAC Service: Refrigerant recharge, component replacement (compressor, condenser, evaporator). Body And Interior Repair: Panel replacement, interior trim fitting, glass replacement. Technical Depth Depth: Full factory level diagnostics, repair, and overhaul procedures. Diagnostic Troubleshooting: Includes diagnostic trouble codes (DTCs) and specific troubleshooting trees. Torque Specifications: Precise torque values for all fasteners. Clearances And Tolerances: Specifications for engine internal clearances, bearing tolerances, etc. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: High-resolution scans, allowing for clear printing of all pages or sections. Searchability: Text-searchable PDF for quick information retrieval. Binding Type Binding Method: N/A (Digital Product) Paper Type Paper Quality: N/A (Digital Product) ⚙️ Engine Specifications Primary Engine Engine Code Base: EJ20 (various configurations), EJ25 Displacement Base: 2.0L (1994cc) and 2.5L (2457cc) Configuration: Horizontally-opposed (Boxer) 4-cylinder Aspirated Power Specs: e.g., 2.5i: 165 hp @ 5600 rpm, 166 lb-ft @ 4000 rpm Turbocharged Power Specs: e.g., WRX: 227-230 hp @ 5600 rpm, 236-240 lb-ft @ 3600 rpm; WRX STI: 300 hp @ 6000 rpm, 300 lb-ft @ 4000 rpm Performance Compression Ratio Base: Typically 8.5:1 to 10.0:1 depending on engine variant. Redline Base: Approximately 6500-7000 rpm for naturally aspirated, 7000-7500 rpm for turbocharged. Fuel System Fuel Delivery: Multi-point fuel injection (MPI) or Sequential Electronic Fuel Injection (SEFI). Fuel Type: Unleaded Gasoline (91 octane or higher recommended for WRX/STI). 🔧 Transmission Standard Transmission Type Base: 5-speed Manual Transmission (MT) Optional Transmission Type Optional: 4-speed Automatic Transmission (AT) with Sportshift on some models. Features AWD Coupling: Driver Controlled Center Differential (DCCD) on STI, Viscous Coupling AWD on other models. Manual Gear Ratios: Varies by model and engine. Specific ratios detailed in the manual. Automatic Gear Ratios: Fixed ratios for 4-speed automatic. Specific ratios detailed in the manual. 📐 Dimensions Exterior Length: Sedan: ~174.5 inches, Wagon: ~175.8 inches (varies slightly by year/trim). Width: ~68.1 inches Height: Sedan: ~56.1 inches, Wagon: ~57.0 inches (varies slightly). Wheelbase: ~104.0 inches Weights Curb Weight: Approx. 2900-3400 lbs, depending on configuration and drivetrain. Gross Vehicle Weight Rating: Varies by model, typically around 4200-4500 lbs. 🛡️ Safety Features Ratings NHTSA Front Crash: Good (for models...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Impreza

Generation:

2nd Generation (GD/GG)

Codes

Chassis Codes:

GD (Sedan), GG (Wagon)

Production Years Covered:

2002, 2003, 2004, 2005, 2006

👋 Introduction

Market Position

Segment:

Compact/Small Family Car, Rally-inspired Sedan/Hatchback

Symmetrical All-Wheel Drive, turbocharged WRX and STI performance variants, practical and durable.

Competitive Analysis

Key Competitors:

Mitsubishi Lancer Evolution, Honda Civic Si, Mazda3, Toyota Corolla.

Key Features

AWD System:

Standard Symmetrical All-Wheel Drive on most models, providing excellent traction and handling.

Performance Variants:

Iconic WRX and WRX STI models with turbocharged engines and enhanced performance features.

Body Styles:

Available as a 4-door sedan and a 5-door wagon (classified as GG chassis).

📋 Manual Details

Coverage Areas

Diagnostic Procedures:

Comprehensive diagnostic procedures for all systems.

Repair Procedures:

Detailed step-by-step repair procedures for all components.

Maintenance Schedules:

Scheduled maintenance intervals and recommended services.

Wiring Diagrams:

Complete electrical wiring diagrams.

Troubleshooting Guides:

Extensive troubleshooting guides for common and complex issues.

Technical Specifications:

In-depth technical specifications for all vehicle systems.

Special Tools:

Listing and usage of specialized tools required for repairs.

Page Count

Estimated Pages:

Over 2000 pages (typical for a complete factory manual).

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Digital (Printable PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshaft, timing belt/chain, lubrication system, cooling system.

Engine Performance:

Fuel injection system, ignition system, emissions control system, turbocharger system (if applicable).

Transmission Manual:

Clutch system, manual transmission assembly, disassembly, gears, bearings, seals.

Transmission Automatic:

Automatic transmission assembly, disassembly, torque converter, valve body, hydraulic control.

Drivetrain:

All-Wheel Drive (AWD) system, viscous coupling, center differential, rear differential, driveshafts, CV joints.

Suspension:

Front and rear suspension components, struts, shocks, control arms, sway bars, bushings.

Steering:

Power steering system, steering rack, tie rods, steering column.

Brakes:

Brake system components (master cylinder, calipers, pads, rotors), ABS system, parking brake.

Electrical System:

Battery, charging system (alternator), starting system, lighting, accessories, fuses, relays.

Body And Frame:

Body panel removal/installation, interior trim, exterior trim, glass, sunroof.

HVAC:

Heating, ventilation, and air conditioning system components, refrigerant, controls.

Safety Systems:

Airbag system, seat belt system.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs.

Component Replacement:

Replacement of worn or failed parts like alternators, starters, water pumps, fuel pumps, etc.

Engine Rebuild:

Complete engine disassembly and reassembly procedures.

Transmission Overhaul:

Detailed procedures for overhauling both manual and automatic transmissions.

Brake Service:

Brake pad and rotor replacement, brake fluid flush, caliper service.

Suspension And Steering Repair:

Replacement of struts, shocks, ball joints, bushings, and steering components.

Electrical Diagnostics:

Troubleshooting electrical faults using diagrams and test procedures.

Drivetrain Service:

Service and repair of AWD system components, CV joints, and differentials.

HVAC Service:

Refrigerant recharge, component replacement (compressor, condenser, evaporator).

Body And Interior Repair:

Panel replacement, interior trim fitting, glass replacement.

Technical Depth

Depth:

Full factory level diagnostics, repair, and overhaul procedures.

Diagnostic Troubleshooting:

Includes diagnostic trouble codes (DTCs) and specific troubleshooting trees.

Torque Specifications:

Precise torque values for all fasteners.

Clearances And Tolerances:

Specifications for engine internal clearances, bearing tolerances, etc.

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

High-resolution scans, allowing for clear printing of all pages or sections.

Searchability:

Text-searchable PDF for quick information retrieval.

Binding Type

Binding Method:

N/A (Digital Product)

Paper Type

Paper Quality:

N/A (Digital Product)

⚙️ Engine Specifications

Primary Engine

Engine Code Base:

EJ20 (various configurations), EJ25

Displacement Base:

2.0L (1994cc) and 2.5L (2457cc)

Configuration:

Horizontally-opposed (Boxer) 4-cylinder

Aspirated Power Specs:

e.g., 2.5i: 165 hp @ 5600 rpm, 166 lb-ft @ 4000 rpm

Turbocharged Power Specs:

e.g., WRX: 227-230 hp @ 5600 rpm, 236-240 lb-ft @ 3600 rpm; WRX STI: 300 hp @ 6000 rpm, 300 lb-ft @ 4000 rpm

Performance

Compression Ratio Base:

Typically 8.5:1 to 10.0:1 depending on engine variant.

Redline Base:

Approximately 6500-7000 rpm for naturally aspirated, 7000-7500 rpm for turbocharged.

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI) or Sequential Electronic Fuel Injection (SEFI).

Fuel Type:

Unleaded Gasoline (91 octane or higher recommended for WRX/STI).

🔧 Transmission

Standard

Transmission Type Base:

5-speed Manual Transmission (MT)

Optional

Transmission Type Optional:

4-speed Automatic Transmission (AT) with Sportshift on some models.

Features

AWD Coupling:

Driver Controlled Center Differential (DCCD) on STI, Viscous Coupling AWD on other models.

Manual Gear Ratios:

Varies by model and engine. Specific ratios detailed in the manual.

Automatic Gear Ratios:

Fixed ratios for 4-speed automatic. Specific ratios detailed in the manual.

📐 Dimensions

Exterior

Length:

Sedan: ~174.5 inches, Wagon: ~175.8 inches (varies slightly by year/trim).

Width:

~68.1 inches

Height:

Sedan: ~56.1 inches, Wagon: ~57.0 inches (varies slightly).

Wheelbase:

~104.0 inches

Weights

Curb Weight:

Approx. 2900-3400 lbs, depending on configuration and drivetrain.

Gross Vehicle Weight Rating:

Varies by model, typically around 4200-4500 lbs.

🛡️ Safety Features

Ratings

NHTSA Front Crash:

Good (for models tested).

IIHS Side Impact:

Good (for models tested).

Active Features

Standard Anti-lock Braking System (ABS).

Traction Control:

Traction Control System (TCS) often standard or available.

Electronic Stability:

Vehicle Dynamics Control (VDC) often standard on higher trims or available.

Passive Features

Airbags:

Front airbags, available side-impact airbags and curtain airbags.

Seatbelts:

Three-point seatbelts with pretensioners and force limiters.

💡 Technology Features

Infotainment

Head Unit:

Factory-installed CD player, optional premium audio systems, auxiliary input jacks on later models.

Display:

Basic digital display for clock, radio, and climate controls. Advanced displays were not common in this era.

Driver Assistance

Cruise Control:

Standard on most trims.

All Wheel Drive:

The core technological feature, enhancing stability and traction in various conditions.

Connectivity

Usb Ports:

Not typically factory equipped; aftermarket solutions are common.

Bluetooth:

Not factory equipped; aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 3,750 miles or 6 months, but check manual for specific oil type and conditions (synthetic oil can extend intervals).

Spark Plug Replacement:

Intervals vary by plug type (copper, platinum, iridium), often around 30,000-60,000 miles.

Timing Belt Replacement:

For EJ20/EJ25 engines with timing belts: 105,000 miles or 7 years is a common interval. Models with timing chains do not have this interval.

Coolant Flush:

Typically every 30,000 miles or 2 years.

Fluid Specifications

Engine Oil Type:

API SG, SH, SJ, or higher; SAE 5W-30 or 10W-30 recommended (refer to manual for exact specification).

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (check specific manual).

Transmission Fluid Automatic:

Subaru ATF-HP or equivalent.

Coolant Type:

Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Head Gaskets:

While less prevalent than on earlier Subaru models, head gasket leaks can still occur, especially on EJ25 engines. The manual will detail inspection and replacement procedures.

Turbocharger Issues:

On WRX/STI models, oil starvation or turbocharger failure can occur if maintenance is neglected or if the turbo is abused without proper cooldown. Manual covers turbo inspection and replacement.

Clutch Wear:

Clutch wear is typical for manual transmissions, especially with spirited driving. Manual provides clutch inspection and replacement details.

Suspension Wear:

Bushings, ball joints, and struts can wear over time, leading to noise or handling issues. Manual details diagnostics and replacement.

Oil Consumption:

Some EJ25 engines may exhibit higher oil consumption. Regular checks are advised. Manual covers oil level checks and related diagnostics.

📚 Vehicle History

Brand Heritage

Subaru Identity:

Known for Symmetrical All-Wheel Drive, horizontally opposed engines, and rallying heritage.

Model Evolution

Generation Introduction:

The 2nd generation Impreza (GD/GG) debuted in 2000 (Japan) and 2001 (North America) for the 2002 model year, significantly revising styling and platforms from the previous generation.

Facelifts:

Received a significant facelift for the 2004 model year, particularly for WRX/STI models, introducing the distinctive 'bug-eye' headlights (pre-2004) to 'hawk-eye' (2004-2005) and 'wide-body' (2006 STI) designs.

Production

Manufacturing Locations:

Primarily manufactured in Japan (Gunma Plant).

Rally Success:

This generation continued Subaru's success in the World Rally Championship (WRC) with the Impreza WRX STI.

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

Impreza WRX was frequently named to Car and Driver's 10Best list during this generation, particularly the WRX and WRX STI variants, for their performance and value.

Wrc Titles:

While the 2nd generation Impreza chassis achieved significant rally success, the specific years and drivers are tied to the WRC program's ongoing achievements during this period.