Subaru Impreza 2002 Repair Service Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Year: 2002 👋 Introduction Market Position Segment: Compact/Small Family Car Target Audience: Individuals seeking an affordable, reliable, and capable AWD vehicle, often appealing to enthusiasts due to its rally heritage. Competitive Analysis Key Competitors: Honda Civic, Toyota Corolla, Mazda3, Ford Focus, Mitsubishi Lancer. Key Features Standard AWD: Subaru's signature Symmetrical All-Wheel Drive system, offering superior traction and handling in various conditions. Engine Options: Horizontally opposed ('boxer') engines known for their low center of gravity and smooth operation. Body Styles: Available as a 4-door Sedan and a 5-door Wagon (often referred to as the 'Outback Sport' in higher trims). Rally Heritage: Strong ties to World Rally Championship (WRC) success, influencing performance and enthusiast appeal. 📋 Manual Details Coverage Areas Manual Type: Repair Service Manual Language: English Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed information on all engine components, including disassembly, assembly, and specifications for EJ20 and EJ25 series engines (e.g., EJ201, EJ202, EJ251, EJ253). Engine Electrical: Wiring diagrams, ignition system, fuel injection system (MPI), starting and charging systems, sensors and actuators, ECU diagnosis and component locations. Transmission: Coverage for both manual (5-speed) and automatic (4-speed) transmissions, including removal, installation, overhaul, clutch system, torque converter, and shift control. Drivetrain: Front and rear differentials, driveshafts, axles, constant velocity (CV) joints, and Subaru's Symmetrical All-Wheel Drive (AWD) system operation and maintenance. Suspension And Steering: Front and rear suspension systems (MacPherson struts, multi-link), shock absorbers, springs, control arms, bushings, power steering system, steering rack, and alignment specifications. Brakes: Front and rear brake systems (disc brakes), ABS system, hydraulic circuits, brake calipers, rotors, pads, master cylinder, brake fluid specifications, and bleeding procedures. Body And Chassis: Body panel removal and installation, door mechanisms, interior trim, glass, weatherstripping, chassis structure, and corrosion protection. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, compressor, evaporator, condenser, blower motor, and control systems. Electrical Accessories: Lighting systems (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, audio system, and fuse/relay box locations. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant checks and changes, brake fluid flush, differential fluid changes, transmission fluid changes. Engine Repair: Head gasket replacement, piston ring replacement, valve adjustments, timing belt/chain replacement, oil pump service, fuel injector testing and replacement. Transmission Service: Clutch replacement, transmission fluid and filter replacement (for automatic), manual transmission gear replacement, seal replacement. Brake Service: Brake pad and rotor replacement, caliper rebuilding, brake line replacement, ABS sensor diagnostics and replacement, brake system bleeding. Suspension Steering Repair: Replacement of struts, shocks, ball joints, tie rod ends, control arm bushings, power steering pump and rack replacement. Electrical Diagnostics: Troubleshooting electrical issues using wiring diagrams, testing sensors and actuators, diagnosing ECU faults, repairing wiring harness issues. Troubleshooting Guides: Systematic diagnostic procedures for common symptoms like starting problems, engine misfires, poor performance, braking issues, and electrical malfunctions. Technical Depth Diagnostic Procedures: Comprehensive diagnostic flowcharts and procedures for identifying and resolving issues across all major vehicle systems. Torque Specifications: Detailed torque specifications for all critical fasteners and components during assembly and disassembly. Clearances And Tolerances: Precise specifications for engine clearances, bearing tolerances, and other critical measurements required for proper engine function and longevity. Wiring Diagrams: High-quality, detailed wiring diagrams for all electrical systems, color-coded for ease of identification. Special Tools: Identification and usage instructions for any special tools or equipment required for specific repair or maintenance procedures. 📊 Manual Specifications File Format File Format: PDF Searchability: Fully searchable text for quick information retrieval. Printability: Printable pages for on-the-go use or large format viewing. Quality: High-resolution scans ensuring clarity of diagrams and text. Compatibility: Compatible with all PDF readers on Windows, Mac, Linux, tablets, and smartphones. ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ251 (2.5L SOHC NA) Displacement 1: 2457 cc Configuration 1: 2.5L Flat-4 (Boxer) Horsepower 1: 165 hp @ 5600 rpm Torque 1: 166 lb-ft @ 4000 rpm Fuel Induction 1: Multi-Point Fuel Injection (MPI) Engine Code 2: EJ201 (2.0L SOHC NA - Common in non-North American markets or base trims) Displacement 2: 1994 cc Configuration 2: 2.0L Flat-4 (Boxer) Horsepower 2: 142 hp @ 6000 rpm Torque 2: 137 lb-ft @ 4400 rpm Fuel System Fuel Type: Unleaded Gasoline Fuel Pressure: 37-44 psi (255-303 kPa) for EJ251 MPI Ignition System: Distributorless ignition system (DOHC engines may have coil-on-plug) 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Optional Transmission Type Optional: 4-Speed Automatic (with electronic control) Features AWD System: Subaru's Symmetrical All-Wheel Drive system is standard on all models, integrated with both transmission types. Manual transmission utilizes a viscous coupling center differential, while automatic uses an electronically controlled transfer clutch. Clutch Type: Dry single-plate clutch (for manual transmission) Fluid Specifications Manual Transmission Fluid: API GL-5, SAE 75W-90 synthetic gear oil (e.g., Subaru Genuine Gear Oil...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Impreza

Year:

👋 Introduction

Market Position

Segment:

Compact/Small Family Car

Target Audience:

Individuals seeking an affordable, reliable, and capable AWD vehicle, often appealing to enthusiasts due to its rally heritage.

Competitive Analysis

Key Competitors:

Honda Civic, Toyota Corolla, Mazda3, Ford Focus, Mitsubishi Lancer.

Key Features

Standard AWD:

Subaru's signature Symmetrical All-Wheel Drive system, offering superior traction and handling in various conditions.

Engine Options:

Horizontally opposed ('boxer') engines known for their low center of gravity and smooth operation.

Body Styles:

Available as a 4-door Sedan and a 5-door Wagon (often referred to as the 'Outback Sport' in higher trims).

Rally Heritage:

Strong ties to World Rally Championship (WRC) success, influencing performance and enthusiast appeal.

📋 Manual Details

Coverage Areas

Manual Type:

Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed information on all engine components, including disassembly, assembly, and specifications for EJ20 and EJ25 series engines (e.g., EJ201, EJ202, EJ251, EJ253).

Engine Electrical:

Wiring diagrams, ignition system, fuel injection system (MPI), starting and charging systems, sensors and actuators, ECU diagnosis and component locations.

Transmission:

Coverage for both manual (5-speed) and automatic (4-speed) transmissions, including removal, installation, overhaul, clutch system, torque converter, and shift control.

Drivetrain:

Front and rear differentials, driveshafts, axles, constant velocity (CV) joints, and Subaru's Symmetrical All-Wheel Drive (AWD) system operation and maintenance.

Suspension And Steering:

Front and rear suspension systems (MacPherson struts, multi-link), shock absorbers, springs, control arms, bushings, power steering system, steering rack, and alignment specifications.

Brakes:

Front and rear brake systems (disc brakes), ABS system, hydraulic circuits, brake calipers, rotors, pads, master cylinder, brake fluid specifications, and bleeding procedures.

Body And Chassis:

Body panel removal and installation, door mechanisms, interior trim, glass, weatherstripping, chassis structure, and corrosion protection.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, refrigerant handling, compressor, evaporator, condenser, blower motor, and control systems.

Electrical Accessories:

Lighting systems (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, audio system, and fuse/relay box locations.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant checks and changes, brake fluid flush, differential fluid changes, transmission fluid changes.

Engine Repair:

Head gasket replacement, piston ring replacement, valve adjustments, timing belt/chain replacement, oil pump service, fuel injector testing and replacement.

Transmission Service:

Clutch replacement, transmission fluid and filter replacement (for automatic), manual transmission gear replacement, seal replacement.

Brake Service:

Brake pad and rotor replacement, caliper rebuilding, brake line replacement, ABS sensor diagnostics and replacement, brake system bleeding.

Suspension Steering Repair:

Replacement of struts, shocks, ball joints, tie rod ends, control arm bushings, power steering pump and rack replacement.

Electrical Diagnostics:

Troubleshooting electrical issues using wiring diagrams, testing sensors and actuators, diagnosing ECU faults, repairing wiring harness issues.

Troubleshooting Guides:

Systematic diagnostic procedures for common symptoms like starting problems, engine misfires, poor performance, braking issues, and electrical malfunctions.

Technical Depth

Diagnostic Procedures:

Comprehensive diagnostic flowcharts and procedures for identifying and resolving issues across all major vehicle systems.

Torque Specifications:

Detailed torque specifications for all critical fasteners and components during assembly and disassembly.

Clearances And Tolerances:

Precise specifications for engine clearances, bearing tolerances, and other critical measurements required for proper engine function and longevity.

Wiring Diagrams:

High-quality, detailed wiring diagrams for all electrical systems, color-coded for ease of identification.

Special Tools:

Identification and usage instructions for any special tools or equipment required for specific repair or maintenance procedures.

📊 Manual Specifications

File Format

File Format:

Searchability:

Fully searchable text for quick information retrieval.

Printability:

Printable pages for on-the-go use or large format viewing.

Quality:

High-resolution scans ensuring clarity of diagrams and text.

Compatibility:

Compatible with all PDF readers on Windows, Mac, Linux, tablets, and smartphones.

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ251 (2.5L SOHC NA)

Displacement 1:

2457 cc

Configuration 1:

2.5L Flat-4 (Boxer)

Horsepower 1:

165 hp @ 5600 rpm

Torque 1:

166 lb-ft @ 4000 rpm

Fuel Induction 1:

Multi-Point Fuel Injection (MPI)

Engine Code 2:

EJ201 (2.0L SOHC NA - Common in non-North American markets or base trims)

Displacement 2:

1994 cc

Configuration 2:

2.0L Flat-4 (Boxer)

Horsepower 2:

142 hp @ 6000 rpm

Torque 2:

137 lb-ft @ 4400 rpm

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Pressure:

37-44 psi (255-303 kPa) for EJ251 MPI

Ignition System:

Distributorless ignition system (DOHC engines may have coil-on-plug)

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual

Optional

Transmission Type Optional:

4-Speed Automatic (with electronic control)

Features

AWD System:

Subaru's Symmetrical All-Wheel Drive system is standard on all models, integrated with both transmission types. Manual transmission utilizes a viscous coupling center differential, while automatic uses an electronically controlled transfer clutch.

Clutch Type:

Dry single-plate clutch (for manual transmission)

Fluid Specifications

Manual Transmission Fluid:

API GL-5, SAE 75W-90 synthetic gear oil (e.g., Subaru Genuine Gear Oil or equivalent)

Automatic Transmission Fluid:

Dexron III or equivalent (e.g., Subaru ATF-HP or equivalent)

📐 Dimensions

Exterior

Length Sedan:

Approx. 175.8 inches (4465 mm)

Length Wagon:

Approx. 177.0 inches (4495 mm)

Width:

Approx. 67.9 inches (1725 mm)

Height Sedan:

Approx. 56.1 inches (1425 mm)

Height Wagon:

Approx. 54.5 inches (1385 mm)

Wheelbase:

Approx. 104.0 inches (2640 mm)

Ground Clearance:

Approx. 6.1 inches (155 mm)

Weights

Curb Weight Manual:

Approx. 2800-3000 lbs (1270-1360 kg), varies by trim and body style

Curb Weight Automatic:

Approx. 2900-3100 lbs (1315-1405 kg), varies by trim and body style

Gross Vehicle Weight Rating:

Typically around 4000 lbs (1815 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Good (2002 model year specific ratings may vary)

NHTSA Front Impact Passenger:

Good (2002 model year specific ratings may vary)

IIHS Front Offset:

Good (for models tested, check specific trim)

Active Features

Standard 4-wheel Anti-lock Braking System (ABS)

Traction Control:

Optional on some trims, or integrated with AWD system.

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional front side-impact airbags on higher trims

Seatbelts:

3-point front and rear seatbelts, driver's seatbelt pretensioner

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM stereo with CD player. Optional premium audio system with subwoofer available on higher trims.

Display:

Basic digital or analog display for climate control and radio functions. No integrated touchscreen infotainment system.

Driver Assistance

Cruise Control:

Standard cruise control on most trims.

Connectivity

Auxiliary Input:

Rarely equipped with standard auxiliary audio input; aftermarket solutions may be required.

Bluetooth:

Not available from the factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3.75 months (severe use), or 7,500 miles or 7.5 months (normal use), using synthetic oil.

Engine Air Filter:

Replace every 15,000 miles or 15 months.

Cabin Air Filter:

Replace every 15,000 miles or 15 months (if equipped).

Spark Plugs:

Replace every 60,000 miles (use iridium type plugs for longest life).

Coolant Flush:

Replace coolant every 30,000 miles or 30 months.

Timing Belt:

Replace every 105,000 miles or 105 months (crucial for interference engines like the EJ251).

Fluid Specifications

Engine Oil Capacity:

4.5 US quarts (4.3 liters) with filter for EJ251/EJ201.

Engine Oil Type:

SAE 5W-30 synthetic recommended. Check manual for specific viscosity requirements based on ambient temperature.

Coolant Type:

Subaru Super Coolant (Blue) or equivalent P-HOAT coolant.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Head Gasket Leaks:

The EJ251 SOHC engine (and some DOHC variants) is known for potential head gasket failures, often due to coolant leaks or internal porosity. This is a common repair addressed in the manual.

Rear Main Seal Leaks:

Leaking rear main crankshaft seal can occur over time.

Wheel Bearing Wear:

Front wheel bearings can wear prematurely, leading to noise.

Catalytic Converter Issues:

Catalytic converters can fail due to engine issues or age.

📚 Vehicle History

Brand Heritage

Subaru Heritage:

Subaru (Fuji Heavy Industries) has a long history of producing reliable and capable vehicles, often with a focus on all-wheel-drive technology and distinctive boxer engines.

Model Evolution

Impreza Generations:

The 2002 model year marks the beginning of the second generation (GD/GG) Impreza, succeeding the original (GC/GF) platform. This generation introduced revised styling, improved safety, and updated chassis components.

Trim Levels 2002:

Common trims included 2.5 RS, Outback Sport, and base models. Performance-oriented WRX variant was introduced later in the model year or for 2003 in North America.

Production

Production Location:

Japan (and potentially other Subaru assembly plants globally)

Production Years:

2002-2007 for the second generation (GD/GG)

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

While not a 'Top Safety Pick' designation in the modern sense, the 2002 Impreza received good crash test ratings from the IIHS for its time.

Consumer Reports Reliability:

Reliability ratings varied by model year and specific components. The manual is essential for addressing common issues and maintaining good reliability.