2001 2002 SUBARU IMPREZA STi Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STi Model Code: GDB (specifically for STi variants) Model Generation: Second Generation (GD/GG) Model Variant: WRX STi Covered Years: 2001, 2002 👋 Introduction Market Position Positioning: The 2001-2002 Subaru Impreza WRX STi (GDB) represents the pinnacle of Subaru's rally-bred performance in its second generation. Positioned as a halo performance car, it competed with other iconic performance sedans and coupes of its era, offering unparalleled all-wheel-drive dynamics and a turbocharged boxer engine. Competitive Analysis Competitors: Mitsubishi Lancer Evolution, Ford Focus RS, Honda Civic Type R (though often in different performance brackets). Key Features Features: Symmetrical All-Wheel Drive, potent EJ207 turbocharged engine, close-ratio 6-speed manual transmission, Driver's Control Center Differential (DCCD), aggressive aerodynamic enhancements, sport-tuned suspension. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual (FSM) / Repair Manual Language: English Format: Digital (likely PDF or similar, based on typical product offerings) Page Count Estimate: Approximately 1500-2500 pages (typical for comprehensive FSMs of this era) Vehicle Variants Covered: Specifically covers the WRX STi variant for the 2001 and 2002 model years, detailing unique components and specifications for this high-performance model. 📖 Manual Coverage Systems Covered Engine Mechanical: EJ207 engine; cylinder head, block assembly, pistons, crankshaft, camshafts, valve train, timing belt/chain, lubrication system, cooling system Engine Performance: Turbocharger (IHI VF35/VF36), intercooler, fuel injection, ignition system, emissions control, engine management system (ECU diagnostics and programming) Transmission: 6-speed manual transmission (TY856WB1AA, TY856WB2AA); clutch system, gearbox assembly, gear ratios, driveline components (driveshafts, differentials) Drivetrain: All-Wheel Drive system (Subaru's Symmetrical AWD), DCCD (Driver's Control Center Differential) operation and adjustment, viscous coupling center differential, limited-slip differentials (front and rear) Suspension: Front MacPherson struts, rear multi-link independent suspension; springs, shock absorbers, control arms, anti-roll bars, bushings Steering: Hydraulic power steering system, steering rack, column, tie rods, alignment specifications Brakes: Front and rear ventilated disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake calipers, master cylinder, brake lines, parking brake Electrical System: Battery, charging system (alternator), starter motor, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, grounds Body And Chassis: Body panels, doors, hood, trunk, bumpers, glass, interior trim, chassis components, corrosion protection HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system; blower motor, evaporator, condenser, refrigerant, climate controls Safety Systems: Airbags (SRS), seatbelts, ABS system diagnostics, vehicle security system Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspection, spark plug replacement Diagnostics: Troubleshooting guides for all major systems, diagnostic trouble codes (DTCs), OBD-II functionality, sensor testing Repair And Rebuild: Engine rebuild procedures, transmission overhaul, suspension component replacement, brake caliper rebuild, radiator replacement, starter/alternator replacement Adjustment: Valve lash adjustment, clutch pedal adjustment, handbrake adjustment, DCCD operation adjustment Wiring Diagrams: Detailed electrical schematics for all systems, including engine, chassis, lighting, and comfort features Bodywork Repair: Includes procedures for body panel alignment, door and latch adjustments, and basic structural component identification. Wheel Alignment: Detailed alignment specifications and procedures for front and rear suspension. Technical Depth Depth: Comprehensive; covers from basic maintenance to complete engine and transmission overhauls, including diagnostic procedures and specifications. Specialized Procedures: Detailed procedures for DCCD calibration, ECU diagnostics and remapping specifications (though not necessarily tuning itself), clutch type and replacement. 📊 Manual Specifications File Format Format: Digital (likely PDF, offering searchability and easy navigation) Print Quality Quality: High-resolution scans providing clear text and diagrams (expected for factory manuals). Binding Type Binding: N/A (Digital Format) Paper Type Type: N/A (Digital Format) Completeness Completeness: Full factory service manual coverage, essential for any owner or mechanic working on these vehicles. ⚙️ Engine Specifications Primary Engine Engine Code: EJ207 Engine Type: Horizontally-opposed (Boxer) 4-cylinder, turbocharged, intercooled Displacement: 1994 cc (2.0 Liters) Bore X Stroke: 92.0 mm x 75.0 mm Compression Ratio: 8.0:1 Valvetrain: DOHC (Dual Overhead Camshafts), 16 valves (4 per cylinder), belt-driven Performance Horsepower: Approximately 280 PS (276 bhp) at 6,000 rpm (JDM specification, often slightly lower for export markets or unverified). Torque: Approximately 337 Nm (248 lb-ft) at 4,000 rpm (JDM specification). Turbocharger: IHI VF35 (or VF36 for some variants); twin-scroll design, water-cooled Intercooler: Top-mounted, air-to-air Engine Management: ECU controlled, with specific tuning parameters documented for factory settings. Fuel System Fuel Delivery: Sequential multi-point fuel injection (MPI) Fuel Type: Premium Unleaded Gasoline (98 RON / 93 AKI recommended) Throttle Body: Drive-by-wire throttle control 🔧 Transmission Standard Transmission Type: 6-speed Manual Transmission Transmission Model: Subaru TY856WB series Optional Optional Transmissions: None (STi models were exclusively manual) Features Dccd: Driver's Control Center Differential (DCCD) allowing manual adjustment of front/rear torque split (Auto and Manual modes) Final Drive Ratio: Typically 3.538:1 (46/13), varies slightly by specific model/market. 📐 Dimensions Exterior Length: Approximately 4,405 mm (173.4 in) Width: Approximately 1,770 mm (69.7 in) Height: Approximately 1,400 mm (55.1 in) Wheelbase: Approximately 2,510 mm (98.8 in) Ground Clearance: Approximately 135 mm (5.3 in) Wheel Bolt Pattern: 5x100 mm...

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Tags: 2001 2002 Car Cars IMPREZA STi Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Impreza WRX STi

Model Code:

GDB (specifically for STi variants)

Model Generation:

Second Generation (GD/GG)

Model Variant:

WRX STi

Covered Years:

2001, 2002

👋 Introduction

Market Position

Positioning:

The 2001-2002 Subaru Impreza WRX STi (GDB) represents the pinnacle of Subaru's rally-bred performance in its second generation. Positioned as a halo performance car, it competed with other iconic performance sedans and coupes of its era, offering unparalleled all-wheel-drive dynamics and a turbocharged boxer engine.

Competitive Analysis

Competitors:

Mitsubishi Lancer Evolution, Ford Focus RS, Honda Civic Type R (though often in different performance brackets).

Key Features

Features:

Symmetrical All-Wheel Drive, potent EJ207 turbocharged engine, close-ratio 6-speed manual transmission, Driver's Control Center Differential (DCCD), aggressive aerodynamic enhancements, sport-tuned suspension.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual (FSM) / Repair Manual

Language:

English

Format:

Digital (likely PDF or similar, based on typical product offerings)

Page Count Estimate:

Approximately 1500-2500 pages (typical for comprehensive FSMs of this era)

Vehicle Variants Covered:

Specifically covers the WRX STi variant for the 2001 and 2002 model years, detailing unique components and specifications for this high-performance model.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

EJ207 engine; cylinder head, block assembly, pistons, crankshaft, camshafts, valve train, timing belt/chain, lubrication system, cooling system

Engine Performance:

Turbocharger (IHI VF35/VF36), intercooler, fuel injection, ignition system, emissions control, engine management system (ECU diagnostics and programming)

Transmission:

6-speed manual transmission (TY856WB1AA, TY856WB2AA); clutch system, gearbox assembly, gear ratios, driveline components (driveshafts, differentials)

Drivetrain:

All-Wheel Drive system (Subaru's Symmetrical AWD), DCCD (Driver's Control Center Differential) operation and adjustment, viscous coupling center differential, limited-slip differentials (front and rear)

Suspension:

Front MacPherson struts, rear multi-link independent suspension; springs, shock absorbers, control arms, anti-roll bars, bushings

Steering:

Hydraulic power steering system, steering rack, column, tie rods, alignment specifications

Brakes:

Front and rear ventilated disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake calipers, master cylinder, brake lines, parking brake

Electrical System:

Battery, charging system (alternator), starter motor, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, grounds

Body And Chassis:

Body panels, doors, hood, trunk, bumpers, glass, interior trim, chassis components, corrosion protection

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system; blower motor, evaporator, condenser, refrigerant, climate controls

Safety Systems:

Airbags (SRS), seatbelts, ABS system diagnostics, vehicle security system

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspection, spark plug replacement

Diagnostics:

Troubleshooting guides for all major systems, diagnostic trouble codes (DTCs), OBD-II functionality, sensor testing

Repair And Rebuild:

Engine rebuild procedures, transmission overhaul, suspension component replacement, brake caliper rebuild, radiator replacement, starter/alternator replacement

Adjustment:

Valve lash adjustment, clutch pedal adjustment, handbrake adjustment, DCCD operation adjustment

Wiring Diagrams:

Detailed electrical schematics for all systems, including engine, chassis, lighting, and comfort features

Bodywork Repair:

Includes procedures for body panel alignment, door and latch adjustments, and basic structural component identification.

Wheel Alignment:

Detailed alignment specifications and procedures for front and rear suspension.

Technical Depth

Depth:

Comprehensive; covers from basic maintenance to complete engine and transmission overhauls, including diagnostic procedures and specifications.

Specialized Procedures:

Detailed procedures for DCCD calibration, ECU diagnostics and remapping specifications (though not necessarily tuning itself), clutch type and replacement.

📊 Manual Specifications

File Format

Format:

Digital (likely PDF, offering searchability and easy navigation)

Print Quality

Quality:

High-resolution scans providing clear text and diagrams (expected for factory manuals).

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Type:

N/A (Digital Format)

Completeness

Completeness:

Full factory service manual coverage, essential for any owner or mechanic working on these vehicles.

⚙️ Engine Specifications

Primary Engine

Engine Code:

EJ207

Engine Type:

Horizontally-opposed (Boxer) 4-cylinder, turbocharged, intercooled

Displacement:

1994 cc (2.0 Liters)

Bore X Stroke:

92.0 mm x 75.0 mm

Compression Ratio:

8.0:1

Valvetrain:

DOHC (Dual Overhead Camshafts), 16 valves (4 per cylinder), belt-driven

Performance

Horsepower:

Approximately 280 PS (276 bhp) at 6,000 rpm (JDM specification, often slightly lower for export markets or unverified).

Torque:

Approximately 337 Nm (248 lb-ft) at 4,000 rpm (JDM specification).

Turbocharger:

IHI VF35 (or VF36 for some variants); twin-scroll design, water-cooled

Intercooler:

Top-mounted, air-to-air

Engine Management:

ECU controlled, with specific tuning parameters documented for factory settings.

Fuel System

Fuel Delivery:

Sequential multi-point fuel injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (98 RON / 93 AKI recommended)

Throttle Body:

Drive-by-wire throttle control

🔧 Transmission

Standard

Transmission Type:

6-speed Manual Transmission

Transmission Model:

Subaru TY856WB series

Optional

Optional Transmissions:

None (STi models were exclusively manual)

Features

Dccd:

Driver's Control Center Differential (DCCD) allowing manual adjustment of front/rear torque split (Auto and Manual modes)

Final Drive Ratio:

Typically 3.538:1 (46/13), varies slightly by specific model/market.

📐 Dimensions

Exterior

Length:

Approximately 4,405 mm (173.4 in)

Width:

Approximately 1,770 mm (69.7 in)

Height:

Approximately 1,400 mm (55.1 in)

Wheelbase:

Approximately 2,510 mm (98.8 in)

Ground Clearance:

Approximately 135 mm (5.3 in)

Wheel Bolt Pattern:

5x100 mm

Wheel Size:

17x7.5 inches (standard STi alloy wheels)

Weights

Curb Weight:

Approximately 1,430 kg (3,153 lbs)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-star (driver), 4-star (passenger) (for standard Impreza sedan, STi likely similar or unrated separately by NHTSA for these specific model years in all markets).

Active Features

Standard Anti-lock Braking System (ABS)

Standard Electronic Brakeforce Distribution (EBD)

Passive Features

Airbags:

Driver and front passenger airbags (SRS)

Seatbelts:

3-point front seatbelts with pretensioners and load limiters, 3-point rear seatbelts

💡 Technology Features

Infotainment

Head Unit:

Factory original Clarion or Panasonic head unit with CD player, radio, and possibly cassette. Limited connectivity by modern standards.

Speakers:

Standard speaker system, often with component speakers in the front doors.

Driver Assistance

Driver Aids:

ABS, EBD, DCCD (active torque distribution).

Connectivity

Connectivity Features:

Limited. Primarily a manual transmission focused performance vehicle. No Bluetooth, USB, or auxiliary input as standard.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles or 6 months (whichever comes first), or more frequently under severe driving conditions.

Spark Plug Replacement:

Typically every 30,000-60,000 miles, depending on plug type (iridium recommended).

Timing Belt Replacement:

Every 90,000 - 105,000 miles or 7-10 years (critical for EJ engines, includes idlers and tensioner).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 or 10W-30, API SJ or higher, ILSAC GF-3 or higher. Synthetic oil is highly recommended for performance driving.

Engine Oil Capacity:

4.5 Liters (4.8 US Quarts) with filter change

Coolant Type:

Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.

Coolant Capacity:

Approximately 7.3 Liters (7.7 US Quarts)

Transmission Fluid Type:

API GL-5, SAE 75W-90 synthetic gear oil (e.g., Subaru Extra-S, Motul Gear 300).

Transmission Fluid Capacity:

Approximately 3.2 Liters (3.4 US Quarts)

Differential Fluid Type:

API GL-5, SAE 75W-90 synthetic gear oil.

Differential Fluid Capacity Front:

Approximately 1.0 Liter (1.1 US Quarts)

Differential Fluid Capacity Rear:

Approximately 1.3 Liters (1.4 US Quarts)

Known Issues

Engine Common Problems:

Head gasket failures (less common on EJ207 than EJ25, but still possible), turbocharger wear, piston ring land failure on high-mileage/abused engines, valve float at high RPM.

Dccd Common Problems:

DCCD unit failure or actuator issues leading to improper torque bias.

Suspension Common Problems:

Worn bushings (control arms, sway bars), premature strut failure, wheel bearing wear.

Electronics Common Problems:

Condensation in headlight housings, aging wiring harnesses, fuel pump issues.

📚 Vehicle History

Brand Heritage

Heritage:

Subaru has a long and storied history in motorsport, particularly in rallying, with the Impreza WRX STi being its flagship rally homologation special. This lineage imbues the model with a robust and performance-oriented DNA.

Model Evolution

Generation:

The 2001-2002 models mark the beginning of the second generation (GDB/GG) for the Impreza WRX STi, introducing a significant redesign over the previous GC8 chassis. Key updates included a larger chassis, more refined styling, and the introduction of the EJ207 engine and 6-speed transmission for the STi variants.

Production

Manufacturing Location:

Japan

Production Years:

Second Generation (GDB/GG): 2000-2007 (STi variants vary by market and year)

🏆 Awards & Recognition

Recognitions

Rally Heritage:

The Impreza platform, particularly the WRX STi, is globally renowned for its success in the World Rally Championship (WRC), earning multiple driver and manufacturer titles.

Ratings

Performance Reviews:

Consistently praised by automotive journalists for its exceptional handling, grip, and raw performance, often cited as one of the best affordable performance cars of its era.