Subaru Impreza 2002-2006 Factory Service Repair Manual Pdf

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Generation: Second Generation (GD/GG) Body Styles Covered: Sedan, Wagon Model Years Covered: 2002, 2003, 2004, 2005, 2006 Codes Chassis Codes: GD (Sedan), GG (Wagon) 👋 Introduction Market Position Segment: Compact Car / Performance Compact Target Audience: Enthusiasts, DIY mechanics, owners seeking detailed repair information Competitive Analysis Competitors: Mitsubishi Lancer Evolution, Honda Civic Si, Volkswagen GTI, Ford Focus SVT Key Features Unique Selling Points: Standard Symmetrical All-Wheel Drive, strong rally heritage, available turbocharged performance variants (WRX, STI) Manual Value Proposition Value For Owners: Provides dealer-level diagnostic and repair information, enabling owners to perform complex maintenance and repairs, saving significant costs. 📋 Manual Details Coverage Areas Engine Variants Covered: H4DOTC (Turbocharged), H4SO (Naturally Aspirated) Transmission Variants Covered: Manual (5-speed, 6-speed on STI), Automatic (4-speed) Drive Type Coverage: All-Wheel Drive (AWD) Page Count Estimated Page Count: Extensive (Typical factory service manuals for this era exceed 1500 pages, though exact count not provided) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Yes (Engine disassembly, assembly, cylinder head, block, pistons, crankshaft, timing system, lubrication system, cooling system) Engine Management: Yes (Fuel injection, ignition system, emission control systems, ECU diagnostics, sensors, actuators) Transmission Manual: Yes (Clutch, gearbox operation, overhaul, shifter mechanism, fluid specifications) Transmission Automatic: Yes (Automatic transmission operation, overhaul, hydraulic control, torque converter, fluid specifications) Drivetrain: Yes (All-Wheel Drive system, front/rear differentials, driveshafts, wheel hubs) Suspension: Yes (Front and rear suspension components, struts, springs, control arms, bushings, alignment specifications) Steering: Yes (Power steering system, steering rack, column, components) Brakes: Yes (Front/rear brake systems, calipers, rotors, pads, ABS system, hydraulic lines) Electrical System: Yes (Battery, alternator, starter, lighting system, power windows, locks, mirrors, interior electronics) Wiring Diagrams: Yes (Comprehensive wiring schematics for all systems) HVAC: Yes (Heating, Ventilation, and Air Conditioning system diagnostics and repair) Body: Yes (Body panel removal/installation, interior trim, glass, doors, bumpers) Chassis: Yes (Frame, subframes, structural components) Procedures Included Routine Maintenance: Yes (Oil changes, filter replacements, fluid checks, spark plugs, belt inspections) Troubleshooting: Yes (Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides) Component Replacement: Yes (Step-by-step instructions for replacing most major and minor components) Rebuilding Procedures: Yes (Detailed instructions for engine and transmission overhauls) Diagnostic Procedures: Yes (Procedures for testing sensors, actuators, and electrical circuits) Specification Setting: Yes (Torque specifications, alignment angles, valve clearances, etc.) Technical Depth Depth: Comprehensive Factory Level (Covers everything from basic maintenance to complete vehicle diagnostics and major component overhauls) 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Yes (All pages printable) Binding Type Binding: N/A (Digital Download - PDF) Paper Type Paper Type: N/A (Digital Download - PDF) Compatibility Operating Systems: Windows, Mac Requirements Software Required: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Naturally Aspirated Engine: 2.5L EJ25S Naturally Aspirated H4 (SOhc or DoHC depending on exact model/market) Turbocharged Engine: 2.0L EJ205 Turbocharged H4 (DOTC - WRX models) Turbocharged Engine Sti: 2.5L EJ257 Turbocharged H4 (DOTC - STI models) Performance Naturally Aspirated Hp: Approx. 165-175 hp (Varies by specific market and engine variant) Naturally Aspirated Torque: Approx. 166-170 lb-ft (Varies) Wrx Hp: Approx. 227 hp (EJ205) Wrx Torque: Approx. 217 lb-ft (EJ205) Sti Hp: Approx. 300 hp (EJ257) Sti Torque: Approx. 300 lb-ft (EJ257) Fuel System Induction: Multi-point Fuel Injection (Naturally Aspirated), Sequential Electronic Fuel Injection with Turbocharger and Intercooler (Turbocharged) Fuel Type: Unleaded Gasoline (Premium Unleaded recommended/required for turbo models) Technical Specs Bore Stroke Ej25S: 92.0 mm x 91.0 mm Bore Stroke Ej205: 92.0 mm x 75.0 mm Bore Stroke Ej257: 99.5 mm x 79.0 mm Compression Ratio Ej25S: 9.7:1 (typical) Compression Ratio Ej205: 8.8:1 (typical) Compression Ratio Ej257: 8.2:1 (typical) 🔧 Transmission Standard Transmission Type Base: 5-Speed Manual Optional Transmission Type Optional: 4-Speed Automatic (except STI) Transmission Type Sti: 6-Speed Manual (STI models) Features AWD System: Symmetrical All-Wheel Drive with Viscous Center Coupling (Manual Transmissions) / Electronically Controlled Transfer Clutch (Automatic Transmissions) Sti Features: Driver Controlled Center Differential (DCCD), Helical Front Limited Slip Differential (LSD), Torsen Rear LSD Fluid Specifications Manual Transmission Fluid: API GL-5, SAE 75W-90 Gear Oil (Refer to manual for specific Subaru specifications, e.g., SOA425T0001) Automatic Transmission Fluid: Subaru ATF-HP (e.g., SOA868V9603) or equivalent (Refer to manual for specific capacity and change intervals) 📐 Dimensions Exterior Wheelbase: Approx. 2530 mm (99.6 in) Length: Approx. 4405 mm (Sedan) / 4415 mm (Wagon) Width: Approx. 1740 mm (68.5 in) Height: Approx. 1445 mm (Sedan) / 1485 mm (Wagon) Weights Curb Weight Base Model: Approx. 1300-1350 kg (2866-2976 lbs) Curb Weight Wrx: Approx. 1380-1400 kg (3042-3086 lbs) Curb Weight Sti: Approx. 1460-1480 kg (3219-3263 lbs) Wheel Bolt Pattern: 5x100 mm Wheel Offset: +53mm (typical, check specific trims) Tire Sizes Base: 205/55R16 Tire Sizes Wrx: 205/50R17 or 215/45R17 Tire Sizes Sti: 225/45R17 🛡️ Safety Features Ratings NHTSA Front Driver: Good (2002-2003 models)...

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Tags: 2002 2003 2004 2005 2006 Car Engines H4DOTC Impreza Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Impreza

Generation:

Second Generation (GD/GG)

Body Styles Covered:

Sedan, Wagon

Model Years Covered:

2002, 2003, 2004, 2005, 2006

Codes

Chassis Codes:

GD (Sedan), GG (Wagon)

👋 Introduction

Market Position

Segment:

Compact Car / Performance Compact

Target Audience:

Enthusiasts, DIY mechanics, owners seeking detailed repair information

Competitive Analysis

Competitors:

Mitsubishi Lancer Evolution, Honda Civic Si, Volkswagen GTI, Ford Focus SVT

Key Features

Unique Selling Points:

Standard Symmetrical All-Wheel Drive, strong rally heritage, available turbocharged performance variants (WRX, STI)

Manual Value Proposition

Value For Owners:

Provides dealer-level diagnostic and repair information, enabling owners to perform complex maintenance and repairs, saving significant costs.

📋 Manual Details

Coverage Areas

Engine Variants Covered:

H4DOTC (Turbocharged), H4SO (Naturally Aspirated)

Transmission Variants Covered:

Manual (5-speed, 6-speed on STI), Automatic (4-speed)

Drive Type Coverage:

All-Wheel Drive (AWD)

Page Count

Estimated Page Count:

Extensive (Typical factory service manuals for this era exceed 1500 pages, though exact count not provided)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Yes (Engine disassembly, assembly, cylinder head, block, pistons, crankshaft, timing system, lubrication system, cooling system)

Engine Management:

Yes (Fuel injection, ignition system, emission control systems, ECU diagnostics, sensors, actuators)

Transmission Manual:

Yes (Clutch, gearbox operation, overhaul, shifter mechanism, fluid specifications)

Transmission Automatic:

Yes (Automatic transmission operation, overhaul, hydraulic control, torque converter, fluid specifications)

Drivetrain:

Yes (All-Wheel Drive system, front/rear differentials, driveshafts, wheel hubs)

Suspension:

Yes (Front and rear suspension components, struts, springs, control arms, bushings, alignment specifications)

Steering:

Yes (Power steering system, steering rack, column, components)

Brakes:

Yes (Front/rear brake systems, calipers, rotors, pads, ABS system, hydraulic lines)

Electrical System:

Yes (Battery, alternator, starter, lighting system, power windows, locks, mirrors, interior electronics)

Wiring Diagrams:

Yes (Comprehensive wiring schematics for all systems)

HVAC:

Yes (Heating, Ventilation, and Air Conditioning system diagnostics and repair)

Body:

Yes (Body panel removal/installation, interior trim, glass, doors, bumpers)

Chassis:

Yes (Frame, subframes, structural components)

Procedures Included

Routine Maintenance:

Yes (Oil changes, filter replacements, fluid checks, spark plugs, belt inspections)

Troubleshooting:

Yes (Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides)

Component Replacement:

Yes (Step-by-step instructions for replacing most major and minor components)

Rebuilding Procedures:

Yes (Detailed instructions for engine and transmission overhauls)

Diagnostic Procedures:

Yes (Procedures for testing sensors, actuators, and electrical circuits)

Specification Setting:

Yes (Torque specifications, alignment angles, valve clearances, etc.)

Technical Depth

Depth:

Comprehensive Factory Level (Covers everything from basic maintenance to complete vehicle diagnostics and major component overhauls)

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Yes (All pages printable)

Binding Type

Binding:

N/A (Digital Download - PDF)

Paper Type

Paper Type:

N/A (Digital Download - PDF)

Compatibility

Operating Systems:

Windows, Mac

Requirements

Software Required:

Adobe PDF Reader

⚙️ Engine Specifications

Primary Engine

Naturally Aspirated Engine:

2.5L EJ25S Naturally Aspirated H4 (SOhc or DoHC depending on exact model/market)

Turbocharged Engine:

2.0L EJ205 Turbocharged H4 (DOTC - WRX models)

Turbocharged Engine Sti:

2.5L EJ257 Turbocharged H4 (DOTC - STI models)

Performance

Naturally Aspirated Hp:

Approx. 165-175 hp (Varies by specific market and engine variant)

Naturally Aspirated Torque:

Approx. 166-170 lb-ft (Varies)

Wrx Hp:

Approx. 227 hp (EJ205)

Wrx Torque:

Approx. 217 lb-ft (EJ205)

Sti Hp:

Approx. 300 hp (EJ257)

Sti Torque:

Approx. 300 lb-ft (EJ257)

Fuel System

Induction:

Multi-point Fuel Injection (Naturally Aspirated), Sequential Electronic Fuel Injection with Turbocharger and Intercooler (Turbocharged)

Fuel Type:

Unleaded Gasoline (Premium Unleaded recommended/required for turbo models)

Technical Specs

Bore Stroke Ej25S:

92.0 mm x 91.0 mm

Bore Stroke Ej205:

92.0 mm x 75.0 mm

Bore Stroke Ej257:

99.5 mm x 79.0 mm

Compression Ratio Ej25S:

9.7:1 (typical)

Compression Ratio Ej205:

8.8:1 (typical)

Compression Ratio Ej257:

8.2:1 (typical)

🔧 Transmission

Standard

Transmission Type Base:

5-Speed Manual

Optional

Transmission Type Optional:

4-Speed Automatic (except STI)

Transmission Type Sti:

6-Speed Manual (STI models)

Features

AWD System:

Symmetrical All-Wheel Drive with Viscous Center Coupling (Manual Transmissions) / Electronically Controlled Transfer Clutch (Automatic Transmissions)

Sti Features:

Driver Controlled Center Differential (DCCD), Helical Front Limited Slip Differential (LSD), Torsen Rear LSD

Fluid Specifications

Manual Transmission Fluid:

API GL-5, SAE 75W-90 Gear Oil (Refer to manual for specific Subaru specifications, e.g., SOA425T0001)

Automatic Transmission Fluid:

Subaru ATF-HP (e.g., SOA868V9603) or equivalent (Refer to manual for specific capacity and change intervals)

📐 Dimensions

Exterior

Wheelbase:

Approx. 2530 mm (99.6 in)

Length:

Approx. 4405 mm (Sedan) / 4415 mm (Wagon)

Width:

Approx. 1740 mm (68.5 in)

Height:

Approx. 1445 mm (Sedan) / 1485 mm (Wagon)

Weights

Curb Weight Base Model:

Approx. 1300-1350 kg (2866-2976 lbs)

Curb Weight Wrx:

Approx. 1380-1400 kg (3042-3086 lbs)

Curb Weight Sti:

Approx. 1460-1480 kg (3219-3263 lbs)

Wheel Bolt Pattern:

5x100 mm

Wheel Offset:

+53mm (typical, check specific trims)

Tire Sizes Base:

205/55R16

Tire Sizes Wrx:

205/50R17 or 215/45R17

Tire Sizes Sti:

225/45R17

🛡️ Safety Features

Ratings

NHTSA Front Driver:

Good (2002-2003 models)

NHTSA Front Passenger:

Good (2002-2003 models)

IIHS Moderate Overlap Front:

Good (2002-2004 models), Acceptable (2005-2006 models)

Active Features

Standard (on most models)

Traction Control:

Available (on some models, e.g., AWD-T)

Electronic Stability Control:

Not widely available on this generation

Passive Features

Airbags Front:

Standard

Airbags Side Curtain:

Available on later models/higher trims

Seatbelts:

3-point height adjustable front seatbelts with pretensioners and load limiters

💡 Technology Features

Infotainment

Audio System:

Factory fitted with CD player and AM/FM radio. Higher trims may have premium audio systems.

Navigation:

Optional factory navigation system available on some models.

Driver Assistance

Cruise Control:

Standard on most models.

ABS Control:

Anti-lock Braking System (ABS) is standard on most models.

Connectivity

Auxiliary Input:

Not standard. Aftermarket solutions or specific factory options may exist.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (severe service) or 7,500 miles (normal service) or 6 months. Refer to manual for exact guidance.

Engine Air Filter:

Inspect every 15,000 miles, replace as needed or every 30,000 miles.

Cabin Air Filter:

Replace every 15,000 miles or 12 months.

Spark Plugs:

Replace every 60,000 miles (standard models, Iridium plugs)

Timing Belt:

Replace every 105,000 miles or 105 months (non-interference engine, though checking belt condition is crucial)

Coolant Flush:

Every 30,000 miles or 3 years.

Transmission Fluid Change Manual:

Inspect every 15,000 miles, replace every 45,000 miles or 45 months.

Transmission Fluid Change Automatic:

Every 30,000 miles or 30 months (severe conditions may require more frequent changes).

Fluid Specifications

Engine Oil Capacity:

Approx. 4.8 quarts (4.5 Liters) with filter (EJ25S), Approx. 4.5 quarts (4.3 Liters) with filter (EJ205/EJ257). Refer to manual for exact capacity.

Engine Oil Type:

API SN/SP, ILSAC GF-6A compliant, SAE 5W-30 or 10W-30 (depending on climate). Synthetic oil recommended.

Coolant Type:

Subaru Super Coolant (Blue) or equivalent P-HOAT coolant. Do not mix with other types.

Known Issues

Head Gaskets:

While less common than earlier EJ engines, some EJ25 SOHC engines can develop head gasket leaks. The manual will detail diagnostic procedures and replacement steps.

Turbo Oil Lines:

Pre-2008 WRX models are known for potential turbo oil line failures (cracking/leaking). Regular inspection and replacement with upgraded lines is recommended. The manual covers inspection.

Clutch Wear:

Sporty driving can accelerate clutch wear. Manual covers clutch inspection and replacement procedures.

Suspension Bushings:

Wear in control arm and sway bar bushings can lead to noise and handling degradation over time. Manual provides replacement procedures.

📚 Vehicle History

Brand Heritage

Subaru Motorsport:

Strong ties to World Rally Championship (WRC) with the Impreza WRX and WRX STI, influencing the performance variants.

Model Evolution

Second Generation Introduction:

Introduced for the 2002 model year, featuring a distinctive 'bug-eye' headlight design (later revised for 2004 to 'hawk-eye' and 2006 to 'dog-eye').

Performance Variants:

The WRX and WRX STI models offered significantly increased performance over the standard Impreza, becoming icons of the tuner and rally scene.

Production

Manufacturing Locations:

Japan (Gunma Plant)

Production Years Global:

2000-2007

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Impreza WRX was frequently named to Car and Driver's 10Best list during this generation for its performance and value.

Wrc Success:

The Impreza WRX STI achieved significant success in the World Rally Championship during this period, reinforcing its performance credentials.

Ratings

Top Gear Magazine Reviews:

Received highly positive reviews from publications like Top Gear for its driving dynamics and all-weather capability.