Subaru Impreza 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Year: 2002 Codes Chassis Code: GDA/GDB (WRX/STI), GG2/GG3/GG9 (Wagon), GD2/GD3/GD9 (Sedan) 👋 Introduction Market Position Vehicle Segment: Compact/Sport Compact Target Audience: Enthusiasts, performance-oriented drivers, rally fans, DIY mechanics. Competitive Analysis Key Competitors: Mitsubishi Lancer Evolution, Honda Civic Si, Acura RSX, Toyota Celica GT-S. Key Features All Wheel Drive: Standard Subaru Symmetrical All-Wheel Drive system (except for select base models). Performance Variants: WRX and STI models offer turbocharged engines and performance-tuned suspensions. Rally Heritage: Strong ties to the World Rally Championship (WRC), influencing its sporty image and capabilities. 📋 Manual Details Coverage Areas Engine Variants Covered: 2.5L EJ251 (Naturally Aspirated), 2.0L EJ205 (Turbocharged WRX), 2.0L EJ207 (Turbocharged STI) Page Count Estimated Page Count: Approximately 1500-2000 pages (typical for comprehensive factory service manuals) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF) or Printed Book 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, camshafts, pistons, crankshaft, lubrication system, cooling system, timing belt/chain, seals and gaskets. Engine Performance: Fuel injection system, ignition system, emissions control system, turbocharger system (WRX/STI). Transmission: Manual transmission (5-speed & 6-speed STI), automatic transmission (4-speed), transfer case, differentials (front, center, rear). Drivetrain: Driveshafts, axles, CV joints, wheel bearings, AWD system operation. Suspension: Front suspension (MacPherson struts), rear suspension (double wishbone/multi-link), springs, shock absorbers, control arms, bushings, sway bars. Steering: Power steering system, steering column, steering rack, tie rod ends. Brakes: Front and rear disc brakes, ABS system, brake lines, master cylinder, calipers, rotors, brake pads, parking brake. Electrical System: Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting system, horn, power windows, central locking. Body And Chassis: Body panels, doors, hood, trunk, bumpers, interior trim, chassis components, corrosion protection. HVAC System: Air conditioning, heating, ventilation, climate control, blower motor, evaporator, condenser, refrigerant. Safety Systems: Airbags, seat belts, SRS system, child seat anchors. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid level checks and top-offs, tire rotation and pressure checks. Engine Repair: Engine overhaul, cylinder head gasket replacement, timing belt replacement, piston ring replacement, valve adjustments. Transmission Repair: Transmission disassembly, reassembly, clutch replacement, torque converter replacement, gear inspection and replacement. Brake Service: Brake pad replacement, rotor resurfacing/replacement, brake caliper overhaul, brake bleeding, ABS system diagnostics and repair. Suspension And Steering Repair: Shock absorber/strut replacement, control arm replacement, ball joint replacement, tie rod end replacement, power steering pump replacement. Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, starter and alternator testing, power window and lock repair. Bodywork And Trim: Panel replacement, door mechanism adjustment, interior panel removal and installation, bumper repair. Troubleshooting Guides: System-specific diagnostic flowcharts and symptom-based troubleshooting procedures. Technical Depth Diagnostic Capability: Advanced diagnostic procedures, including ECU code reading, sensor testing, and actuator testing. Rebuild Procedures: Comprehensive instructions for complete engine, transmission, and differential rebuilds. Specifications Accuracy: Precise torque specifications, clearances, fluid capacities, and alignment data. Wiring Diagrams: Detailed, system-specific electrical wiring diagrams for easy troubleshooting. 📊 Manual Specifications File Format PDF Quality: High-resolution scans or digital creation, ensuring clarity of text and diagrams. Searchability: Text-searchable PDF for quick access to specific information. Print Quality Printed Format: Professional printing with durable pages for workshop use. Binding Type Binding Type: Comb binding or perfect binding for lay-flat usability. Paper Type Paper Type: High-quality, durable paper stock suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Naturally Aspirated Engine: 2.5L (2457cc) EJ251 Flat-4 (Boxer) Turbocharged Engine Wrx: 2.0L (1994cc) EJ205 Turbocharged Flat-4 (Boxer) Turbocharged Engine Sti: 2.0L (1994cc) EJ207 Twin-Scroll Turbocharged Flat-4 (Boxer) Performance Ej251 Horsepower: 165 hp @ 5600 rpm Ej251 Torque: 166 lb-ft @ 4000 rpm Ej205 Horsepower: 227 hp @ 5600 rpm Ej205 Torque: 217 lb-ft @ 4000 rpm Ej207 Horsepower: 261 hp @ 6000 rpm (approximate for US market STI variant) Ej207 Torque: 250 lb-ft @ 4000 rpm (approximate for US market STI variant) Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Fuel Type: Unleaded gasoline (91 octane or higher recommended for WRX/STI) 🔧 Transmission Standard Manual Transmission: 5-speed manual (standard on NA, WRX), 6-speed manual (STI) Optional Automatic Transmission: 4-speed automatic (available on some naturally aspirated models) Features AWD System: Subaru Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled center differential (automatic). Sti Differentials: Driver Controlled Center Differential (DCCD) on STI models. 📐 Dimensions Exterior Overall Length Sedan: 173.4 inches (4405 mm) Overall Length Wagon: 174.2 inches (4425 mm) Overall Width: 66.9 inches (1700 mm) Overall Height Sedan: 55.1 inches (1400 mm) Overall Height Wagon: 56.5 inches (1435 mm) Wheelbase: 101.4 inches (2575 mm) Weights Curb Weight Sedan: 2840-3200 lbs (1288-1451 kg) depending on trim and drivetrain Curb Weight Wagon: 2900-3300 lbs (1315-1497 kg) depending on trim and drivetrain 🛡️ Safety Features Ratings NHTSA Frontal Driver Impact: Good (for models equipped with side airbags) NHTSA Frontal Passenger Impact: Good (for models...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Impreza

Year:

Codes

Chassis Code:

GDA/GDB (WRX/STI), GG2/GG3/GG9 (Wagon), GD2/GD3/GD9 (Sedan)

👋 Introduction

Market Position

Vehicle Segment:

Compact/Sport Compact

Target Audience:

Enthusiasts, performance-oriented drivers, rally fans, DIY mechanics.

Competitive Analysis

Key Competitors:

Mitsubishi Lancer Evolution, Honda Civic Si, Acura RSX, Toyota Celica GT-S.

Key Features

All Wheel Drive:

Standard Subaru Symmetrical All-Wheel Drive system (except for select base models).

Performance Variants:

WRX and STI models offer turbocharged engines and performance-tuned suspensions.

Rally Heritage:

Strong ties to the World Rally Championship (WRC), influencing its sporty image and capabilities.

📋 Manual Details

Coverage Areas

Engine Variants Covered:

2.5L EJ251 (Naturally Aspirated), 2.0L EJ205 (Turbocharged WRX), 2.0L EJ207 (Turbocharged STI)

Page Count

Estimated Page Count:

Approximately 1500-2000 pages (typical for comprehensive factory service manuals)

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF) or Printed Book

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, camshafts, pistons, crankshaft, lubrication system, cooling system, timing belt/chain, seals and gaskets.

Engine Performance:

Fuel injection system, ignition system, emissions control system, turbocharger system (WRX/STI).

Transmission:

Manual transmission (5-speed & 6-speed STI), automatic transmission (4-speed), transfer case, differentials (front, center, rear).

Drivetrain:

Driveshafts, axles, CV joints, wheel bearings, AWD system operation.

Suspension:

Front suspension (MacPherson struts), rear suspension (double wishbone/multi-link), springs, shock absorbers, control arms, bushings, sway bars.

Steering:

Power steering system, steering column, steering rack, tie rod ends.

Brakes:

Front and rear disc brakes, ABS system, brake lines, master cylinder, calipers, rotors, brake pads, parking brake.

Electrical System:

Battery, alternator, starter motor, wiring diagrams, fuses, relays, lighting system, horn, power windows, central locking.

Body And Chassis:

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

HVAC System:

Air conditioning, heating, ventilation, climate control, blower motor, evaporator, condenser, refrigerant.

Safety Systems:

Airbags, seat belts, SRS system, child seat anchors.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid level checks and top-offs, tire rotation and pressure checks.

Engine Repair:

Engine overhaul, cylinder head gasket replacement, timing belt replacement, piston ring replacement, valve adjustments.

Transmission Repair:

Transmission disassembly, reassembly, clutch replacement, torque converter replacement, gear inspection and replacement.

Brake Service:

Brake pad replacement, rotor resurfacing/replacement, brake caliper overhaul, brake bleeding, ABS system diagnostics and repair.

Suspension And Steering Repair:

Shock absorber/strut replacement, control arm replacement, ball joint replacement, tie rod end replacement, power steering pump replacement.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, starter and alternator testing, power window and lock repair.

Bodywork And Trim:

Panel replacement, door mechanism adjustment, interior panel removal and installation, bumper repair.

Troubleshooting Guides:

System-specific diagnostic flowcharts and symptom-based troubleshooting procedures.

Technical Depth

Diagnostic Capability:

Advanced diagnostic procedures, including ECU code reading, sensor testing, and actuator testing.

Rebuild Procedures:

Comprehensive instructions for complete engine, transmission, and differential rebuilds.

Specifications Accuracy:

Precise torque specifications, clearances, fluid capacities, and alignment data.

Wiring Diagrams:

Detailed, system-specific electrical wiring diagrams for easy troubleshooting.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution scans or digital creation, ensuring clarity of text and diagrams.

Searchability:

Text-searchable PDF for quick access to specific information.

Print Quality

Printed Format:

Professional printing with durable pages for workshop use.

Binding Type

Binding Type:

Comb binding or perfect binding for lay-flat usability.

Paper Type

Paper Type:

High-quality, durable paper stock suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Naturally Aspirated Engine:

2.5L (2457cc) EJ251 Flat-4 (Boxer)

Turbocharged Engine Wrx:

2.0L (1994cc) EJ205 Turbocharged Flat-4 (Boxer)

Turbocharged Engine Sti:

2.0L (1994cc) EJ207 Twin-Scroll Turbocharged Flat-4 (Boxer)

Performance

Ej251 Horsepower:

165 hp @ 5600 rpm

Ej251 Torque:

166 lb-ft @ 4000 rpm

Ej205 Horsepower:

227 hp @ 5600 rpm

Ej205 Torque:

217 lb-ft @ 4000 rpm

Ej207 Horsepower:

261 hp @ 6000 rpm (approximate for US market STI variant)

Ej207 Torque:

250 lb-ft @ 4000 rpm (approximate for US market STI variant)

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI)

Fuel Type:

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

🔧 Transmission

Standard

Manual Transmission:

5-speed manual (standard on NA, WRX), 6-speed manual (STI)

Optional

Automatic Transmission:

4-speed automatic (available on some naturally aspirated models)

Features

AWD System:

Subaru Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled center differential (automatic).

Sti Differentials:

Driver Controlled Center Differential (DCCD) on STI models.

📐 Dimensions

Exterior

Overall Length Sedan:

173.4 inches (4405 mm)

Overall Length Wagon:

174.2 inches (4425 mm)

Overall Width:

66.9 inches (1700 mm)

Overall Height Sedan:

55.1 inches (1400 mm)

Overall Height Wagon:

56.5 inches (1435 mm)

Wheelbase:

101.4 inches (2575 mm)

Weights

Curb Weight Sedan:

2840-3200 lbs (1288-1451 kg) depending on trim and drivetrain

Curb Weight Wagon:

2900-3300 lbs (1315-1497 kg) depending on trim and drivetrain

🛡️ Safety Features

Ratings

NHTSA Frontal Driver Impact:

Good (for models equipped with side airbags)

NHTSA Frontal Passenger Impact:

Good (for models equipped with side airbags)

Active Features

Standard Anti-lock Braking System (ABS)

Symmetrical All-Wheel Drive provides enhanced traction and stability.

Passive Features

Airbags:

Front driver and passenger airbags. Optional side airbags and curtain airbags available on some trims.

Seat Belts:

3-point front and rear seat belts with pretensioners.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM stereo with CD player. Premium audio systems available on higher trims.

Display:

Basic dashboard display for audio and climate controls. No integrated navigation or large color screens.

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Traction Control:

Traction control system (TCS) available on some models, particularly WRX/STI.

Connectivity

Auxiliary Input:

No factory auxiliary input or USB ports standard.

Bluetooth:

Not available from the factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months (severe driving) / 7,500 miles or 6 months (normal driving), consult manual for specifics.

Timing Belt Replacement:

Every 105,000 miles or 7 years (for EJ251 and EJ205 engines). Refer to manual for EJ207.

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API SG or higher) or SAE 10W-30 (API SG or higher) - consult manual for specific viscosity recommendations based on climate.

Engine Oil Capacity:

4.8 US quarts (4.5 liters) with filter for 2.5L; 4.0 US quarts (3.8 liters) with filter for 2.0L.

Coolant Type:

Subaru Super Coolant (Blue) or equivalent silicate-free antifreeze/coolant.

Transmission Fluid Manual:

GL-4 SAE 75W-90 gear oil.

Transmission Fluid Automatic:

Subaru ATF-HP or equivalent DEXRON-III H/MERCON approved fluid.

Known Issues

Head Gasket Leaks:

While less prevalent in the EJ205/EJ207 than some other EJ variants, head gasket leaks can still occur. The EJ251 is more prone to this issue.

Turbocharger Failure:

On WRX models, turbocharger issues can arise from lack of proper warm-up/cool-down or oil starvation. Intercooler piping leaks are also common.

Suspension Wear:

Bushings and ball joints can wear over time, leading to noise and handling degradation.

Clutch Wear:

Performance driving can accelerate clutch wear.

Ignition Coil Failure:

Ignition coil packs can fail, leading to misfires.

📚 Vehicle History

Brand Heritage

Subaru History:

Subaru Corporation, formerly Fuji Heavy Industries, has a long history in aviation and automotive manufacturing, known for its pioneering use of all-wheel drive and boxer engines.

Model Evolution

Impreza Generations:

The 2002 model year marks the introduction of the second generation (GD/GG) Impreza, replacing the first-generation (GC/GF).

Wrx Debut:

The WRX variant, a rally homologation special, gained significant popularity in the early 2000s, bringing Subaru's rally success to the road.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

While the 2002 model year might not have specific '10Best' listings, subsequent Subaru Impreza WRX models frequently appeared on this prestigious list for their performance value.

Ratings

Insurance Institute Highway Safety Top Safety Pick:

Early second-generation models received good ratings in frontal offset crash tests, but specific 'Top Safety Pick' designations may not apply to this exact year.