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Subaru Impreza 2002-2006 Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Generation: Second Generation (GD/GG) Model Years Covered: 2002, 2003, 2004, 2005, 2006 👋 Introduction Market Position Segment: Compact Car / Performance Sedan...
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Subaru Impreza 2002-2006 Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza
Generation:
Second Generation (GD/GG)
Model Years Covered:
2002, 2003, 2004, 2005, 2006
👋 Introduction
Market Position
Segment:
Compact Car / Performance Sedan
Usp:
Affordable performance, standard Symmetrical All-Wheel Drive, rally-bred heritage.
Competitive Analysis
Key Competitors:
Mitsubishi Lancer Evolution, Honda Civic Si, Mazda3, Volkswagen GTI.
Key Features
Performance Variants:
WRX and STI (high-performance turbocharged models), offering significant tuning potential.
AWD System:
Subaru's Symmetrical All-Wheel Drive provides superior traction and handling in various conditions.
Durability:
Known for robust mechanical components, particularly the engine and drivetrain, when properly maintained.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Repair and Maintenance
Specific Models:
All Subaru Impreza models within the 2002-2006 model years, including sedan and wagon body styles, and various trim levels (e.g., RS, WRX).
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (EJ205, EJ251, EJ255), Fuel System, Exhaust System, Ignition System, Cooling System, Lubrication System.
Drivetrain:
Manual Transmission (5-speed), Automatic Transmission (4-speed), All-Wheel Drive (AWD) System (including front and rear differentials, driveshafts, viscous coupling).
Chassis:
Suspension (front MacPherson strut, rear multi-link), Steering System (rack and pinion, power steering), Braking System (front ventilated discs, rear solid discs; ABS).
Electrical:
Battery, Charging System, Starting System, Lighting System, Ignition System, Body Control Modules, Instrument Cluster, HVAC Controls, Audio System.
Body And Interior:
Body panels, doors, windows, seats, trim, airbags, seat belts, exterior and interior lighting, climate control.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake, transmission, differential), filter replacements, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting for common drivability, electrical, and mechanical issues.
Repair:
Detailed step-by-step instructions for component removal, installation, and repair of all major vehicle systems.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), component testing procedures, wiring diagrams, connector pinouts.
Technical Depth
Depth:
Comprehensive: Covers everything from basic fluid checks and filter changes to complete engine and transmission overhauls, electrical system diagnostics, and bodywork repairs.
📊 Manual Specifications
File Format
PDF Features:
Searchable text, bookmarked chapters, printable pages.
Print Quality
Quality:
High-resolution, clear diagrams and text.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Base Models:
EJ251 (2.5L Naturally Aspirated SOHC)
Engine Code Wrx:
EJ205 (2.0L Turbocharged DOHC)
Performance
Horsepower Ej251:
165 hp @ 5600 rpm
Torque Ej251:
166 lb-ft @ 4000 rpm
Horsepower Ej205:
227 hp @ 5600 rpm
Torque Ej205:
250 lb-ft @ 3000 rpm
Fuel System
Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (91 octane recommended for WRX/STI)
Cooling System
Coolant Type:
Subaru Super Coolant (Blue) or equivalent phosphate-free ethylene glycol based antifreeze
Lubrication System
Oil Type:
SAE 5W-30 Synthetic (recommended by Subaru)
Oil Capacity Ej251:
4.8 US quarts (4.5 liters) with filter
Oil Capacity Ej205:
4.2 US quarts (4.0 liters) with filter
🔧 Transmission
Standard
Type Base Models:
5-Speed Manual Transmission (TY757)
Optional
Type Optional:
4-Speed Automatic Transmission (4EAT)
Features
AWD Engagement Manual:
Driver-controlled center differential (DCCD on STI models) with viscous coupling.
AWD Engagement Auto:
Active All-Wheel Drive system with viscous coupling.
Fluid Specifications
Manual Transmission Fluid:
SAE 75W-90 GL-5 Hypoid Gear Oil
Automatic Transmission Fluid:
Subaru ATF-HP or Dexron III/Mercon compatible fluid
📐 Dimensions
Exterior
Wheelbase:
2525 mm (99.4 inches)
Length:
4415 mm (173.8 inches) - Sedan, 4465 mm (175.8 inches) - Wagon
Width:
1700 mm (66.9 inches)
Height:
1410 mm (55.5 inches) - Sedan, 1445 mm (56.9 inches) - Wagon
Weights
Curb Weight Base Models:
Approx. 1360 kg (2998 lbs)
Curb Weight Wrx:
Approx. 1430 kg (3153 lbs)
Gross Vehicle Weight Rating:
Varies by model and trim, consult specific vehicle VIN
Towing Capacity:
Not Recommended
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-star (Driver), 4-star (Passenger) for sedans.
IIHS Frontal Offset:
Good
Active Features
ABS:
Standard on most models (4-wheel disc brakes).
Traction Control:
Optional on some models, standard on specific higher trims/years.
Stability Control:
Introduced on later models, typically not standard on early 2002-2003 WRX.
Passive Features
Airbags:
Dual front airbags, optional side airbags.
Seatbelts:
Three-point seatbelts with pretensioners and force limiters.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with 4 or 6 speaker configuration. Optional premium audio systems available on higher trims.
Navigation:
Rarely offered from the factory for this generation.
Driver Assistance
Cruise Control:
Standard on most models.
Anti Lock Brakes:
Standard on most trims.
Connectivity
Auxiliary Input:
Not typically found on factory units; aftermarket solutions common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe service), 7,500 miles or 12 months (normal service).
Engine Air Filter Replacement:
Every 15,000 miles or 12 months.
Cabin Air Filter Replacement:
Every 15,000 miles or 12 months.
Spark Plug Replacement Ej251:
Every 60,000 miles (OEM Iridium)
Spark Plug Replacement Ej205:
Every 30,000 miles (OEM Platinum/Iridium)
Timing Belt Replacement:
Every 105,000 miles or 7 years (for EJ251 engine). EJ205 uses a timing chain.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (check cap or manual)
Power Steering Fluid:
ATF Dexron II or Subaru special fluid
Known Issues
Head Gaskets:
A common concern on EJ251 engines, though less prevalent than on earlier generations. Internal coolant leaks can occur.
Turbo Failure Wrx:
Can occur due to oil starvation, overheating, or excessive boost. Proper warm-up/cool-down procedures are critical.
Clutch Wear:
Can be accelerated by aggressive driving, especially in WRX models.
Differential Lock Issues:
Rare, but can occur with extreme off-road use or lack of fluid maintenance.
Rust And Corrosion:
Can affect body panels, especially in areas with road salt. Subframe and suspension components may also be susceptible.
📚 Vehicle History
Brand Heritage
Motorsport:
Strong roots in World Rally Championship (WRC), contributing to the Impreza's performance image.
Model Evolution
Generation Introduction:
The GD/GG generation marked a significant redesign from the GC/GF generation, featuring a more aerodynamic and modern design, particularly the 'bug-eye' front end of early models.
Facelifts:
The front-end styling underwent facelifts (e.g., 'hawk-eye' in 2004, 'blob-eye' in 2006) which also often included minor mechanical and interior updates.
Production
Manufacturing Location:
Mainly Japan (Gunma Prefecture)
Sales Performance:
Popular worldwide, especially in North America, Europe, and Japan, with the WRX variant becoming a cult classic.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
Impreza WRX often featured on Car and Driver's 10Best list for its performance and value.
Motor Trend Car Of The Year:
While not typically winning the overall award, Impreza variants often received praise in comparison tests.
Certifications
Emissions Compliance:
Meets EPA and CARB emissions standards for its respective model years.
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