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Subaru Impreza 2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Year: 2002 Codes Chassis Code: GDA/GDB (WRX/STI), GD2/GD3/GD9 (NA) Engine Codes: EJ205 (2.0L Turbo WRX), EJ255 (2.5L Turbo WRX - some markets),...
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Subaru Impreza 2002 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza
Year:
2002
Codes
Chassis Code:
GDA/GDB (WRX/STI), GD2/GD3/GD9 (NA)
Engine Codes:
EJ205 (2.0L Turbo WRX), EJ255 (2.5L Turbo WRX - some markets), EJ207 (2.0L Twin-Scroll Turbo STI), EJ251 (2.5L NA), EJ201 (2.0L NA)
👋 Introduction
Market Position
Market Position:
The 2002 Subaru Impreza, part of the second generation (GD/GG), solidified Subaru's reputation for rally-bred performance and all-weather capability. It competed against models like the Mitsubishi Lancer Evolution, Volkswagen Golf GTI, and Honda Civic Si.
Competitive Analysis
Competitive Analysis:
The Impreza's key differentiator was its standard Symmetrical All-Wheel Drive system, offering superior traction and handling. The WRX and STI variants, in particular, offered potent turbocharged performance, appealing to enthusiasts.
Key Features
Key Features:
Standard Symmetrical AWD, Boxer engine layout, available turbocharged performance (WRX/STI), durable construction, rally heritage.
📋 Manual Details
Coverage Areas
Coverage Areas:
North America, Europe, General International Markets
Page Count
Page Count:
~1500-2000 pages (estimated for comprehensive factory-level manual)
Manual Type
Manual Type:
Full Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF) / Printable
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical (including disassembly, inspection, reassembly), Engine control systems (ECU, sensors, actuators), Fuel system (injection, pump, lines), Ignition system, Exhaust system, Cooling system, Lubrication system, Drivetrain (manual and automatic transmissions, differentials, AWD system), Suspension (front and rear), Steering system, Brakes (hydraulic, ABS), Electrical system (wiring diagrams, components, troubleshooting), Body and chassis (panels, frame, glass), HVAC system, Interior trim, Safety systems (airbags, seatbelts)
Procedures Included
Procedures Included:
Scheduled maintenance, Tune-up procedures, Engine rebuilding (short block, long block, cylinder head), Transmission overhaul, Differential service, Brake caliper and rotor replacement, Suspension component replacement (struts, ball joints, bushings), Steering rack service, Electrical diagnostics, Air conditioning system service, Body panel alignment and repair, OBD-II diagnostics and code clearing, Clutch replacement, Timing belt replacement, Turbocharger inspection and service (for turbo models)
Diagnostic Procedures:
Extensive diagnostic procedures for all engine control, ABS, and HVAC systems, including troubleshooting tables and flowcharts for common electrical and mechanical faults.
Technical Depth
Technical Depth:
Factory-level detail, including torque specifications, clearance measurements, diagnostic flowcharts, wiring schematics, and component testing procedures. Suitable for professional technicians and advanced DIY mechanics.
📊 Manual Specifications
File Format
File Format:
Searchable PDF with hyperlinked sections for easy navigation.
Print Quality
Print Quality:
High-resolution scans with clear diagrams and legible text, suitable for printing individual sections or the entire manual.
Binding Type
Binding Type:
Digital download (no physical binding)
Paper Type
Paper Type:
N/A (Digital Format)
Content Organization
Content Organization:
Logically structured with chapters for each major system, detailed sub-sections for specific components, troubleshooting guides, and clear step-by-step repair instructions.
⚙️ Engine Specifications
Primary Engine
Primary Engine:
EJ251 2.5-liter SOHC horizontally opposed 4-cylinder (Naturally Aspirated)
Performance
Hp Na:
165 hp @ 5600 rpm (EJ251)
Torque Na:
166 lb-ft @ 4000 rpm (EJ251)
Hp Turbo:
227 hp @ 5600 rpm (EJ205 WRX), 300 hp @ 6200 rpm (EJ207 STI - JDM)
Torque Turbo:
236 lb-ft @ 3500 rpm (EJ205 WRX), 271 lb-ft @ 4000 rpm (EJ207 STI - JDM)
Fuel System
Fuel System:
Multi-point fuel injection (MPI) for all models. Turbocharged models feature advanced fuel delivery systems for higher boost pressures.
Engine Management
Engine Management:
Subaru Select Monitor (SSM) for diagnostics, ECU-controlled ignition and fuel timing.
Timing Mechanism
Timing Mechanism:
Timing belt driven. Critical replacement interval (typically 90,000-105,000 miles).
Bore Stroke
Bore Stroke Na:
99.5 mm x 79.0 mm (EJ251)
Bore Stroke Turbo:
92.0 mm x 75.0 mm (EJ205/EJ207)
Compression Ratio
Compression Ratio Na:
9.7:1 (EJ251)
Compression Ratio Turbo:
8.5:1 (EJ205), 8.0:1 (EJ207)
Engine Layout
Engine Layout:
Horizontally Opposed (Boxer) 4-Cylinder
Valvetrain
Valvetrain:
SOHC 16-valve (NA), DOHC 16-valve (Turbo)
Cooling System
Cooling System:
Pressurized liquid cooling system with radiator, fan, thermostat, and expansion tank.
Oil Capacity
Engine Oil Capacity:
Approx. 4.5 US quarts (4.3 liters) with filter change (EJ251), 4.8 US quarts (4.5 liters) with filter change (EJ205/EJ207)
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission
Optional
Optional Transmission:
4-speed automatic transmission (available on most NA models, some markets)
Features
AWD System:
Symmetrical All-Wheel Drive (standard on all models). Viscous coupling center differential (manual) or electronically controlled multi-plate transfer clutch (automatic).
Fluid Specifications
Manual Transmission Fluid:
Subaru Extra LPS Fluid (GL-5, SAE 75W-90) or equivalent.
Automatic Transmission Fluid:
Subaru ATF-HP or equivalent.
Differential Fluid
Front Rear Differential Fluid:
Subaru Extra LPS Fluid (GL-5, SAE 75W-90) or equivalent.
📐 Dimensions
Exterior
Length:
Approx. 4415 mm (173.8 in)
Width:
Approx. 1700 mm (66.9 in)
Height:
Approx. 1410 mm (55.5 in) (sedan) / 1440 mm (56.7 in) (wagon)
Weights
Curb Weight:
Approx. 1350-1450 kg (2976-3197 lbs) depending on trim and drivetrain
Gross Vehicle Weight Rating:
Varies by model, typically around 1900-2000 kg (4189-4409 lbs)
Wheelbase
Wheelbase:
Approx. 2525 mm (99.4 in)
Wheelbase Subaru Impreza 2002:
2525 mm (99.4 in)
Track Width
Front Rear Track Width:
Approx. 1465 mm (57.7 in) / 1460 mm (57.5 in)
Ground Clearance
Ground Clearance:
Approx. 140 mm (5.5 in)
Cargo
Cargo Volume Sedan:
Approx. 11.6 cu ft (328 liters)
Cargo Volume Wagon:
Approx. 37.7 cu ft (1068 liters) with rear seats up
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4 stars (driver and passenger)
IIHS Side Impact:
Good (1999-2003 models)
Active Features
Active Features:
Anti-lock Braking System (ABS) standard on most trims, Optional Electronic Brake-force Distribution (EBD) on some models.
Passive Features
Passive Features:
Front airbags (driver and passenger), Optional side airbags, Three-point seatbelts with pretensioners, Crumple zones, Side impact door beams.
Recall Information
Common Recalls:
Takata airbag inflator recall (affected models), potential for minor electrical issues.
💡 Technology Features
Infotainment
Infotainment System:
Basic factory radio with CD player, AM/FM tuner. Optional premium audio systems were available.
Driver Assistance
Driver Assistance Features:
Limited. Primarily ABS on most models. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist were offered.
Connectivity
Connectivity:
No integrated Bluetooth or USB ports from the factory. Auxiliary input may be present on some aftermarket head units or later factory upgrades.
Instrumentation
Instrumentation:
Analog gauges for speedometer, tachometer, fuel level, and engine temperature. Multi-function display for odometer, trip meters, and warning lights. WRX/STI models feature a prominent boost gauge.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months, whichever comes first (severe duty) or 7,500 miles or 12 months (normal duty).
Timing Belt Replacement:
Recommended at 90,000-105,000 miles or 105 months, whichever comes first. Includes tensioner and idler pulleys.
Coolant Replacement:
First replacement at 30,000 miles or 36 months, then every 15,000 miles or 18 months thereafter.
Fluid Specifications
Engine Oil Spec:
API SG or higher, SAE 5W-30 synthetic recommended. Check owner's manual for specific viscosity based on ambient temperature.
Brake Fluid Spec:
DOT 3 or DOT 4.
Power Steering Fluid Spec:
Subaru Genuine Power Steering Fluid or Dexron III/Mercon ATF.
Known Issues
Known Issues:
Head gasket leaks (particularly on EJ25 engines, though less prevalent than later generations), turbocharger failure (on WRX/STI due to high-performance use and oil starvation if not maintained), clutch wear (especially in manual transmission models), wheel bearing failure, and occasional electrical gremlins. Oil consumption can occur on higher mileage EJ engines.
Filter Part Numbers
Oil Filter Part Number:
Subaru OEM: 15208AA100 or equivalent aftermarket (e.g., Wix 57356, Purolator PL14610).
Air Filter Part Number:
Subaru OEM: 16546AA12A or equivalent aftermarket.
Maintenance Schedule Summary
Maintenance Schedule Summary:
Includes recommended checks and replacements at intervals such as 7,500 miles (12,000 km), 15,000 miles (24,000 km), 30,000 miles (48,000 km), and major services at 90,000-105,000 miles (timing belt).
📚 Vehicle History
Brand Heritage
Brand Heritage:
Subaru, a division of Subaru Corporation, has a history of producing reliable vehicles with a focus on all-wheel-drive technology, stemming from their early aircraft manufacturing roots.
Model Evolution
Model Evolution:
The 2002 Impreza marked the beginning of the second generation (GD/GG), featuring a significant redesign with a more rounded and aerodynamic body style. This generation introduced the iconic wide-body styling for WRX and STI models.
Production
Production Years:
2002-2007 (Second Generation GD/GG)
Manufacturing Locations:
Japan (Gunma Plant), and various assembly plants globally.
🏆 Awards & Recognition
Recognitions
Recognitions:
The Subaru Impreza, particularly the WRX and STI variants, has received numerous accolades from automotive publications and enthusiasts for its performance, handling, and rally-inspired capabilities. Often cited as a benchmark for affordable performance AWD sedans.
Ratings
Consumer Reports Reliability:
Variable. Early models had some reliability concerns, particularly with head gaskets, but the overall platform is considered robust with proper maintenance.
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