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Subaru Impreza 2002 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Year: 2002 Generation Generation Code: GD/GG Generation Name: Second Generation Codes Chassis Codes: GD (Sedan), GG (Wagon) 👋 Introduction Market Position Positioning:...
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Subaru Impreza 2002 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza
Year:
2002
Generation
Generation Code:
GD/GG
Generation Name:
Second Generation
Codes
Chassis Codes:
GD (Sedan), GG (Wagon)
👋 Introduction
Market Position
Positioning:
The Subaru Impreza (GD/GG generation) was positioned as a compact car known for its standard Symmetrical All-Wheel Drive system and sporty driving dynamics, particularly the WRX variant.
Target Audience:
Enthusiasts, DIY mechanics, and professional technicians seeking in-depth repair and maintenance information.
Competitive Analysis
Competitors 2002:
Honda Civic, Toyota Corolla, Mazda Protegé, Mitsubishi Lancer, Ford Focus, Volkswagen Golf.
Differentiation:
Standard AWD, rally-bred WRX performance variant, boxer engine reputation.
Key Features
Standard AWD:
Subaru's signature Symmetrical All-Wheel Drive system providing enhanced traction and stability.
Engine Options:
Choice of naturally aspirated EJ-series boxer engines and the iconic turbocharged EJ205 (WRX).
Body Styles:
Available as a 4-door sedan and a 5-door wagon (often referred to as the Sportwagon or Outback Sport).
Performance Variant:
The WRX model offered significantly higher performance with a turbocharged engine, intercooler, and sport-tuned suspension.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Engine Options Covered:
EJ201, EJ202, EJ251, EJ253 (Naturally Aspirated and Turbocharged variants)
Transmission Options Covered:
5-Speed Manual, 4-Speed Automatic
Trim Levels Covered:
Outback Sport, RS, TS, WRX (specific components applicable to WRX variants)
Page Count
Estimated Page Count:
1500-2000+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel injection, ignition, exhaust, cooling, lubrication, forced induction (turbocharging for WRX)
Drivetrain:
Front-wheel drive, All-wheel drive (AWD) system, differentials, driveshafts, hubs
Transmission:
Manual and Automatic transmission overhaul, operation, troubleshooting
Suspension:
Front and Rear suspension components, steering system, wheel alignment
Brakes:
Hydraulic system, ABS (Anti-lock Braking System), brake disc/pad replacement, caliper overhaul
Electrical:
Wiring diagrams, ECU (Engine Control Unit), lighting, accessories, starting and charging system, SRS (Supplemental Restraint System)
Body:
Body panels, interior trim, glass, doors, bumpers, chassis repair, corrosion protection
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis and repair
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and flushes, spark plug replacement
Troubleshooting:
Diagnostic procedures, fault code interpretation, common problem diagnosis
Repair:
Component removal and installation, overhaul procedures, component replacement
Diagnostics:
OBD-II diagnostics, sensor testing, actuator testing, electrical circuit tracing
Technical Depth
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds.
Detail Level:
Includes torque specifications, clearances, diagnostic flowcharts, wiring diagrams, and component testing procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text, allowing quick access to specific topics.
Print Quality
Image Resolution:
High-resolution images and diagrams suitable for printing.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Naturally Aspirated Base:
2.5L (2457cc) EJ251/EJ253 SOHC Flat-4 Boxer
Naturally Aspirated Power:
Approx. 165-170 hp @ 5600-6000 rpm
Naturally Aspirated Torque:
Approx. 166-170 lb-ft @ 3600-4000 rpm
Turbocharged Performance:
2.0L (1994cc) EJ205 DOHC Turbocharged Flat-4 Boxer
Turbocharged Power:
Approx. 227 hp @ 5600 rpm (WRX)
Turbocharged Torque:
Approx. 217 lb-ft @ 3600 rpm (WRX)
Performance
Compression Ratio Ej25:
9.7:1
Compression Ratio Ej205:
8.0:1
Redline Ej25:
6500 rpm
Redline Ej205:
7000 rpm
Fuel System
Injection Type:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane for NA, 91 octane recommended for WRX)
Turbocharger Model:
IHI VF39 (WRX)
🔧 Transmission
Standard
Manual:
5-Speed Manual Transmission (TY75)
Optional
Automatic:
4-Speed Automatic Transmission
Features
AWD Coupling:
Viscous coupling center differential (AWD system)
Limited Slip Differential:
Optional LSD available for rear differential on some trims.
Fluid Type Manual:
API GL-5 SAE 75W-90 Gear Oil
Fluid Type Automatic:
Dexron III / Mercon Automatic Transmission Fluid
📐 Dimensions
Exterior
Length Sedan:
4415 mm (173.8 in)
Length Wagon:
4405 mm (173.4 in)
Width:
1700 mm (66.9 in)
Height Sedan:
1410 mm (55.5 in)
Height Wagon:
1445 mm (56.9 in)
Wheelbase:
2535 mm (99.8 in)
Ground Clearance:
135 mm (5.3 in) (standard), 145 mm (5.7 in) (WRX)
Weights
Curb Weight Range:
1300 - 1450 kg (2866 - 3197 lbs)
Gross Vehicle Weight Rating:
Approx. 1800-1950 kg
Cargo
Cargo Volume Sedan:
Approx. 0.37 m³ (13.1 cu ft)
Cargo Volume Wagon:
Approx. 0.76 m³ (26.8 cu ft) (seats up)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
Good (for 2002 model year, but varies by specific test)
NHTSA Frontal Impact Passenger:
Good (for 2002 model year, but varies by specific test)
IIHS Front Offset Crash Rating:
Acceptable (for 2002 model year, but varies by specific test)
Active Features
ABS:
Standard (4-wheel disc brakes with ABS on most trims)
Traction Control:
Optional on some models, standard on certain WRX variants.
Passive Features
Airbags Front:
Driver and Passenger airbags standard.
Airbags Side:
Optional front side-impact airbags on some trims.
Seatbelts:
3-point height-adjustable front seatbelts with pretensioners and force limiters, rear 3-point seatbelts.
Srs System:
Supplemental Restraint System (SRS) controls airbags and seatbelt pretensioners.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, optional premium audio systems with more speakers available on higher trims.
Display:
Basic dashboard display with analog gauges for speed, RPM, fuel, and temperature. No central infotainment screen.
Driver Assistance
Cruise Control:
Available on most models.
Anti Lock Brakes:
Standard ABS provides enhanced braking control.
Connectivity
Auxiliary Input:
Not typically available from the factory; aftermarket solutions are common.
Bluetooth:
Not available from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe conditions) or 7,500 miles or 12 months (normal conditions) - refer to manual for specifics.
Engine Oil Filter Replacement:
At every oil change.
Air Filter Replacement:
Every 15,000-30,000 miles or as needed.
Cabin Air Filter Replacement:
Every 15,000-30,000 miles or annually.
Spark Plug Replacement Na:
Every 60,000 miles (NGK Iridium or Platinum recommended).
Spark Plug Replacement Turbo:
Every 30,000 miles (NGK Iridium or Platinum recommended, one step colder heat range for performance).
Coolant Flush Interval:
Every 30,000 miles or 2 years.
Timing Belt Replacement:
Every 90,000-105,000 miles or 7 years (critical for EJ series engines).
Fluid Specifications
Engine Oil Viscosity:
SAE 5W-30 (API SG, SH, or SJ classification).
Engine Oil Capacity:
Approx. 4.5 US quarts (4.2 L) with filter change (EJ25).
Coolant Type:
Subaru Super Coolant (Blue) or equivalent; 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid:
Subaru ATF-HP orDexron III/Mercon equivalent.
Known Issues
Head Gaskets:
While less prevalent than earlier generations, EJ25 engines can still be prone to head gasket failures; a key focus area for the manual.
Wrx Clutch Wear:
Aggressive driving can lead to accelerated clutch wear on WRX models.
Oil Leaks:
Common areas for oil leaks include valve cover gaskets and oil pan gaskets.
Catalytic Converter:
Older catalytic converters can degrade and cause performance issues.
Rust And Corrosion:
Like many vehicles of this era, rust can be an issue in areas prone to road salt, particularly in the wheel wells and rocker panels.
📚 Vehicle History
Brand Heritage
Subaru Motorsports:
Subaru's long history and success in World Rally Championship (WRC) heavily influenced the development and perception of the Impreza WRX.
Model Evolution
Previous Generation:
The GC/GM generation (1992-2001) established the Impreza's AWD reputation and introduced the performance WRX variant.
Second Generation Launch:
The GD/GG generation debuted in 2000 in Japan and later in North America for the 2002 model year, featuring a significant redesign with a more aggressive and rounded styling.
Wrx Usdm Introduction:
The WRX variant was officially introduced to the United States for the 2002 model year, building on its international popularity.
Production
Manufacturing Locations:
Japan (Ota, Gunma Plant)
Production Years Gd Gg:
2000-2007 (Globally), 2002-2007 (North America)
🏆 Awards & Recognition
Recognitions
Car And Driver నించ:
Car and Driver magazine often included the Impreza WRX on its '10Best' list in various years for its performance and value.
Wrc Success:
Subaru's multiple World Rally Championship constructor titles (with the Impreza platform) cemented its performance credentials.
Ratings
Consumer Reports Reliability:
Variable; often rated average to below average in reliability for specific components but praised for performance and AWD.
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