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Subaru Impreza WRX 2002 Factory Service Repair Manual

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$16.99
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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX Year: 2002 Codes Chassis Code: GDB Engine Code: EJ205 👋 Introduction Market Position Market Position: The 2002 Subaru Impreza WRX (often...
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Subaru Impreza WRX 2002 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza WRX
Year:
2002
Codes
Chassis Code:
GDB
Engine Code:
EJ205
👋 Introduction
Market Position
Market Position:
The 2002 Subaru Impreza WRX (often referred to as the 'Bugeye' WRX in North America) was a cornerstone of the rally-inspired performance sedan market, offering potent turbocharged power, all-wheel-drive capability, and an accessible price point compared to exotic sports cars.
Competitive Analysis
Competitive Analysis:
Competed against performance variants of cars like the Mitsubishi Lancer Evolution (though the Evo VII was not officially sold in the US for 2002), Volkswagen GTI, Ford Focus SVT, and various European hot hatches. The WRX's unique selling proposition was its standard Symmetrical All-Wheel Drive and turbocharged Boxer engine.
Key Features
Key Features:
Turbocharged Boxer engine, Subaru's Symmetrical All-Wheel Drive, performance-tuned suspension, distinctive aggressive styling, aerodynamic enhancements, driver-focused interior.
📋 Manual Details
Coverage Areas
Coverage Areas:
All mechanical and electrical systems, bodywork, maintenance, troubleshooting, diagnostics, repair procedures.
Page Count
Page Count:
Approximately 1800 pages (estimated for a complete factory service manual of this era).
Manual Type
Manual Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Likely a scanned PDF or a digital reproduction of the original factory printed manual.
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical, engine control systems (ECU, sensors, actuators), fuel system, ignition system, exhaust system, cooling system, lubrication system, powertrain control, manual transmission, all-wheel drive system, braking system (including ABS), steering system, suspension system (front and rear), electrical systems (wiring diagrams, lighting, accessories), HVAC system, body and chassis, interior components, safety systems (airbags).
Procedures Included
Procedures Included:
Routine maintenance, scheduled service intervals, diagnostic procedures for all systems, troubleshooting guides for common and uncommon faults, step-by-step repair and overhaul instructions for major components (engine rebuild, transmission removal/installation, suspension overhaul), component testing, specifications, tightening torques, special tool requirements, body panel repair, interior trim removal/installation, electrical component testing and replacement.
Technical Depth
Technical Depth:
Comprehensive, covering everything from basic fluid changes and inspections to complete engine and transmission rebuilds, advanced electrical diagnostics, and body repair.
📊 Manual Specifications
File Format
File Format:
PDF (Searchable text is highly desirable for ease of use).
Print Quality
Print Quality:
High-resolution scans ensuring clarity of diagrams, illustrations, and text.
Binding Type
Binding Type:
N/A (for digital format)
Paper Type
Paper Type:
N/A (for digital format)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
2.0L EJ205 Turbocharged Flat-4 Boxer Engine
Performance
Horsepower:
227 hp @ 5600 rpm (approx.)
Torque:
217 lb-ft @ 4000 rpm (approx.)
Fuel System
Fuel System:
Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI), Turbocharged Intercooled.
Engine Management
Engine Management System:
Subaru Engine Control Unit (ECU) with diagnostic connectors (OBD-II).
Displacement
Displacement:
1994 cc
Bore X Stroke
Bore X Stroke:
92.0 mm x 75.0 mm
Compression Ratio
Compression Ratio:
8.0:1
Turbocharger
Turbocharger Model:
IHI VF22 (often, though variations exist)
Ignition System
Ignition System:
Electronic ignition with coil-on-plug or distributor-based system (depending on market and specific model sub-variant).
Emissions Controls
Emissions Controls:
Catalytic converter, EGR (Exhaust Gas Recirculation), secondary air injection (on some models).
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual Transmission
Optional
Optional Transmission:
4-Speed Automatic Transmission (less common on performance trims, but available on standard Impreza models that share chassis/drivetrain elements).
Features
Drivetrain:
Subaru Symmetrical All-Wheel Drive (AWD)
Gear Ratios
Gear Ratios 5Mt:
Detailed ratios available in the manual, critical for performance tuning.
Clutch
Clutch Type:
Hydraulically operated, single dry plate clutch.
Differential Type
Differential Type:
Front: Open Differential; Rear: Viscous Center Differential (VCD) integrated into the transfer case, providing variable torque split. Some models might have mechanical LSD in the rear.
📐 Dimensions
Exterior
Length:
Approx. 4415 mm (173.8 in)
Width:
Approx. 1730 mm (68.1 in)
Height:
Approx. 1440 mm (56.7 in)
Wheelbase:
Approx. 2515 mm (99.0 in)
Weights
Curb Weight:
Approx. 1400-1450 kg (3086-3197 lbs)
Gross Vehicle Weight Rating:
Varies by specific model and options.
Cargo
Cargo Volume:
Sedan: Approx. 12.0 cu ft; Wagon: Approx. 33.5 cu ft (rear seats up).
Wheels
Wheel Bolt Pattern:
5x100 mm
Wheel Size:
Standard 16-inch or optional 17-inch alloy wheels.
Tires
Tire Size Standard:
205/55 R16 or 215/55 R16 (depending on trim).
Tire Size Optional:
215/45 R17 (for WRX models).
🛡️ Safety Features
Ratings
NHTSA Front Crash Test Rating:
Not explicitly rated for 2002 model year under current NHTSA standards, but generally considered a safe vehicle for its time.
IIHS Rating:
Good (for front impact) in its class.
Active Features
Active Features:
ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), All-Wheel Drive (primary safety feature for traction).
Passive Features
Passive Features:
Front airbags, side airbags (optional on some trims), pretensioner seatbelts, crumple zones.
Child Seat Anchors
Child Seat Anchors:
LATCH system (Lower Anchors and Tethers for CHildren) available in rear seats.
💡 Technology Features
Infotainment
Infotainment System:
Basic factory installed radio/CD player. Limited connectivity by modern standards, typically featuring AM/FM tuner and CD playback.
Driver Assistance
Driver Assistance Features:
None beyond standard ABS and AWD. This era predates widespread advanced driver-assistance systems (ADAS).
Connectivity
Connectivity Options:
Typically basic auxiliary inputs if available, or aftermarket solutions for modern device integration.
Instrumentation
Instrumentation:
Tachometer, speedometer, fuel gauge, coolant temperature gauge, boost gauge (on some WRX models), various warning lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (severe use requires more frequent changes).
Timing Belt Replacement Interval:
Every 105,000 miles or 7 years (whichever comes first) for the EJ205 engine. Critical maintenance item.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-30, 10W-30, or 10W-40 depending on ambient temperature. Synthetic oil highly recommended for turbocharged engines.
Coolant Type:
Subaru Super Coolant (Blue) or equivalent long-life coolant, 50/50 mix with distilled water.
Transmission Fluid Type 5Mt:
API GL-5, SAE 75W-90 Gear Oil.
Differential Fluid Type:
API GL-5, SAE 75W-90 Gear Oil (front and rear).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Known Issues:
Head gasket leaks (common on EJ series engines, though less prevalent on EJ205 than later EJ25 models), turbocharger wear/failure, piston ring land failure (ringland failure) due to detonation/abuse, clutch wear, suspension component wear (bushings, ball joints), catalytic converter failure, oil consumption.
Tune Up Specifications
Spark Plug Type:
NGK PFR6G-11 (or equivalent).
Spark Plug Gap:
1.0-1.1 mm (0.040-0.044 inches).
📚 Vehicle History
Brand Heritage
Brand Heritage:
Subaru has a strong heritage in motorsport, particularly in the World Rally Championship (WRC), which heavily influenced the development and appeal of the Impreza WRX.
Model Evolution
Model Evolution:
The 2002 model year marked the beginning of the second generation (GD chassis) Subaru Impreza, significantly restyled from the previous GC chassis, featuring the distinctive 'Bugeye' front-end design that became a hallmark of this era.
Production
Production Location:
Gunma Plant, Japan
Production Years For Gd Chassis:
2002-2007 (North America); globally varied.
🏆 Awards & Recognition
Recognitions
Recognitions:
The Subaru Impreza WRX platform has historically been a darling of automotive publications for its performance and value. While specific awards for the 2002 model year might vary, it was consistently recognized for its driving dynamics and rally-inspired character.
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