Subaru 2002 Impreza User manual

2002 Model Year
PDF Service Manual
Supplement For STi Model
GENERAL INFORMATION SECTION (Pub.No.G1841GE1)
ENGINE 2 SECTION (Pub.No.G1841GE3)
TRANSMISSION SECTION (Pub.No.G1841GE4)
CHASSIS SECTION (Pub.No.G1841GE5)
BODY SECTION (Pub.No.G1841GE6)
WIRING SYSTEM SECTION (Pub.No.G1841GE7)

FUJI HEAVY INDUSTRIES LTD. G1841GE1
2002 IMPREZA STi SERVICE MANUAL QUICK REFERENCE INDEX
GENERAL INFORMATION
SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
SPECIFICATIONS SPC
IDENTIFICATION ID

SPECIFICATIONS
SPC
Page
1. Impreza .......................................................................................................2

SPC-2
SPECIFICATIONS
IMPREZA
1. Impreza
A: DIMENSIONS
★1: 1.6 L
★2: 2.0 L
★3: 2.0 L Turbo
★4: With roof rail
★5: With sun roof
B: ENGINE
Model Sedan Wagon OUTBACK STi
Overall length mm (in) 4,405 (173.4)
Overall width mm (in) 1,730 (68.1) 1,695 (66.7) 1,710 (67.3) 1,730 (68.1)
Overall height (at C.W.) mm (in) 1,440 (56.7) 1,465 (57.7),
1,485 (58.5)★4
1,475 (58.1),
1,495 (58.9)★41,440 (56.7)
Compartment Length mm (in) 1,890 (74.4) 1,845 (72.6) 1,890 (74.4)
Width mm (in) 1,380 (54.3)
Height mm (in) 1,180 (46.5),
1,125 (44.3)★5
1,200 (47.2),
1,150 (45.3)★5
1,200 (47.2),
1,150 (45.3)★51,180 (46.5)
Wheelbase mm (in) 2,525 (99.4)
Tread Front mm (in) 1,485 (58.5) 1,460 (57.5)★1,
1,465 (57.7) 1,460 (57.5) 1,490 (58.7)
Rear mm (in) 1,475 (58.1),
1,480 (58.3)★3
1,450 (57.1)★1,
1,455 (57.3) 1,455 (57.3) 1,480 (58.3)
Minimum road
clearance
Without catalytic
converter
mm (in) 150 (5.9),
155 (6.1)★2
150 (5.9),
155 (6.1)★2160 (6.3) —
With catalytic
converter
mm (in) 150 (5.9),
155 (6.1)★3
150 (5.9),
155 (6.1)★3160 (6.3) 155 (6.1)
Model 1.6 L Non-Turbo 2.0 L Turbo 2.0 L 2.5 L STi
Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine
Valve arrangement Overhead camshaft type
Bore ×Stroke mm (in) 87.9 ×65.8
(3.461 ×2.591)
92 ×75
(3.62 ×2.95)
99.5 ×79
(3.92 ×3.11)
92 ×75
(3.62 ×2.95)
Displacement cm3(cu in) 1,597 (97.45) 1,994 (121.67) 2,475 (151.02) 1,994 (121.67)
Compression ratio 10.0 ±0.2 8.0 ±0.2 10.0 ±0.2 8.0 ±0.2
Firing order 1 — 3 — 2 — 4
Idle speed at
Park/Neutral position
rpm 700 ±100 750 ±100 700 ±100 700 ±100
Maximum output kW (HP)/rpm 70
(94)/5,200
92
(123)/5,600
160
(215)/5,600
112
(150)/5,600
195
(261)/6,000
Maximum torque N·m (kgf-m, ft-lb)
/rpm
143
(14.6, 105.5)
/3,600
184
(18.8, 136.0)
/3,600
292
(29.8, 215.4)
/3,600
223
(22.7, 164.5)
/3,600
343
(35.0, 253.0)
/4,000

SPC-3
SPECIFICATIONS
IMPREZA
C: ELECTRICAL
Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi
Ignition timing at
idling speed
BTDC/rpm 5°±10°/700 10°±10°/700 12°±10°/750 MT: 10°±10°/700
AT: 15°±10°/700 12°±10°/700
Spark
plug
Type and
manufacturer
Without
OBD
NGK: BKR6E
(without catalyst)
CHAMPION:
RC8YC4
(with catalyst)
NGK: BKR6E-11
(with catalyst)
NGK: BKR6E
(without catalyst)
CHAMPION:
RC10YC4
(with catalyst)
NGK: BKR5E-11
(with catalyst)
—
NGK: BKR6E (with-
out catalyst)
CHAMPION:
RC10YC4 (with cat-
alyst)
NGK: BKR5E-11
(with catalyst)
—
With OBD CHAMPION:
RC8YC4
CHAMPION:
RC10YC4 NGK: PFR6G
CHAMPION:
RC10YC4 NGK: PFR6G
Alternate
NGK: BKR6E-11
Alternate
NGK: BKR5E-11
Alternate
NGK: BKR6E-11
Generator 12V — 75A
Battery Type and
capacity
(5HR)
For
Europe
and South
America
12V — 48AH
(55D23L)
MT: 12V — 48AH (55D23L)
AT: 12V — 52AH (65D23L)
MT: 12V — 48AH
(55D23L)
AT: 12V — 52AH
(75D23L)
12V — 48AH
(55D23L)
Others 12V — 27AH (34B19L) —

SPC-4
SPECIFICATIONS
IMPREZA
D: TRANSMISSION
5MT: 5-forward speeds with synchromesh and 1-reverse
4AT: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse
6MT: 6-forward speeds with synchromesh and 1-reverse
DSPD: Dry Single Plate Diaphragm
TCC: Torque Converter Clutch
★1: Australia spec vehicle
E: STEERING
F: SUSPENSION
Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi
Transmission type 5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT 6MT
Clutch type DSPD TCC DSPD TCC DSPD TCC DSPD TCC DSPD
Gear ratio 1st 3.454 2.785 3.454 2.785 3.454,
3.166★12.785 3.454 2.785 3.636
2nd 2.062 1.545 2.062 1.545 1.947,
1.882★11.545 2.062 1.545 2.375
3rd 1.448 1.000 1.448 1.000 1.366,
1.296★11.000 1.448 1.000 1.761
4th 1.088 0.694 1.088 0.694 0.972 0.694 1.088 0.694 1.346
5th 0.825 — 0.825 — 0.738 — 0.871,
0.780★1—0.971, 1.062★1
6th ———————— 0.756,
0.842★1
Reverse 3.333 2.272 3.333 2.272 3.333 2.272 3.333 2.272 3.545
Dual
range 1.447—1.447——————
Reduction
gear (Front
drive)
1st
reduction
Type of
gear — Helical — Helical — Helical — Helical —
Gear
ratio — 1.000 — 1.000 — 1.000 — 1.000 —
Final
reduction
Type of
gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid
Gear
ratio 4.111 4.444 3.900 4.111 3.900,
4.444★14.111 3.700,
4.111★14.111 3.900
Reduction
gear (Rear
drive)
Transfer
reduction
Type of
gear Helical — Helical — Helical — Helical — Helical
Gear
ratio 1.000 — 1.000 — 1.100, 1.000★1—1.000—
1.100,
1.000★1
Final
reduction
Type of
gear Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid Hypoid
Gear
ratio 4.111 4.444 3.900 4.111 3.545,
4.444★14.111 3.700,
4.111★14.111 3.545,
3.900★1
Model Turbo 2.0 L, 2.5 L OUTBACK OTHERS STi
Type Rack and Pinion
Turns, lock to lock RHD: 2.7
LHD: 3.0 3.0 3.2 2.7
Minimum turning circle m (ft) Curb to curb 11.0 (36.1) 10.8 (35.4) 10.4 (34.1) 11.0
Wall to wall 12.0 (39.4) 11.6 (38.1) 11.2 (36.7) 12.0
Front Macpherson strut type, Independent, Coil spring
Rear Dual-link type, Independent, Coil spring

SPC-5
SPECIFICATIONS
IMPREZA
G: BRAKE
H: TIRE
I: CAPACITY
★1: Dual range
Model 1.6 L Non-turbo 2.0 L, 2.5 L Turbo 2.0 L, STi
Service brake system Dual circuit hydraulic with vacuum suspended power unit
Front Ventilated disc brake
Rear Drum brake Disc brake Ventilated disc brake
Parking brake Mechanical on rear brakes
Rim size 14 ×51/2JJ 15 ×6JJ 16 ×61/2JJ 17 ×7JJ 17 ×71/2JJ
Tire size 175/70R14 84T
185/70R14 88H
185/65R15 88H
195/60R15 88H
P205/55R16 89V
205/50R16 87V
215/45R17 87W 225/45R17 90W
215/45R17 87W
Type Steel belted radial, Tubeless
Model 1.6 L Non-turbo 2.0 L Turbo 2.0 L 2.5 L STi
5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT 6MT
Fuel tank 2(US gal,
Imp gal) 50 (13.2, 11.0) 50 (13.2, 11.0) 60 (15.9, 13.2)
Engine
oil
Total
capacity
2(US qt,
Imp qt) 4.0 (4.2, 3.5) 4.5 (4.8, 4.0) 4.0 (4.2, 3.5) 4.5 (4.8, 4.0)
Engine
oil
amount
for refill
2(US qt,
Imp qt) Approx. 4.0 (4.2, 3.5) Approx.
4.5 (4.8, 4.0)
Approx.
4.0 (4.2, 3.5)
Approx.
4.5
(4.8, 4.0)
Transmission
gear oil
2(US qt,
Imp qt)
3.5
(3.7, 3.1),
4.0
(4.2, 3.5)
★1
—
3.5
(3.7, 3.1),
4.0
(4.2, 3.5)
★1
—3.5
(3.7, 3.1) —3.5
(3.7, 3.1) —4.1
(4.3, 3.6)
Automatic trans-
mission fluid
2(US qt,
Imp qt) —8.4 (8.9, 7.4) —8.4 (8.9, 7.4) —9.3 (9.8, 8.2) —9.3 (9.8, 8.2) —
AT differential
gear oil
2(US qt,
Imp qt) —1.2
(1.3, 1.1) —1.2
(1.3, 1.1) —1.2
(1.3, 1.1) —1.2
(1.3, 1.1) —
AWD rear differ-
ential gear oil
2(US qt,
Imp qt) 0.8 (0.8, 0.7) 1.0
(1.1, 0.9)
Power steering
fluid
2(US qt,
Imp qt) 0.7 (0.7, 0.6)
Engine coolant 2(US qt,
Imp qt)
7.4
(7.8, 6.5)
7.3
(7.7, 6.4)
7.0
(7.4, 6.2)
6.9
(7.3, 6.1)
7.7
(8.1, 6.8)
7.7
(8.1, 6.8)
7.0
(7.4, 6.2)
6.9
(7.3, 6.1)
7.7
(8.1, 6.8)

SPC-6
SPECIFICATIONS
IMPREZA
J: WEIGHT
1. LHD VEHICLE
Sedan
★1: For option code, refer to ID section. <Ref. to ID-5, Option code.>
Option code★1ECK4K0KS
Model 1.6 L
AWD
TS
5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kgf (lb) 730
(1,609)
750
(1,654)
750
(1,654)
770
(1,698)
750
(1,654)
770
(1,698)
740
(1,631)
760
(1,676)
Rear kgf (lb) 520
(1,146)
520
(1,146)
520
(1,146)
520
(1,146)
520
(1,146)
520
(1,146)
535
(1,179)
535
(1,179)
Total kgf (lb) 1,250
(2,755)
1,270
(2,800)
1,270
(2,800)
1,290
(2,844)
1,270
(2,800)
1,290
(2,844)
1,275
(2,810)
1,295
(2,855)
Maximum permissible
axle weight (M.P.A.W.)
Front kgf (lb) 890
(1,962)
890
(1,962)
890
(1,962)
890
(1,962)
890
(1,962)
890
(1,962)
890
(1,962)
890
(1,962)
Rear kgf (lb) 890
(1,962)
890
(1,962)
890
(1,962)
890
(1,962)
890
(1,962)
890
(1,962)
890
(1,962)
890
(1,962)
Maximum permissible
weight (M.P.W.)
Total kgf (lb) 1,700
(3,748)
1,700
(3,748)
1,700
(3,748)
1,700
(3,748)
1,700
(3,748)
1,700
(3,748)
1,700
(3,748)
1,700
(3,748)
Option Air conditioner ——❍❍❍❍❍❍
Cruise control ————————
ABS ————————
Aluminium wheel ————————
Rear spoiler ————————
Spoiler pac ————————
Option code★1ECK4K0KS
Model 2.0 L
AWD
GX
5MT 4AT 5MT 4AT 5MT 4AT 5MT 4AT
Curb weight (C.W.) Front kgf (lb) 745
(1,643)
770
(1,698)
765
(1,687)
790
(1,742)
760
(1,676)
795
(1,753)
750
(1,653)
780
(1,720)
Rear kgf (lb) 535
(1,179)
530
(1,168)
530
(1,168)
525
(1,157)
525
(1,157)
530
(1,168)
550
(1,213)
545
(1,202)
Total kgf (lb) 1,280
(2,822)
1,300
(2,866)
1,295
(2,855)
1,315
(2,899)
1,285
(2,833)
1,325
(2,921)
1,300
(2,866)
1,325
(2,922)
Maximum permissible
axle weight (M.P.A.W.)
Front kgf (lb) 920
(2,028)
920
(2,028)
920
(2,028)
920
(2,028)
920
(2,028)
920
(2,028)
920
(2,028)
920
(2,028)
Rear kgf (lb) 910
(2,006)
910
(2,006)
910
(2,006)
910
(2,006)
910
(2,006)
910
(2,006)
910
(2,006)
910
(2,006)
Maximum permissible
weight (M.P.W.)
Total kgf (lb) 1,760
(3,880)
1,760
(3,880)
1,760
(3,880)
1,760
(3,880)
1,760
(3,880)
1,760
(3,880)
1,760
(3,880)
1,760
(3,880)
Option Air conditioner ——❍❍❍❍❍❍
Cruise control ————————
ABS ——❍❍❍❍—❍
Aluminium wheel ——❍❍——❍❍
Rear spoiler ——————❍❍
Spoiler pac ————————