2002-2003 Subaru Impreza (incl. WRX) Factory Service Manual

Description

includes electrical wiring diagram and engine internals. same engine for 2002-2005 WRX (USDM EJ205) has all torque specs 1 - General Info General Information Foreword How To Use This Manual Specifications Precaution Note Identification Recommended Materials Pre-Delivery Inspection Periodic Maintenance Services General Description Schedule Engine Oil Engine Oil Filter Spark Plugs Drive Belt(s) Camshaft Drive Belt Fuel Line Fuel Filter Air Cleaner Element Cooling System Coolant Idle Mixture Clutch System Transmission Oil ATF Front & Rear Differential Oil Brake Line Brake Fluid Disc Brake Pads and Discs Brake Linings and Drums Suspension Wheel Bearing Axle Boots & Joints Steering System (Power Steering) Supplemental Restraint System 2 - SOHC Engine SOHC Engine Section Fuel Injection General Description Throttle Body Intake Manifold Engine Coolant Sensor Crank Position Sensor Cam Position Sensor Knock Sensor Throttle Position Sensor Intake Air and Pressure Sensor Atmospheric Pressure Sensor IAC Solenoid Valve Air Assis Injector Solenoid Valve Fuel Injector Front (A/F) Sensor Rear Oxygen Sensor ECM Main Relay Fuel Pump Relay Fuel Fuel Tank Fuel Filler Pipe Fuel Pump Fuel Level Sensor Fuel Sub Level Sensor Fuel Filter Fuel Cut Valve Fuel Damper Valve Fuel Delivery, Return, and Evap lines Fuel System Trouble in General Emission Control General Description Front Cat Rear Cat Canister Purge Control Solenoid Valve Mail Fuel Level Sensor Fuel Temp Sensor Sub Fuel Level Sensor Fuel Tank Pressure Sensor Pressure Control Solenoid Valve Drain Filter Vent Valve Shut Valve Drain Valve Intake General Description Air Cleaner Air Cleaner Case Air Intake Duct Resonator Chamber Mechanical General Description Compression Idle Speed Ignition Timing Intake Manifold Vacuum Engine Oil Pressure Fuel Pressure Valve Clearance Engine Assembly Engine Mounting Prep for Overhaul V-Belt Crank Pulley Belt Cover Timing Belt Assembly Cam Sprocket Crank Sprocket Valve Rocker Assembly Camshaft Cylinder Head Assembly Cylinder Block Engine Trouble in General Engine Noise Cooling General Description Radiator Main Fan System Radiator Sub Fan System Engine Coolant Water Pump Thermostat Radiator Radiator Cap Radiator Main Fan and Motor Radiator Sub Fan and Motor Reservoir Tank Cooland Filler Tank Engine Cooling System Trouble in General Exhaust General Description Front Exhaust Pipe Center Exhaust Pipe Rear Exhaust Pipe Muffler Lubrication General Description Oil Pressure System Engine Oil Oil Pump Oil Pan and Strainer Oil Pressure Switch Engine Oil Cooler Engine Oil Filter Engine Lubrication System Trouble in General Speed Control Systems General Description Accelerator Pedal Accelerator Control Cable Ignition General Description Spark Plug Ignition Coild and Ignitor Assembly Spark plug Cord Starting/Charging Systems General Description Starter Generator Battery Engine Diagnostics Basic Diagnostic Procedure Check List for Interview General Description Electrical Components Location ECM I/O Signal Engine Condition Data TCM I/O Signal Data Link Connector OBD-II General Scan Tool Subaru Select Monitor Read Diagnostic Trouble Code Inspection Mode Clear Memory Mode Compulsory Valve Operation Check Mode Engine MIL (Check Engine Light) Dignostic for Engine Starting Failure List of DTCs Diagnostic Procedure with DTC General Diagnostic Table 3 - DOHC Engine DOHC Engine Section Fuel Injection General Description Throttle Body Intake Manifold Engine Coolant Sensor Crank Position Sensor Cam Position Sensor Knock Sensor TPS MAF and Air Temp Sensor Pressure Sensor IAC Valve Fuel Injector Tumble Generator Valve Assembly Wastegate Control Solenoid Valve Front O2 Sensor Rear O2 Sensor EGT Sensor Engine Control Module Main Relay Fuel Pump Relay Fuel Pump Controller Fuel Fuel Tank Fuel Filler Pipe Fuel Pump Fuel Level Sensor Fuel Sub Level Sensor Fuel Filter Fuel Cut Valve Fuel Damper Valve Fuel Delivery, Return lines Fuel System Trouble in General Engine Diagnostics Basic Diagnostics Check List for Interview General Description Electrical Components Location ECM I/O Signal Engine Condition Data TCM I/O Signal Data Link Connector OBD II Scan Tool Subaru Select Monitor Read DTC Inspection Mode Clear Memory Mode Valve Operation Check Mode Check Engine Light Diagnostics for Engine non Start List of DTC DIagnostic Procedure with DTC General Diagnostic Table Emission Control General Description Front Cat Rear Cat Pre Cat Canister Purge Control Valve Main Fuel Level Sensor Fuel Temp Sensor Fuel Sub Level Sensor Fuel Tank Pressure Sensor Pressure Control Valve Drain Filter Vent Valve Shut Valve Drain Valve Intake General Description Air Cleaner Air Intake Duct Intake Duct Intercooler Turbocharger Air ByPass Valve Mechanical General Description Compression Idle Speed Ignition Timing Intake Manifold Vacuum Engine Oil Pressure Fuel Pressure Valve Clearance Engine Assembly Engine Mounting Prep for Overhaul V-Belt Crank Pulley Belt Cover Timing Belt Assembly Cam Sprocket Crank Sprocket Camshaft Cylinder Head Assembly Cylinder Block Engine Troube in General Engine Noise Exhaust General Description Front Exhaust Pipe Center Exhaust Pipe Joint Pipe Rear Exhaust Pipe Muffler Ignition General Description Spark Plug Ignition Coil and Assembly 4 - Transmission Transmission Section Control Systems General Description Electrical Component AT Shift Lock System Select Lever Select Cable AT Shift Lock Solenoid Integrated Module MT Gear Shift Lever General Diagnostic Automatic Transmission General Description Auto Tranny Fluid Differential Gear Oil Road Test Stall Test Time Lag Test Line Pressure Test Transfer Clutch Pressure Test Auto Tranny Assembly Tranny Mounting System Extension Oil Case Seal Inhibitor Switch Front Vehicle Speed Sensor Rear Vehicle Speed Sensor Torque Converter Sensor Control Valve Body Shift Solenoids ATF Filter TCM Dropping Resistor ATF Cooler Pipe and Hose Auto Transmission Diagnostic Basic Diagnostic Procedure Check List for Interview General Description Electrical Components Locations TCM I/O Signal Subaru Select Monitor Read DTC Inspection Mode Clear Memory Mode AT Oil Temp Display List of DTC Oil Temp Light Diagnostic Select Monitor Diagnostic DTC Diagnostic No-DTC Diagnostic Symptom Related Diagnositc Manual Transmission General Description Tranny Gear Oil Manual Tranny Assembly Tranny Mounting System Oil Seal Switches and Harnesses Vehicle Speed Sensor Perp for Overhaul Transfer Case Assembly Transfer Drive Gear Transfer Driven Gear Center Differential Reverse Check Sleeve Tranny Case Main Shaft Assembly Drive Pinion Shaft Assembly Front Differential Assembly Speedo Gear Reverse Idler Gear Shifter Fork and Rod General Diagnostic Clutch System General Description Clutch Disc and Cover Flywheel Release Bearing and Lever Operating Cylinder Master Cylinder Clutch Pipe and Hose Clutch Fluid Cutch Fluid Air Bleeding Cutch Pedal Clutch Switch General Diagnostic Table 5 - Chassis Chassis Section Front Suspension General Description Wheel Alignment Sub Frame Front Traverse Link Front Ball Joint Front Strut Front Stabilizer Front Crossmember General Diagnostic Table Rear Suspension General Description Wheel Alignment Rear Stabilizer Rear Trailing LInk Rear Strut Lateral Link Rear Crossmember General Diagnostic Table Wheel and Tire System General Description Tire Steel Wheel Aluminium Wheel Wheel Balancing T-Type Tire Full Wheel Cap General Diagnostic Table Differentials General Description Differential Gear Oil Front Differential Rear Differential Rear Diff Front Oil Seal Rear Diff Side Oil Seal Rear Diff Member General Diagnostic Table Transfer Case General Description T-Case and Extension for MR T-Case and Extension for AT Oil Seal Transfer Driven Gear (MT) Transfer Driven Gear (AT) Reduction Drive Gear without VTD Reduction Drive Gear with VTD Reduction Driven Gear without VTD Reduction Driven Gear with VTD Center Diff Transfer Clutch Pressure Test Transfer Duty Solenoid Drive Shaft System General Description Propeller Shaft Front Axle Rear Axle Front Drive Shaft Front Drive Shaft Boots Rear Drive Shaft Rear Drive Shaft Boots General Diagnostic Table ABS General Description ABS Control Module ABS Sequence Control Front ABS Sensor Rear ABS Sensor Front Tone Wheel Rear Tone Wheel G-Sensor ABS Diagnostics Basic Diagnostic Procedure Check List for Interview General Description Electrical Components Location Control Module I/O Signal Subaru Select Monitor Read DTC Inspection Mode Clear Memory Mode ABS Warning Light List of DTC Diagnostics Chart wit Connector Diagnostics Chart with Subaru Monitor General Diagnostics Table Brake General Description Front Brake Pad Front Disc Rotor Front Disc Brake Assembly Rear Disk Pad Rear Disk Rotor Rear Disk Brake Assembly Rear Drum Brake Shoe Rear Drum Brake Drum Rear Drum Brake Assembly Master Cylinder Brake Booster Proprtioning Valve Brake Fluid Air Bleeding Brake Hose Brake Pipe Brake Pedal Stop Light Switch General Diagnostics Parking Brake General Description Parking Brake Lever Parking Brake Cable Parking Brake Assembly General Diagnostic Table Power Steering General Description Steering Wheel Universal Joing Tilt Steering Steering Gearbox Pipe Assembly Oil Pump Resrvoir Tank Power Steering Fluid General Diagnostic Table 6 - Body Body Section HVAC System General Description Refrigirant Pressures Refrigirant Recovery Refrigirant Charging Refrigirant Leak Check Compressor Oil Blower Motor Unit Assembly Blower Resistor Heater Core Control Unit Compressor Condenser Heater and Cooling Unit Evaporator Hose and Tube Relay and Fuse Pressure Switch Air Vent Grille Heater Duct Heater Vent Duct General Diagnostics Airbag System General Description Airbag Connector Inspection Locations Drivers Module Passenger Module Side Module Airbag Control Module Side Airbag Sensor Roll Connector Front Sub Sensor Airbag Diagnostic Basic Diagnostics Check List for Interview General Description Electrical Components A/B Control Module Airbag Connector Airbag Warning Light Read Diagnostic Trouble Code Inspection Module Clear Memory Module Airbag Warning Light List of Diagnostic Codes Diagnostic Chart with Trouble Code Seat Belt System General Description Pretension Connector Inspection Locations Front Seat Belt Rear Seat Belt Lighting System General Description Headlight and Tail Lights Front Fog Lights Turn Signal and Hazard Lights Back-Up Lights Stop Lights Interior Light System Combination Switch Headlight Assembly Headlight Bulb Front Turn Signal Bulb Clearance/Parking Light Bulb Front Fog Light Assembly Front Fog Light Bulb Front Side Marker Light Assembly Rear Combination Light Assembly Stop / Tail Light Bulb Back-Up Light Bulb Rear Turn Signal Bulb Rear Side Marker Bulb License Plate Light High-Mounted Stop Light Spot Light Room Light Luggage Room Light Trunk Room Light Glove Box Light Wiper and Washer Systems General Description Wiper and Washer System Combination Switch Wiper Blade Washer Tank and Motor Front Wiper Arm Front Wiper Motor and Link Front Washer Nozzle Rear Wiper Arm Rear Wiper Motor Rear Washer Nozzle Wiper Control Relay Entertainment General Description Radio System Cigarette Lighter System Radio Body Front Speaker Tweeter Rear Speaker Antenna Cigarette Lighter Communication System General Description Horn System Horn Horn Switch Glass / Windows / Mirrors General Description Power Window System Rear Window Defogger Remote Control Mirror System Front Door Glass Front Regulator and Motor Assembly Rear Door Glass Rear Regulator and Motor Assembly Windshield Glass Rear Gate Glass Rear Quarter Glass Rear Window Glass Inner Rearview Mirror Power Window Control Switch Rear Window Defogger Outer Mirror Assembly Outer Mirror Remote Control Mirror Switch Body Structure General Description Datum Points Datum Description Instrumentation General Description Combination Meter System Combination Meter Assembly Speedometer Tachometer Fuel Gauge Water Temp Gauge Ambient Sensor Seats General Description Front Seat Rear Seat Security and Locks General Description Door Lock System Keyless Entry System Security System Front Inner Remote Front Outer Handle Front Door Latch Assembly Front Door Lock Actuator Rear Inner Remote Rear Outer Handle Rear Door Latch Assembly Rear Door Lock Assembly Rear Gate Outer Handle Rear Gate Latch Assembly Rear Gate Latch Lock Actuator Trunk Lid Lock Assembly Trunk Lid Release Handle Front Hood Lock Assembly Remote Openers Ignition Key Lock Key Lock Cylinders Security Control Module Security Horn Security Horn Relay Interrupt Relay Keyless Entry Control Module Integrated Module Keyless Transmitter Exterior / Interior Trim General Description Front Grill Hood Grill Front Under Cover Front Bumper Rear Bumper Mud Guard Cowl Panel Roof Spoiler Rear Spoiler Side Sill Spoiler Front Door Trim Rear Door Trim Glove Box Roof Rail Console Box Instrument Panel Upper Inner Trim Lower Inner Trim Rear Quarter Trim Sun Visor Roof Trim Rear Gate Trim Rear Shelf Trim Trunk Trim Floor Mat Luggage Floor Mat Trunk Room Mat Exterior Body Panels General Description Front Hood Fender Panel Front Door Panel Front Sealing Cover Rear Door Panel Rear Sealing Cover Trunk Lid Panel Rear Gate Panel Cruise Control System General Description Actuator CC Module CC Main Switch CC Command Switch Stop and Brake Switch Clutch Switch Inhibitor Switch Cruise Control Diagnostics Diagnostic Procedure General Description Electrical Comp Location Cruise Control I/O Signal Subaru Select Monitor Diagnostic Chart List of DTCs Diagnostic Chart with DTCs Option Parts General Description Rear Spolier Crossbar Trailer Hitch Rear Diff Protector 7 - Wiring Wiring Section Wiring System Basic Diagnostic Procedure Working Precautions SMJ Power Supply Routing Ground Distribution Airbag System AC System ABS System A/T Control System A/T Shift Lock Control Audio System Charging System Clock System Combination Meter Compass Mirror System Cruise Control System Door Lock System Enging Coolant Temp Engine Electrical System Fuel Gauge System Front Accessory Power Stream Horn System Keyless Entry System Back-Up Light System Clearance Light System Front Fog Light System Headlight System In Compartment Light System Stop Light System Turn Signal Lights Oil Pressure Light System Outside Temp Display Parking Brake System Power Window System Radiator Fan System Rear Accessory Power Stream Rear Window Defogger Rearview Mirror System Seat Belt Warning Seat Heater System Security System Starter System Wiper and Washer System (Front) Wiper and Washer System (Rear) Overall Systems Front Wiring Harness Bulkhead harness (Engine) Bulkhead harness (Compartment) Engine Wiring Harness Instrument Panel Harness Rear Wiring Harness Door Cord Trunk Lid Cord Rear Gate Cord 8 - Car Information Car Information Section Specifications Fuel Injection (SOHC) General Air Line Fuel Line Sensors and Switches Control System On-Board Diagnosis Fuel injection (DOHC) General Air Line Fuel Line Sensors and Switches Control System On-Board Diagnosis Emission Control (SOHC) System Overview Schematic Diagrams Crankcase Emission Three-Way Catalyst A/F Control System Ignition Control System EE Control System ORVR System Vacuum Connections Emission Control (DOHC) System Overview Schematic Diagrams Crankcase Emissions Three-Way Catalyst A/F Control System Ignition Control System EE Control System ORVR System Vacuum Connections Intake (SOHC) Intake (DOHC) Intake System Turbo System Mechanical (SOHC) General Timing Belt Tension Adjuster Belt Cover Valve Rocker Assembly Camshaft Cylinder Head Cylinder Block Crankshaft Piston Engine Mounting Mechanical (DOHC) General Timing Belt Tension Adjuster Bolt Cover Camshaft Cylinder Head Cylinder Block Crankshaft Piston Engine Mounting Exhaust (SOHC) General Composition Exhaust (DOHC) General Contruction Cooling General Cooling Circuits Water Pump Mechanical Seal Thermostat Radiator Fan Lubrication General Engine Oil Flow Oil Pump Oil Filter Oil Pan and Oil Strainer Oil Pressure Switch Oil Cooler (Turbo) Speed Control System Ignition (SOHC) Ignition Coil Spark Plug Ignition (DOHC) Ignition Coil Spark Plug Starting / Charging Starter Generator Battery Control System Gear Shift Lever Select Lever Shift Lock System Auto Transmission Electrohydraulic System TCM Module On-Board Diagnostics Fail-Safe Function Transmission Mounting Manual Transmission General Reverse Check Mechanism Center Differential Transmission Mounting Clutch Outline Operation Cross-Sectional View Flywheel Hydraulic Clutch Front Suspension Rear Suspension Differentials Rear Differential LSD Drive Shaft System Propeller Shaft Front Axle Rear Axle ABS Brakes Front and Rear Disc Brakes Rear Drum Brakes Master Cylinder Brake Booster Proportioning Valve Parking Brake Rear Disc Rear Drum Power Steering Tilt Steering Column Power Steering System HVAC System Heater System AC Airbag System Airbag System Construction Seat Belt System Wiper and Washer System Front Wiper Rear Wiper Glass / Window / Mirrors Body Structure Steering Support Beam Quietness Body Sealing Painting ACC Application SGC Application Sealer Application Anti-Rust Wax Application PVC Application Hot Wax Application Galvanized Sheet Metal Application Aluminium Sheet Metal Application Ventilation Child Seat Anchors Instrumentation Combination Meter Outside Temp Display Seats Front Seat Rear Seat Security and Locks Ignition Switch Power Door Lock Keyless Entry System Security System Trunk Lid Release Handle Exterior / Interior Trim Exterior Body Panels Cruise Control