User manual SUBARU IMPREZA STI SERVICE MANUAL 2002

[. . . ] 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) 2002 IMPREZA STi SERVICE MANUAL GENERAL INFORMATION SECTION SPECIFICATIONS IDENTIFICATION QUICK REFERENCE INDEX SPC ID 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, reassembling, inspection and adjustment of components and diagnostics for guidance 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 specifications contained in this manual are based on the latest product information available at the time of publication approval. FUJI HEAVY INDUSTRIES LTD. [. . . ] NOTE: Make sure to install the friction plate in proper direction. (C) (D) A (C) TR0797 (A) TR0798 (B) (A) Sub gear (B) Spring (C) Punch mark (mark A) D: ASSEMBLY 1) Install the sub gear and spring. NOTE: · Install the spring with white marking on hook part facing to sub gear side. · Install the sub gear with punch mark (mark A) facing outside. (A) (B) (A) (B) (C) (D) Friction plate Snap ring Snap ring side Sub gear side 3) Sufficiently apply gear oil to the shaft, needle bearing and inner periphery of reverse drive gear. 4) Install the knock pin. (C) (A) Sub gear (B) Spring (C) Punch mark (mark A) · Install the spring and sub gear, taking care to install the sub gear installation hole in proper direction. (C) (A) Installation hole A TR0797 TR0935 5) Install the washer and needle bearing. NOTE: Install the washer with groove facing to reverse idler gear. A (B) (A) TR0799 (A) TR0951 (A) Groove (B) Washer (C) Needle bearing 6MT-98 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 6) Install the reverse idler gear No. 2. 8) Install the reverse sleeve to reverse idler gear No. 2. NOTE: Make sure to install the reverse sleeve in proper direction. TR0936 7) Install the shifting insert key in proper place of reverse sleeve. NOTE: Angle of each shifting insert key is 120° apart. (A) (B) TR0801 9) Sufficiently apply gear oil to the collar, needle bearing and inner periphery of reverse drive gear. 10) Install the outer baulk ring, reverse synchro cone and inner baulk ring. (A) (A) (B) (C) TR0802 (B) (A) Outer baulk ring (B) Reverse synchro cone (C) Inner baulk ring TR0800 11) Install the collar and needle bearing, then install the knock pin. (A) Reverse sleeve (B) Shifting in sert key (C) (B) (A) TR0803 (A) Collar (B) Needle bearing (C) Knock pin 6MT-99 REVERSE IDLER GEAR ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 12) Align the protrusion portion of reverse synchro cone with reverse idler gear hole, then install the reverse idler gear. (B) (A) TR0804 3) Gears Replace the gears in the following cases: · The gear teeth surfaces are broken or excessively worn. 4) Baulk ring, synchro cone Replace the baulk ring and synchro cone in the following case: · Worn, rusted and damaged baulk ring 5) Shifting insert key Replace the shifting insert key if deformed, excessively worn or defective in any way. (A) Protrusion portion of reverse synchro cone (B) Reverse idler gear hole 13) Install the washer with groove facing to reverse idler gear. ST 18672AA000 GUIDE CLIP S3M0189 6) Inspect the clearance between snap ring and washer. Specification of clearance: 0. 1--0. 3 mm (0. 0039--0. 0118 in) TR0805 15) Inspect and adjust the clearance between snap ring and washer. to 6MT-100, INSPECTION, Reverse Idler Gear Assembly. > 16) Install a new spring pin. E: INSPECTION Disassembled parts should be washed clean first and then inspected carefully. 1) Bearings Replace the bearings in the following cases: · Worn, rusted and damaged bearing · Bearings that fail to turn smoothly or make abnormal noise when turned · Bearings having other defects 2) Bushing (each gear) Replace the bushings in the following case: · When the sliding surface is damaged or abnormally worn. TR0806 Select and replace the snap ring from the following table if clearance is out of specification. Snap ring Parts No. 031319000 805019030 805019010 Thickness mm (in) 1. 50 (0. 059) 1. 60 (0. 062) 1. 72 (0. 068) Inspect the clearance again after replacing snap ring. 6MT-100 DRIVE PINION SHAFT ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 22. Drive Pinion Shaft Assembly A: REMOVAL 1) Remove the manual transmission assembly from vehicle. to 6MT-37, REMOVAL, Manual Transmission Assembly. > 2) Prepare the transmission for overhaul. to 6MT-42, Preparation for Overhaul. > 3) Remove the oil pipe, neutral position switch, back-up light switch and harness. to 6MT-45, REMOVAL, Back-up Light Switch. > 4) Remove the extension case. to 6MT-49, REMOVAL, Extension Case. > 5) Remove the transfer driven gear. to 6MT60, REMOVAL, Transfer Driven Gear. > 6) Remove the center differential. to 6MT68, REMOVAL, Transmission Case. > 9) Remove each gear assembly. to 6MT-73, REMOVAL, Main Shaft Assembly. > 10) Remove the drive pinion shaft assembly. 3) Install each gear assembly. to 6MT-74, INSTALLATION, Main Shaft Assembly. > 4) Install the transmission case. [. . . ] Outside Air Temperature Display COMBINATION METER Instrumentation/Driver Info 1. STi MODEL NF0592 (1) CHECK ENGINE warning light This light illuminates when a fault occurs in the MFI (Multiple point Fuel Injection) system. (2) Brake fluid level warning / parking brake indicator light This light illuminates when the fluid level in the brake reservoir tank lowers below the specified level and/or when the parking brake is applied. (3) AIRBAG system warning light This light illuminates when a fault occurs in the airbag system. [. . . ]