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. [. . . ] to 6MT68, REMOVAL, Transmission Case. > 9) Remove each gear assembly. to 6MT-73, REMOVAL, Main Shaft Assembly. > 10) Remove the drive pinion shaft assembly. to 6MT-101, REMOVAL, Drive Pinion Shaft Assembly. > 11) Remove the lock plates on both side. 12) Wrap vinyl tape around the spline part of axle shaft. B3M2085A (A) Vinyl tape 13) Using the ST, remove the axle shaft. ST1 499247300 INSTALLER ST2 499095500 REMOVER ASSY NOTE: · Do not reuse the circlip. · Mark to identify the right and left axle shaft. TR0819 (A) TR0818 (A) Lock plate 6MT-107 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 14) Using the ST, remove the differential side retainer on both side. ST1 499787000 WRENCH ASSY (RIGHT SIDE) ST2 18630AA000 WRENCH ASSY (LEFT SIDE) NOTE: Be careful not to damage the part of clutch case where the retainer is to be installed. (B) B: INSTALLATION 1) Install the differential assembly into clutch housing. 2) Apply oil to the threaded portion part of side retainer. 3) Remove the O-ring from side retainer of both side. 4) Using the ST, install the differential side retainer to both side. ST1 499787000 WRENCH ASSY (RIGHT SIDE) ST2 18630AA000 WRENCH ASSY (LEFT SIDE) NOTE: Be careful not to damage the oil seal. (B) (A) (A) TR0820 (A) Right side (B) Left side 15) Remove the front differential. TR0820 (A) Right side (B) Left side 5) Install the axle shaft. NOTE: · Replace the circlip with a new one. · Be careful not to confuse right and left axle shaft. · Wrap vinyl tape around the spline part of axle shaft. 6) Check and adjust the hypoid gear backlash. to 6MT-113, HYPOID GEAR BACKLASH, INSPECTION, Front Differential Assembly. > 7) Check and adjust the tooth contact. to 6MT-105, ADJUSTMENT, Drive Pinion Shaft Assembly. > 6MT-108 FRONT DIFFERENTIAL ASSEMBLY MANUAL TRANSMISSION AND DIFFERENTIAL 8) Mark an engagement point on the right and left side retainer and clutch housing. 14) Apply liquid gasket to the clutch housing. Liquid gasket: THREE BOND 1215 TR0828 9) Remove the differential side retainer from both side. NOTE: Note the rotating number of time till removal, when removing the side retainer. 10) Install a new O-ring to side retainer of both side. 11) Install the differential side retainer to both side. NOTE: Install the side retainer by screwing in the same rotating number of time till removal, and then align the mark. Tightening torque: 25 N·m (2. 5 kgf-m, 18. 1 ft-lb) NOTE: Be careful not to confuse right and left lock plate. TR0711 (A) (B) 15) Install the drive pinion shaft assembly. [. . . ] (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. (4) ABS warning light This light illuminates when a fault occurs in any electrical component of the ABS (Anti-lock Brake System). (5) Charge indicator light This light illuminates when a fault occurs in the charging system while the engine is running. [. . . ]