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Subaru Impreza 1996-2001 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Generations Covered: First Generation (GC/GF/GM) Years Covered: 1996, 1997, 1998, 1999, 2000, 2001 Codes Chassis Codes: GC (Sedan), GF (Wagon), GM (Coupe)...
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Type: Car
Vendor:
Sku: 482641
Subaru Impreza 1996-2001 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza
Generations Covered:
First Generation (GC/GF/GM)
Years Covered:
1996, 1997, 1998, 1999, 2000, 2001
Codes
Chassis Codes:
GC (Sedan), GF (Wagon), GM (Coupe)
👋 Introduction
Market Position
Segment:
Compact car, known for its all-wheel-drive capability and rally heritage.
Target Audience:
Enthusiasts, DIY mechanics, and Subaru owners seeking in-depth technical information.
Competitive Analysis
Competitors:
Mitsubishi Lancer, Honda Civic, Toyota Corolla, Ford Focus.
Key Features
Distinguishing Features:
Standard Symmetrical All-Wheel Drive (SAWD) across most trims, Boxer engine layout, sporty handling.
Performance Variants:
Includes information relevant to higher-performance models like the Impreza WRX (though specific WRX mechanicals might be detailed in a separate WRX supplement if released by Subaru).
📋 Manual Details
Coverage Areas
Coverage:
Complete factory service and repair for all systems of the 1996-2001 Subaru Impreza.
Page Count
Approximate Pages:
1000+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, inspection, repair, and reassembly procedures for all engines including EJ22, EJ25 SOHC, and EJ25 DOHC variants (non-turbo and turbo). Includes timing belt replacement, valve adjustments, piston ring installation, cylinder head resurfacing, and more.
Engine Performance:
Fuel injection system diagnostics and repair, ignition system testing, emissions control systems (catalytic converter, EGR, PCV), turbocharger system (if applicable), engine control module (ECM) troubleshooting, idle control.
Transmission Manual:
Service and repair of 5-speed manual transmissions (e.g., part numbers like TZ1A2ZZA for AWD). Includes clutch inspection and replacement, gear synchronization, shift linkage adjustment, bearing replacement.
Transmission Automatic:
Service and repair of 4-speed automatic transmissions (e.g., part numbers like TZ1A2ZYDA for AWD). Includes fluid changes, torque converter inspection, valve body diagnostics, solenoid testing, transmission control module (TCM) troubleshooting.
Drivetrain:
All-Wheel Drive (AWD) system service, center differential repair, front and rear differential service, driveshaft maintenance, CV axle inspection and replacement, wheel bearing replacement.
Suspension:
Front and rear suspension component inspection, replacement, and alignment specifications. Includes struts, shock absorbers, control arms, bushings, ball joints, tie rod ends, sway bars, and subframe service.
Brakes:
Hydraulic brake system diagnostics and repair, including master cylinder, brake lines, calipers, wheel cylinders, brake pads, and rotors. ABS system diagnostics and component testing. Parking brake adjustment and repair.
Steering:
Power steering system service, including pump, reservoir, lines, and rack and pinion assembly. Steering column components and alignment.
Body:
Body panel removal and installation, door mechanisms, window regulators, sunroof service, interior trim removal, bumper repair, and chassis component service.
Electrical System:
Complete wiring diagrams for all models and trim levels. Troubleshooting guides for starting and charging systems, lighting, instrument cluster, power windows, mirrors, remote keyless entry, and HVAC controls.
HVAC:
Air conditioning system service, refrigerant charging, compressor testing, blower motor, evaporator, condenser, heater core, and temperature control system diagnostics.
Safety Systems:
Airbag system diagnostics and service (SRS). Seat belt mechanisms and pretensioners.
Procedures Included
Preventative Maintenance:
Detailed service schedules, oil change procedures, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, transmission fluid changes, differential fluid changes, and brake fluid flushes.
Troubleshooting:
Comprehensive diagnostic flowcharts and symptom-based troubleshooting for common and uncommon issues across all vehicle systems.
Engine Repair:
Engine overhaul procedures, cylinder head removal/installation, piston and connecting rod installation, crankshaft installation, oil pump service, and timing component replacement.
Transmission Repair:
Manual and automatic transmission disassembly, component replacement, and reassembly. Clutch assembly replacement, flywheel resurfacing/replacement, and torque converter installation.
Brake Repair:
Brake caliper rebuilding, master cylinder replacement, brake line fabrication and installation, ABS sensor replacement, and brake bleeding procedures.
Electrical Diagnostics:
Wiring diagram interpretation, continuity testing, voltage drop testing, sensor testing, actuator testing, and ECM/PCM troubleshooting.
Body And Trim:
Door panel removal, seat removal, dashboard disassembly, bumper cover removal and installation, and weatherstripping replacement.
Wheel Alignment:
Complete wheel alignment specifications for camber, caster, toe, and thrust angle, along with adjustment procedures.
Technical Depth
Depth:
Comprehensive, from basic maintenance and fluid checks to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork.
Diagnostic Codes:
Includes On-Board Diagnostics (OBD-II) trouble codes (DTCs) and diagnostic strategies for early Impreza models.
Special Tools:
Identifies and describes the use of specific Subaru special tools required for various repair procedures.
📊 Manual Specifications
File Format
Format:
PDF
Searchable Text:
Yes
Printable:
Yes, printable pages
Print Quality
Quality:
High resolution, clear text and diagrams
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options:
2.2L EJ22 SOHC (approx. 135 hp), 2.5L EJ25 SOHC (approx. 165 hp), 2.5L EJ25 DOHC Turbocharged (WRX, approx. 227 hp).
Performance
Horsepower Range:
135 hp - 227 hp (depending on variant)
Torque Range:
140 lb-ft - 217 lb-ft (depending on variant)
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (91 octane recommended for turbo models)
Engine Layout
Layout:
Horizontally-opposed (Boxer)
Cooling System
Coolant Type:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant with corrosion inhibitors.
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission
Features
AWD System:
Symmetrical All-Wheel Drive (SAWD) standard on most models.
Fluid Specifications
Manual Transmission Fluid:
GL-5 75W-90 synthetic gear oil is commonly recommended. Check manual for specific Subaru part numbers.
Automatic Transmission Fluid:
Subaru ATF-HP or equivalent Dexron III/Mercon compatible fluid. Check manual for specific Subaru part numbers.
📐 Dimensions
Exterior
Body Styles:
2-door Coupe (GM), 4-door Sedan (GC), 4-door Wagon (GF)
Wheelbase:
Approx. 99.9 inches (2538 mm)
Length:
Sedan: Approx. 170.9 inches (4340 mm), Wagon: Approx. 174.5 inches (4433 mm)
Width:
Approx. 66.7 inches (1694 mm)
Height:
Sedan: Approx. 55.7 inches (1415 mm), Wagon: Approx. 57.7 inches (1466 mm)
Weights
Curb Weight Range:
Approx. 2,800 lbs - 3,200 lbs (1270 kg - 1451 kg), depending on body style and equipment.
Wheels And Tires
Bolt Pattern:
5 x 100mm
Typical Tire Sizes:
185/70R14, 195/60R15, 205/50R16, 215/40R17 (for WRX)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Likely 4-star rating (driver), 4-star rating (passenger) based on contemporary tests, but specific data for all configurations may vary. Consult NHTSA archives for precise data.
IIHS Side Impact:
Likely 'Acceptable' or 'Marginal' rating. Consult IIHS archives for specific data.
Active Features
ABS:
Anti-lock Braking System (ABS) available on higher trims or as an option.
Passive Features
Airbags:
Driver and front passenger airbags standard on most models.
Seatbelts:
3-point front and rear seatbelts, driver's pretensioner.
💡 Technology Features
Infotainment
Audio System:
Factory radio with CD player or cassette, often with 4 or 6 speakers. Upgrade options and wiring diagrams for aftermarket installations are covered.
Driver Assistance
Cruise Control:
Available on most models, troubleshooting and adjustment covered.
Connectivity
Keyless Entry:
Remote keyless entry system available on higher trims. Programming and troubleshooting are detailed.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6 months, depending on driving conditions and oil type used. Refer to the manual for precise intervals.
Timing Belt Replacement:
Crucial maintenance item. Typically recommended every 60,000 to 105,000 miles (96,000 to 168,000 km) or 5-7 years for EJ25 engines. EJ22 may use a timing chain or belt, check specific model. Refer to manual for exact interval and part numbers (e.g., timing belt kit often includes tensioner and idler pulleys).
Spark Plug Replacement:
Typically every 30,000 to 60,000 miles (48,000 to 96,000 km) depending on plug type (copper, platinum, iridium). Refer to manual for correct type and gap.
Fluid Specifications
Engine Oil Capacity:
4.5 US quarts (4.3 liters) with filter for 2.2L and 2.5L naturally aspirated. Turbo models may vary. Check manual for specific engine. Recommended oil: 5W-30 or 10W-30 synthetic blend or full synthetic.
Coolant Capacity:
Approx. 6.3 US quarts (6.0 liters) for models with automatic transmission, approx. 5.8 US quarts (5.5 liters) for manual. Check manual for specific capacity.
Brake Fluid Type:
DOT 3 or DOT 4 synthetic brake fluid.
Known Issues
Head Gaskets:
The EJ25 DOHC naturally aspirated engine (particularly early versions) is known for potential head gasket failures. Proper torque procedures and gasket types are critical during replacement. The manual provides torque specifications and service procedures.
O2 Sensors:
Oxygen sensor failure can lead to rough idling, poor fuel economy, and check engine lights. The manual details testing and replacement.
Cv Axles:
Front CV axle boots can tear, leading to premature wear of the CV joints. Inspection and replacement are covered.
Radiator:
Plastic end tanks on the radiator can become brittle and crack over time, leading to coolant leaks.
📚 Vehicle History
Brand Heritage
Brand Focus:
Subaru is renowned for its engineering, particularly its commitment to all-wheel drive and boxer engines.
Model Evolution
First Generation Launch:
The first generation Impreza (GC/GF/GM) was launched globally in late 1992, with North American introduction for the 1995 model year. The 1996-2001 covers the facelifted version of the first generation.
Facelifts:
The 1996 model year introduced a significant facelift, including updated styling (round headlights, new grille, bumpers) and mechanical revisions. Further minor updates occurred through the production run.
Production
Manufacturing Locations:
Primarily manufactured in Japan.
Rally Icon:
This generation of Impreza, especially the WRX variants, became iconic in the World Rally Championship (WRC), solidifying its sporty image.
🏆 Awards & Recognition
Recognitions
Import Car Of The Year:
While this specific generation might not have major individual awards, Subaru as a brand has consistently been recognized for reliability and AWD capability. The Impreza WRX platform is highly acclaimed for its performance credentials.
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