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1996-2007 Subaru Impreza Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Generations Covered: Second Generation (GD/GG) Model Years Covered: 1996-2007 Chassis Codes: GD (Sedan), GG (Wagon) 👋 Introduction Market Position Model Segment: Compact/Small...
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Type: Car
Vendor:
Sku: 364854
1996-2007 Subaru Impreza Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza
Generations Covered:
Second Generation (GD/GG)
Model Years Covered:
1996-2007
Chassis Codes:
GD (Sedan), GG (Wagon)
👋 Introduction
Market Position
Model Segment:
Compact/Small Family Car
Brand Identity:
Known for its Symmetrical All-Wheel Drive (SAWD) system and rally heritage.
Competitive Analysis
Key Competitors:
Honda Civic, Toyota Corolla, Mitsubishi Lancer, Mazda3.
Key Features
Performance Variants:
Includes information for performance models like the WRX and WRX STI.
All Wheel Drive:
Extensive coverage of Subaru's Symmetrical All-Wheel Drive system.
Turbocharged Engines:
Detailed sections on turbocharged engine maintenance and performance tuning considerations.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Digital (PDF)
Approximate Page Count:
3000+
Primary Geographic Market:
Global (North America, Europe, Asia, Australia)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul, diagnosis, timing belt replacement, component testing (EJ20, EJ25 series engines).
Engine Management:
ECU diagnostics, sensor testing, fuel injection, ignition system, emissions control systems.
Transmission Manual:
Overhaul, clutch replacement, gearbox diagnostics, fluid specifications, shift mechanism.
Transmission Automatic:
Overhaul, torque converter, valve body, electronic controls, fluid specifications.
All Wheel Drive System:
Center differential, front and rear differentials, viscous coupling unit (VCU) diagnostics and servicing.
Suspension System:
Front and rear suspension components, strut replacement, alignment specifications, bushing services.
Braking System:
Front and rear brake caliper service, rotor replacement, ABS system diagnostics, brake fluid specifications.
Steering System:
Power steering pump, rack and pinion repair, tie rod ends, steering column components.
Electrical System:
Wiring diagrams, starter, alternator, battery, lighting, fuses, relays, body control modules (BCM).
HVAC System:
Air conditioning system service, heater core replacement, blower motor, climate control diagnostics.
Body And Interior:
Panel removal/installation, door mechanisms, seat adjustments, dashboard components.
Safety Systems:
Airbag system servicing and diagnostics, seat belt mechanisms.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections.
Diagnostic Procedures:
Troubleshooting guides for common drivability issues, electrical faults, and mechanical failures using symptom-based approaches.
Repair Procedures:
Step-by-step instructions for component replacement and repair, including engine rebuilds, transmission overhauls, and suspension upgrades.
Component Disassembly Assembly:
Detailed instructions for taking apart and reassembling major vehicle components.
Torque Specifications:
Comprehensive list of torque values for critical fasteners across all systems.
Technical Depth
Depth Of Information:
Factory-level detail, suitable for professional technicians and advanced DIY enthusiasts.
Diagnostic Tools:
Information on using Subaru Select Monitor (SSM) and OBD-II scanners for advanced diagnostics.
Wiring Diagrams:
Detailed, system-specific wiring schematics for all electrical components.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval.
Printability:
Printable pages for on-the-go reference.
Print Quality
Image Resolution:
High-resolution images, diagrams, and illustrations.
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Quality:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code Family:
EJ Series (EJ20, EJ25)
Naturally Aspirated Engines:
2.5L (EJ253, EJ254), 2.0L (EJ201, EJ202, EJ203)
Turbocharged Engines:
2.0L Turbo (EJ205), 2.5L Turbo (EJ255, EJ257)
Performance
Horsepower Range:
120 hp to 300+ hp (depending on model and trim)
Torque Range:
137 lb-ft to 300+ lb-ft (depending on model and trim)
Fuel System
Fuel Injection:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane recommended for naturally aspirated, 91+ octane for turbocharged models)
Timing Belt
Timing Belt Replacement Interval:
Typically every 105,000 miles or 105 months, whichever comes first (consult manual for specific engine).
Engine Oil
Engine Oil Type:
Synthetic blend or full synthetic (e.g., SAE 5W-30 or 5W-40, depending on climate and engine)
🔧 Transmission
Standard
Transmission Types:
5-speed manual, 4-speed automatic
Optional
Performance Transmissions:
6-speed manual (on certain WRX/STI models)
Features
All Wheel Drive Coupling:
Symmetrical All-Wheel Drive (SAWD) with viscous coupling (VCU) or mechanical center differential on performance models.
Fluid Specifications
Manual Transmission Fluid:
Subaru Extra-S Gear Oil (or equivalent API GL-5) - check manual for specific viscosity.
Automatic Transmission Fluid:
Subaru ATF-HP (or equivalent DEXRON III/MERCON compatible fluid)
📐 Dimensions
Exterior
Body Styles:
4-door Sedan, 5-door Wagon
Wheelbase Approx:
2515 mm (99.0 inches)
Length Approx:
4415 mm (173.8 inches) Sedan / 4465 mm (175.8 inches) Wagon
Width Approx:
1700 mm (66.9 inches)
Height Approx:
1420 mm (55.9 inches) Sedan / 1445 mm (56.9 inches) Wagon
Weights
Curb Weight Range:
1300 - 1550 kg (approx. 2866 - 3417 lbs)
Gross Vehicle Weight Rating:
Varies by model and configuration, specified in vehicle registration documents.
Wheels Tires
Wheel Bolt Pattern:
5x100 mm
Standard Tire Sizes:
205/50R16, 205/55R16, 215/40R17, 225/45R17 (varies by trim)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by model year and specific test; generally good for its era, with improvements in later years.
IIHS Ratings:
Varies by model year and specific test.
Active Features
Active Safety:
Symmetrical All-Wheel Drive (standard), ABS (standard on most trims).
Passive Features
Passive Safety:
Front airbags, side airbags (optional on some models), three-point seat belts, reinforced safety cell construction.
💡 Technology Features
Infotainment
Infotainment Systems:
Basic AM/FM/CD stereos, optional premium audio systems, cassette players in earlier models.
Driver Assistance
Driver Assistance Features:
Limited to ABS and standard safety features of the era. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.
Connectivity
Connectivity Options:
Basic auxiliary inputs available on later models, no Bluetooth or USB connectivity from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 - 7,500 miles or 6 months, depending on driving conditions and oil type used (refer to owner's manual).
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspection.
Cabin Air Filter Replacement:
Every 15,000 - 20,000 miles or annually.
Brake Fluid Flush:
Every 30,000 miles or 2-3 years.
Coolant Flush:
Every 30,000 miles or 2-3 years with Subaru Super Coolant.
Fluid Specifications
Power Steering Fluid:
Subaru recommends genuine Subaru power steering fluid or Dexron III equivalent.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Head Gaskets:
Premature head gasket failure is a common issue on EJ25 SOHC and DOHC engines, especially those not updated with revised designs. Manual covers inspection and replacement procedures.
Oil Consumption:
Some EJ25 engines may experience higher than normal oil consumption, requiring regular checks and top-offs. Manual provides diagnostic steps.
Clutch Wear:
Clutch wear can be accelerated with spirited driving or performance modifications. Manual covers clutch inspection and replacement.
Turbocharger Issues:
Turbocharger failure can occur due to oil starvation or improper warm-up/cool-down cycles on turbocharged models. Manual details inspection and maintenance.
Viscous Coupling Failure:
The VCU in the center differential can fail over time, affecting AWD performance. Manual provides diagnostic procedures for the AWD system.
📚 Vehicle History
Brand Heritage
Subaru Origins:
Founded in 1953, known for its pioneering use of the boxer engine and Symmetrical All-Wheel Drive.
Model Evolution
First Generation:
GC/GF chassis (1992-2000), established the Impreza as a capable compact car with rally roots.
Second Generation:
GD/GG chassis (2000-2007), introduced a more rounded styling, revised chassis, and advanced AWD systems. The WRX and WRX STI variants gained significant global popularity during this generation.
Production
Manufacturing Locations:
Mainly Japan (Gunma Prefecture), with some assembly in other regions for specific markets.
Rally Dominance:
The Impreza WRX STI achieved significant success in the World Rally Championship (WRC) during the late 1990s and early 2000s, boosting the model's performance image.
🏆 Awards & Recognition
Recognitions
Car And Driver 10 Best:
Various Impreza models, particularly WRX variants, have been recognized by Car and Driver's '10 Best' list for their performance and handling.
IIHS Top Safety Pick:
Specific model years and configurations may have received 'Good' or 'Acceptable' ratings, contributing to its safety reputation.
Certifications
Performance Badges:
WRX and WRX STI models are iconic in the performance car segment, often benchmarked against competitors.
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