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Subaru Impreza 1996-2001 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Generation: First Generation (GC/GF) Model Years Covered: 1996, 1997, 1998, 1999, 2000, 2001 👋 Introduction Market Position Segment: Compact/Small family car, known for its rally heritage and AWD capabilities Competitive Analysis Competitors: Mitsubishi Lancer, Honda Civic, Toyota Corolla, Ford Focus Key Features Distinctive Features: Standard Symmetrical All-Wheel Drive (AWD) across most trims, boxer engine, sporty driving dynamics, rally-bred performance heritage Target Audience Intended Users: DIY mechanics, independent repair shops, Subaru enthusiasts 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine: Comprehensive coverage of all engine types (EJ15, EJ18, EJ20, EJ22, EJ25 - naturally aspirated and turbocharged variants) Transmission: Manual and automatic transmission systems, including removal, installation, and overhaul procedures Drivetrain: All-Wheel Drive (AWD) system components, including viscous couplings, differentials, and driveshafts Suspension: Front and rear suspension, including struts, springs, control arms, sway bars, and wheel bearings Brakes: Hydraulic brake system, including master cylinder, calipers, rotors, pads, lines, and ABS components Steering: Power steering system, including pump, rack and pinion, hoses, and fluid Electrical: Complete electrical system, including battery, alternator, starter, ignition, lighting, fuses, relays, and wiring diagrams Fuel System: Fuel delivery, including pump, filter, injectors, lines, and fuel tank Cooling System: Radiator, fan, thermostat, water pump, hoses, and coolant Exhaust System: Exhaust manifolds, catalytic converter, muffler, and piping HVAC: Heating, Ventilation, and Air Conditioning system components and service Body And Chassis: Body panel removal and installation, frame specifications, and interior trim Procedures Included Maintenance: Routine maintenance procedures such as oil changes, filter replacements, tune-ups, and fluid checks Troubleshooting: Diagnostic procedures and common problem-solving guides for various systems Repair: Detailed step-by-step repair instructions for all major vehicle components Overhaul: Engine and transmission overhaul procedures Alignment: Wheel alignment specifications and procedures Torque Specifications: Detailed torque specifications for all critical fasteners Wiring Diagrams: Comprehensive electrical wiring diagrams for all circuits Technical Depth Depth Level: Comprehensive from basic maintenance to complete engine and transmission rebuilds 📊 Manual Specifications File Format File Type: Likely PDF for digital distribution Searchability: Typically searchable text for quick information retrieval Printable: Designed to be printable for workshop use Page Count: Estimate 1000+ pages (typical for a comprehensive workshop manual) Print Quality Image Resolution: High-resolution for clear diagrams and illustrations Binding Type Binding: N/A (for digital format); If printed, typically comb or perfect bound Paper Type Paper Quality: N/A (for digital format); If printed, usually on durable, matte paper ⚙️ Engine Specifications Primary Engine Engine Options: EJ15 (1.5L), EJ18 (1.8L), EJ20 (2.0L, naturally aspirated and turbocharged), EJ22 (2.2L), EJ25 (2.5L, naturally aspirated and turbocharged SOHC/DOHC) Performance Typical Horsepower: Ranging from 95 hp (EJ15) to over 200 hp (WRX/STi variants) Typical Torque: Ranging from 90 lb-ft (EJ15) to over 200 lb-ft (WRX/STi variants) Fuel System Fuel Delivery: Multi-point fuel injection (MPI) and Electronic Fuel Injection (EFI) Engine Layout Layout: Horizontally-opposed (Boxer) 4-cylinder Engine Management ECM: Engine Control Module (ECM) with diagnostic trouble codes (DTCs) outlined in the manual 🔧 Transmission Standard Standard Transmission Type: 5-speed manual transmission (e.g., TZ1A2ZDCF) Optional Optional Transmission Type: 4-speed automatic transmission (e.g., TZ1A2ZC4) Features AWD System Integration: Active Torque Split All-Wheel Drive (ATS AWD) on manual transmissions; Continuous All-Wheel Drive (CAWD) on automatics Fluid Specifications Manual Transmission Fluid: API GL-5, SAE 75W-90 gear oil (e.g., Subaru Extra-S or equivalent) Automatic Transmission Fluid: Subaru ATF-HP (or Dexron III equivalent for earlier models) 📐 Dimensions Exterior Wheelbase: Approx. 99.9 inches (2535 mm) Length: Approx. 171.7 inches (4360 mm) Width: Approx. 66.7 inches (1695 mm) Height: Approx. 55.7 inches (1415 mm) Weights Curb Weight: Varies by model and trim, typically 2700-3100 lbs (1225-1400 kg) Gross Vehicle Weight Rating: Specifc to each model variant, detailed in manual 🛡️ Safety Features Ratings NHTSA Ratings: Varies by year and specific crash test; manual provides structural information Active Features ABS: Anti-lock Braking System (ABS) available on most models Passive Features Airbags: Driver and passenger front airbags Seatbelts: Three-point inertia-reel seatbelts Child Seat Anchors: LATCH (Lower Anchors and Tethers for CHildren) system not standard in this generation 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM stereo with cassette or CD player. Speaker configurations vary by trim. Climate Control: Manual or automatic climate control systems. Driver Assistance Cruise Control: Standard on most models. Traction Control: Available on select higher trims or later models. Connectivity Wiring Harnesses: Manual provides detailed diagrams for integrating aftermarket electronics (alarms, audio). 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions. Consult manual for specific recommendations. Spark Plug Replacement: Around 60,000-100,000 miles (96,000-160,000 km) depending on plug type (copper vs. platinum/iridium). Timing Belt Replacement: Crucial service around 90,000-105,000 miles (145,000-170,000 km) for EJ series engines due to interference design. Manual will specify exact interval and required components (belt,...
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Subaru Impreza 1996-2001 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza
Generation:
First Generation (GC/GF)
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001
👋 Introduction
Market Position
Segment:
Compact/Small family car, known for its rally heritage and AWD capabilities
Competitive Analysis
Competitors:
Mitsubishi Lancer, Honda Civic, Toyota Corolla, Ford Focus
Key Features
Distinctive Features:
Standard Symmetrical All-Wheel Drive (AWD) across most trims, boxer engine, sporty driving dynamics, rally-bred performance heritage
Target Audience
Intended Users:
DIY mechanics, independent repair shops, Subaru enthusiasts
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive coverage of all engine types (EJ15, EJ18, EJ20, EJ22, EJ25 - naturally aspirated and turbocharged variants)
Transmission:
Manual and automatic transmission systems, including removal, installation, and overhaul procedures
Drivetrain:
All-Wheel Drive (AWD) system components, including viscous couplings, differentials, and driveshafts
Suspension:
Front and rear suspension, including struts, springs, control arms, sway bars, and wheel bearings
Brakes:
Hydraulic brake system, including master cylinder, calipers, rotors, pads, lines, and ABS components
Steering:
Power steering system, including pump, rack and pinion, hoses, and fluid
Electrical:
Complete electrical system, including battery, alternator, starter, ignition, lighting, fuses, relays, and wiring diagrams
Fuel System:
Fuel delivery, including pump, filter, injectors, lines, and fuel tank
Cooling System:
Radiator, fan, thermostat, water pump, hoses, and coolant
Exhaust System:
Exhaust manifolds, catalytic converter, muffler, and piping
HVAC:
Heating, Ventilation, and Air Conditioning system components and service
Body And Chassis:
Body panel removal and installation, frame specifications, and interior trim
Procedures Included
Maintenance:
Routine maintenance procedures such as oil changes, filter replacements, tune-ups, and fluid checks
Troubleshooting:
Diagnostic procedures and common problem-solving guides for various systems
Repair:
Detailed step-by-step repair instructions for all major vehicle components
Overhaul:
Engine and transmission overhaul procedures
Alignment:
Wheel alignment specifications and procedures
Torque Specifications:
Detailed torque specifications for all critical fasteners
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all circuits
Technical Depth
Depth Level:
Comprehensive from basic maintenance to complete engine and transmission rebuilds
📊 Manual Specifications
File Format
File Type:
Likely PDF for digital distribution
Searchability:
Typically searchable text for quick information retrieval
Printable:
Designed to be printable for workshop use
Page Count:
Estimate 1000+ pages (typical for a comprehensive workshop manual)
Print Quality
Image Resolution:
High-resolution for clear diagrams and illustrations
Binding Type
Binding:
N/A (for digital format); If printed, typically comb or perfect bound
Paper Type
Paper Quality:
N/A (for digital format); If printed, usually on durable, matte paper
⚙️ Engine Specifications
Primary Engine
Engine Options:
EJ15 (1.5L), EJ18 (1.8L), EJ20 (2.0L, naturally aspirated and turbocharged), EJ22 (2.2L), EJ25 (2.5L, naturally aspirated and turbocharged SOHC/DOHC)
Performance
Typical Horsepower:
Ranging from 95 hp (EJ15) to over 200 hp (WRX/STi variants)
Typical Torque:
Ranging from 90 lb-ft (EJ15) to over 200 lb-ft (WRX/STi variants)
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) and Electronic Fuel Injection (EFI)
Engine Layout
Layout:
Horizontally-opposed (Boxer) 4-cylinder
Engine Management
ECM:
Engine Control Module (ECM) with diagnostic trouble codes (DTCs) outlined in the manual
🔧 Transmission
Standard
Standard Transmission Type:
5-speed manual transmission (e.g., TZ1A2ZDCF)
Optional
Optional Transmission Type:
4-speed automatic transmission (e.g., TZ1A2ZC4)
Features
AWD System Integration:
Active Torque Split All-Wheel Drive (ATS AWD) on manual transmissions; Continuous All-Wheel Drive (CAWD) on automatics
Fluid Specifications
Manual Transmission Fluid:
API GL-5, SAE 75W-90 gear oil (e.g., Subaru Extra-S or equivalent)
Automatic Transmission Fluid:
Subaru ATF-HP (or Dexron III equivalent for earlier models)
📐 Dimensions
Exterior
Wheelbase:
Approx. 99.9 inches (2535 mm)
Length:
Approx. 171.7 inches (4360 mm)
Width:
Approx. 66.7 inches (1695 mm)
Height:
Approx. 55.7 inches (1415 mm)
Weights
Curb Weight:
Varies by model and trim, typically 2700-3100 lbs (1225-1400 kg)
Gross Vehicle Weight Rating:
Specifc to each model variant, detailed in manual
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by year and specific crash test; manual provides structural information
Active Features
ABS:
Anti-lock Braking System (ABS) available on most models
Passive Features
Airbags:
Driver and passenger front airbags
Seatbelts:
Three-point inertia-reel seatbelts
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system not standard in this generation
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with cassette or CD player. Speaker configurations vary by trim.
Climate Control:
Manual or automatic climate control systems.
Driver Assistance
Cruise Control:
Standard on most models.
Traction Control:
Available on select higher trims or later models.
Connectivity
Wiring Harnesses:
Manual provides detailed diagrams for integrating aftermarket electronics (alarms, audio).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions. Consult manual for specific recommendations.
Spark Plug Replacement:
Around 60,000-100,000 miles (96,000-160,000 km) depending on plug type (copper vs. platinum/iridium).
Timing Belt Replacement:
Crucial service around 90,000-105,000 miles (145,000-170,000 km) for EJ series engines due to interference design. Manual will specify exact interval and required components (belt, tensioner, idlers, water pump).
Fluid Specifications
Engine Oil:
API SG or higher, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on ambient temperature). Capacity approx. 4.5-5.0 quarts with filter.
Coolant:
Subaru's Genuine Coolant (blue) or a compatible 50/50 mix of ethylene glycol and distilled water. Capacity approx. 6.0-7.0 quarts.
Brake Fluid:
DOT 3 or DOT 4.
Power Steering Fluid:
ATF or specific Subaru power steering fluid.
Known Issues
Head Gaskets:
Early EJ25 SOHC engines (pre-2000) were prone to head gasket failure. Manual will cover inspection and replacement procedures.
Oil Leaks:
Common oil leak points include valve cover gaskets and rear main seal. Manual provides torque specs and seal replacement guides.
Radiator:
Cracking plastic tanks on radiators can lead to leaks.
Clutch Wear:
Normal wear item; manual details replacement process for manual transmissions.
AWD System Maintenance:
Regular fluid changes for front and rear differentials and center viscous coupling are recommended. Manual will specify fluid types and intervals.
📚 Vehicle History
Brand Heritage
Subaru Heritage:
Subaru, part of Fuji Heavy Industries, known for its engineering prowess in aviation and its unique boxer engine and AWD technology
Model Evolution
Generation Introduction:
First generation (GC for coupe, GF for wagon, GM for sedan) launched globally in 1992, with this manual covering the mid-cycle updates and variants up to 2001.
Performance Variants:
Introduction of the high-performance WRX (World Rally eXperimental) and WRX STI (Special Tuning) models, which became icons of rally sport.
Production
Manufacturing Locations:
Primarily manufactured in Japan
🏆 Awards & Recognition
Recognitions
Rally Success:
Subaru Impreza WRX and WRX STI achieved significant success in the World Rally Championship (WRC), solidifying its performance image.
Car And Driver Ten Best:
Various Subaru models, including performance variants of the Impreza, have been recognized in automotive publications.
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