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 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...
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.