Subaru Impreza 1992-2001 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Generation: First Generation (GC/GF/GM) Codes Chassis Codes: GC (sedan), GF (wagon), GM (coupe - later models, but covered by this manual's range) Engine Codes: EJ15, EJ16, EJ18, EJ20, EJ22 👋 Introduction Market Position Segment: Compact Car / Rally Homologation Special Key Selling Points: Symmetrical All-Wheel Drive (standard on most North American models), Boxer engine, rally heritage, practical hatchback/sedan/wagon configurations. Competitive Analysis Key Competitors: Mitsubishi Lancer, Toyota Corolla, Honda Civic, Nissan Sentra. Key Features Platform Advantages: Low center of gravity due to Boxer engine and AWD system, excellent traction and stability. Performance Variants: GT, WRX (in some markets, though the iconic WRX became more prominent in later generations, the foundations were laid here). 📋 Manual Details Coverage Areas Covered Years: 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001 Covered Body Styles: Sedan (4-door), Wagon (5-door), Coupe (2-door - depending on market and year within the range) Covered Markets: Global (North America, Europe, Australia, Japan - covers common specifications) Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, disassembly, assembly, timing belt replacement, piston/ring inspection, cylinder head service, valve train, lubrication system, cooling system. Engine Performance: Fuel injection system, ignition system, emissions control systems (catalytic converter, EGR, EVAP), turbocharger (if applicable to specific models covered). Transmission Manual: Clutch system, gear selection mechanisms, internal components, fluid changes, overhaul procedures. Transmission Automatic: Torque converter, hydraulic control system, gear sets, valve body, fluid changes, troubleshooting. Drivetrain AWD: Front differential, rear differential, center differential (viscous coupling unit or mechanical), driveshafts, CV joints, propeller shaft, wheel hub bearings. Suspension Front: MacPherson strut system, control arms, stabilizer bar, ball joints, bushings, alignment specifications. Suspension Rear: Multi-link independent suspension (variations exist), trailing arms, coil springs, shock absorbers, bushings, alignment. Steering: Power steering system (pump, rack, hoses), steering column, tie rod ends, alignment. Brakes: Front and rear disc brakes, ABS system (if equipped), brake fluid specifications, bleeding procedures, caliper overhaul, rotor/pad replacement, parking brake. Electrical System: Battery, charging system (alternator, regulator), starting system (starter motor), lighting systems (headlights, taillights, interior), horn, wipers, power windows, power locks, fuse box diagrams, relay functions. Body Interior: Door panels, dashboard removal, seat removal, headliner, carpeting, interior trim components, HVAC controls. Body Exterior: Bumpers, fenders, hood, trunk lid, doors, glass replacement, weatherstripping, body panel alignment, rust repair techniques. HVAC: Air conditioning system (compressor, condenser, evaporator, refrigerant), heater core, blower motor, climate controls, ducting. Fuel System: Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, fuel tank, EVAP system components. Exhaust System: Exhaust manifold, catalytic converter, muffler, pipes, hangers, oxygen sensors. Emissions Control: EGR system, PCV system, EVAP system, secondary air injection (if applicable). Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid changes, differential fluid changes. Troubleshooting: Diagnostic procedures for common issues, symptom-based troubleshooting guides, electrical system diagnostics, engine performance problems. Engine Repair: Engine rebuilds, cylinder head gasket replacement, timing belt/chain replacement, piston/connecting rod assembly, crankshaft installation, oil pump service. Transmission Repair: Clutch replacement, manual transmission overhaul, automatic transmission rebuild, torque converter replacement. Brake Repair: Brake pad and rotor replacement, caliper overhaul, master cylinder replacement, ABS sensor replacement, brake line repair. Suspension Steering Repair: Control arm bushing replacement, ball joint replacement, tie rod end replacement, wheel bearing replacement, power steering pump replacement, steering rack replacement. Electrical Diagnostics: Wiring diagrams, component testing, short/open circuit diagnosis, sensor troubleshooting, ECU diagnostics (basic). Bodywork Repair: Panel replacement, dent repair, rust mitigation, glass installation, trim piece installation. Diagnostic Codes: OBD-I codes and their meanings (relevant to early 90s vehicles), common diagnostic trouble codes (DTCs). Technical Depth Depth: Comprehensive: Covers everything from basic owner maintenance to full engine and transmission rebuilds, complex electrical diagnostics, and bodywork. Detail Level: Detailed step-by-step instructions with torque specifications, special tool requirements, and clear diagrams. 📊 Manual Specifications File Format File Type: PDF Searchability: Yes, text-searchable Printable: Yes, printable pages Print Quality Image Resolution: High-resolution scans for clear diagrams and images. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Family: Subaru EJ Series Boxer Engine Displacement Common: 1.6L, 1.8L, 2.0L, 2.2L Engine Configuration: Horizontally-opposed (Boxer), Naturally Aspirated or Turbocharged Performance Horsepower Range: Approximately 95 hp (EJ16) to 215 hp (2.0L Turbo GT/WRX variants, depending on market). Torque Range: Approximately 90 lb-ft (EJ16) to 200 lb-ft (2.0L Turbo variants). Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPFI) Fuel Type: Unleaded Gasoline Technical Features DOHc Sohc: Both SOHC and DOHC variants exist depending on engine and trim. 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission Features Drivetrain...

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Tags: 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 Car Cars Impreza Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Impreza

Generation:

First Generation (GC/GF/GM)

Codes

Chassis Codes:

GC (sedan), GF (wagon), GM (coupe - later models, but covered by this manual's range)

Engine Codes:

EJ15, EJ16, EJ18, EJ20, EJ22

👋 Introduction

Market Position

Segment:

Compact Car / Rally Homologation Special

Key Selling Points:

Symmetrical All-Wheel Drive (standard on most North American models), Boxer engine, rally heritage, practical hatchback/sedan/wagon configurations.

Competitive Analysis

Key Competitors:

Mitsubishi Lancer, Toyota Corolla, Honda Civic, Nissan Sentra.

Key Features

Platform Advantages:

Low center of gravity due to Boxer engine and AWD system, excellent traction and stability.

Performance Variants:

GT, WRX (in some markets, though the iconic WRX became more prominent in later generations, the foundations were laid here).

📋 Manual Details

Coverage Areas

Covered Years:

1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001

Covered Body Styles:

Sedan (4-door), Wagon (5-door), Coupe (2-door - depending on market and year within the range)

Covered Markets:

Global (North America, Europe, Australia, Japan - covers common specifications)

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, disassembly, assembly, timing belt replacement, piston/ring inspection, cylinder head service, valve train, lubrication system, cooling system.

Engine Performance:

Fuel injection system, ignition system, emissions control systems (catalytic converter, EGR, EVAP), turbocharger (if applicable to specific models covered).

Transmission Manual:

Clutch system, gear selection mechanisms, internal components, fluid changes, overhaul procedures.

Transmission Automatic:

Torque converter, hydraulic control system, gear sets, valve body, fluid changes, troubleshooting.

Drivetrain AWD:

Front differential, rear differential, center differential (viscous coupling unit or mechanical), driveshafts, CV joints, propeller shaft, wheel hub bearings.

Suspension Front:

MacPherson strut system, control arms, stabilizer bar, ball joints, bushings, alignment specifications.

Suspension Rear:

Multi-link independent suspension (variations exist), trailing arms, coil springs, shock absorbers, bushings, alignment.

Steering:

Power steering system (pump, rack, hoses), steering column, tie rod ends, alignment.

Brakes:

Front and rear disc brakes, ABS system (if equipped), brake fluid specifications, bleeding procedures, caliper overhaul, rotor/pad replacement, parking brake.

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor), lighting systems (headlights, taillights, interior), horn, wipers, power windows, power locks, fuse box diagrams, relay functions.

Body Interior:

Door panels, dashboard removal, seat removal, headliner, carpeting, interior trim components, HVAC controls.

Body Exterior:

Bumpers, fenders, hood, trunk lid, doors, glass replacement, weatherstripping, body panel alignment, rust repair techniques.

HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant), heater core, blower motor, climate controls, ducting.

Fuel System:

Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, fuel tank, EVAP system components.

Exhaust System:

Exhaust manifold, catalytic converter, muffler, pipes, hangers, oxygen sensors.

Emissions Control:

EGR system, PCV system, EVAP system, secondary air injection (if applicable).

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement, coolant flush, brake fluid flush, transmission fluid changes, differential fluid changes.

Troubleshooting:

Diagnostic procedures for common issues, symptom-based troubleshooting guides, electrical system diagnostics, engine performance problems.

Engine Repair:

Engine rebuilds, cylinder head gasket replacement, timing belt/chain replacement, piston/connecting rod assembly, crankshaft installation, oil pump service.

Transmission Repair:

Clutch replacement, manual transmission overhaul, automatic transmission rebuild, torque converter replacement.

Brake Repair:

Brake pad and rotor replacement, caliper overhaul, master cylinder replacement, ABS sensor replacement, brake line repair.

Suspension Steering Repair:

Control arm bushing replacement, ball joint replacement, tie rod end replacement, wheel bearing replacement, power steering pump replacement, steering rack replacement.

Electrical Diagnostics:

Wiring diagrams, component testing, short/open circuit diagnosis, sensor troubleshooting, ECU diagnostics (basic).

Bodywork Repair:

Panel replacement, dent repair, rust mitigation, glass installation, trim piece installation.

Diagnostic Codes:

OBD-I codes and their meanings (relevant to early 90s vehicles), common diagnostic trouble codes (DTCs).

Technical Depth

Depth:

Comprehensive: Covers everything from basic owner maintenance to full engine and transmission rebuilds, complex electrical diagnostics, and bodywork.

Detail Level:

Detailed step-by-step instructions with torque specifications, special tool requirements, and clear diagrams.

📊 Manual Specifications

File Format

File Type:

Searchability:

Yes, text-searchable

Printable:

Yes, printable pages

Print Quality

Image Resolution:

High-resolution scans for clear diagrams and images.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Family:

Subaru EJ Series Boxer

Engine Displacement Common:

1.6L, 1.8L, 2.0L, 2.2L

Engine Configuration:

Horizontally-opposed (Boxer), Naturally Aspirated or Turbocharged

Performance

Horsepower Range:

Approximately 95 hp (EJ16) to 215 hp (2.0L Turbo GT/WRX variants, depending on market).

Torque Range:

Approximately 90 lb-ft (EJ16) to 200 lb-ft (2.0L Turbo variants).

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPFI)

Fuel Type:

Unleaded Gasoline

Technical Features

DOHc Sohc:

Both SOHC and DOHC variants exist depending on engine and trim.

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Optional

Transmission Type Optional:

4-Speed Automatic Transmission

Features

Drivetrain Options:

Symmetrical All-Wheel Drive (Standard on many models), Front-Wheel Drive (less common in North America).

Fluid Specs

Manual Transmission Fluid:

API GL-5, SAE 75W-90 (refer to manual for exact specification for specific transmissions).

Automatic Transmission Fluid:

Subaru ATF-HP or equivalent (check manual for exact spec, often Dexron II/III compatible but specific Subaru fluid recommended).

📐 Dimensions

Exterior

Length Sedan:

Approx. 4,340 mm (170.9 in)

Length Wagon:

Approx. 4,350 mm (171.3 in)

Width:

Approx. 1,690 mm (66.5 in)

Height Sedan:

Approx. 1,390 mm (54.7 in)

Height Wagon:

Approx. 1,415 mm (55.7 in)

Wheelbase:

Approx. 2,520 mm (99.2 in)

Weights

Curb Weight Range:

Approx. 1,200 kg - 1,400 kg (2,645 lbs - 3,086 lbs) depending on configuration.

Wheel Bolt Pattern:

5x100mm

Tire Sizes Common:

185/70R14, 195/60R15, 205/50R16 (higher performance variants)

🛡️ Safety Features

Ratings

NHTSA Ratings Early:

No specific ratings readily available for this early generation by modern standards. Focus on structural integrity of the time.

Active Features

Optional on many models, standard on higher trims/performance variants.

Passive Features

Airbags:

Driver airbag standard, Passenger airbag optional/standard on later models/trims.

Seatbelts:

3-point front and rear seatbelts.

💡 Technology Features

Infotainment

Head Unit:

Factory fitted radio/cassette player or CD player depending on trim and year. Basic analog displays.

Driver Assistance

Anti-lock Braking System (optional/standard based on model/year).

Connectivity

Aux Input:

Rarely standard; often aftermarket head unit installation required for auxiliary or USB connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 - 7,500 miles (6,000 - 12,000 km) or 6 months, depending on driving conditions and oil type (consult manual).

Timing Belt Replacement:

Every 60,000 - 100,000 miles (100,000 - 160,000 km) or 4-5 years, critical for interference engines (refer to specific engine code in manual).

Spark Plug Replacement:

Every 30,000 - 60,000 miles (50,000 - 100,000 km) depending on spark plug type (copper vs. platinum/iridium).

Fluid Specifications

Engine Oil Viscosity:

Commonly 5W-30, 5W-40, or 10W-30 depending on climate and specific engine variant (API SG/SH or later).

Coolant Type:

Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Subaru Super Coolant recommended for later Subaru vehicles, but for this era, standard green coolant is often used. Verify with manual.

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Head Gaskets:

While less prone than some later generations, early EJ22 and EJ25 engines could experience head gasket failures. The EJ20 and EJ18 are generally more robust.

Clutch Wear:

Can wear prematurely with aggressive driving or heavy use, particularly on AWD models.

Turbo Issues:

For turbocharged models (GT, WRX variants), proper maintenance and avoiding heat soak are crucial to turbo longevity. Turbo seals and wastegate issues can occur.

Awt Differential Fluid:

Regularly changing the viscous coupling unit fluid is essential for AWD system health.

Electrical Gremlins:

Aging wiring harnesses and grounds can lead to intermittent electrical issues over time.

📚 Vehicle History

Brand Heritage

Subaru Legacy:

Built upon the rally-winning heritage of Subaru, inheriting the AWD and Boxer engine DNA from models like the Leone and Legacy.

Model Evolution

Launch Year:

Facelifts:

Significant facelift occurred in 1997 (GF8B/GDBA), introducing updated styling and improved chassis.

Rally Origins:

The Impreza became the platform for Subaru's highly successful World Rally Championship (WRC) campaigns, significantly boosting its performance image.

Production

Manufacturing Locations:

Japan (Main production)

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Impreza WRX (though more prominent in the next generation) cemented Subaru's reputation, and the early models laid the groundwork for this recognition, with the base Impreza often featuring on 'best value' lists.

Ratings

Reliability Perception:

Generally good, particularly for naturally aspirated, non-turbocharged AWD models. Turbocharged models require more diligent maintenance.