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SUBARU IMPREZA WRX 1999 2000 Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX Generation: GC8 Model Years Covered: 1999, 2000 Codes Chassis Code: GC8, GF8 (Wagon) Engine Code Primary: EJ20G (2.0L Turbocharged Flat-4) Engine...
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SUBARU IMPREZA WRX 1999 2000 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza WRX
Generation:
GC8
Model Years Covered:
1999, 2000
Codes
Chassis Code:
GC8, GF8 (Wagon)
Engine Code Primary:
EJ20G (2.0L Turbocharged Flat-4)
Engine Code Alternative:
EJ20K, EJ207 (early JDM variants)
👋 Introduction
Market Position
Segment:
Performance Compact Sedan/Wagon (Rally Homologation Special)
Target Audience:
Enthusiasts, motorsport participants, Subaru owners seeking in-depth maintenance and repair knowledge.
Competitive Analysis
Competitors:
Mitsubishi Lancer Evolution, Ford Escort RS Cosworth, Toyota Celica GT-Four.
Unique Selling Points:
Subaru's renowned Symmetrical All-Wheel Drive system, turbocharged boxer engine, rally-bred heritage, and robust chassis.
Key Features
Performance Orientation:
Tuned for performance with emphasis on engine tuning, drivetrain, and suspension dynamics.
AWD System:
Advanced Symmetrical AWD with viscous coupling center differential (VC Diff) and open front/rear differentials, or optional limited-slip differentials.
📋 Manual Details
Coverage Areas
Primary Focus:
Service and Repair
Regional Coverage:
Global (Primarily North American and Japanese Market Specifications)
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair procedures for the EJ20G/EJ20K engine, including cylinder heads, pistons, crankshaft, camshafts, timing belt, oil pump, lubrication system.
Engine Management:
ECU pinouts, sensor diagnostics (MAP, TPS, O2, etc.), fuel injection system (injectors, fuel pump, pressure regulator), ignition system (coils, spark plugs, timing), emission control systems (EVAP, EGR).
Transmission Manual:
Disassembly, assembly, inspection, and repair of the 5-speed manual transmission (e.g., TY754 series), including clutch, gears, synchronizers, shift forks, and bearings.
Transmission Automatic:
If applicable to specific trims, coverage for automatic transmission diagnostics and repair.
Drivetrain AWD:
Detailed information on the Subaru Symmetrical All-Wheel Drive system, including center differential, front and rear differentials, drive shafts, and hubs.
Suspension:
Front and rear suspension component inspection, replacement, and alignment procedures. Includes struts, springs, control arms, sway bars, bushings, and wheel bearings.
Brakes:
Front and rear brake system diagnosis, repair, and maintenance. Includes disc brake pads, rotors, calipers, master cylinder, brake lines, ABS system (if equipped), and parking brake.
Steering:
Power steering system diagnosis and repair, including pump, rack and pinion, tie rods, and steering column.
Electrical System:
Comprehensive wiring diagrams, fuse box layouts, component testing, starting and charging system, lighting systems, instrument cluster, wipers, and power accessories.
Body Interior:
Body panel removal and installation, door mechanisms, interior trim components, seats, dashboard removal, HVAC system, and door lock actuators.
Cooling System:
Radiator, thermostat, water pump, cooling fan, and heater core diagnosis and service.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, and fuel pressure regulation.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, air filter service, belt inspections.
Troubleshooting:
Diagnostic flowcharts for common drivability issues, electrical faults, and mechanical problems.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls.
Component Replacement:
Step-by-step instructions for replacing virtually any component on the vehicle.
Diagnostics:
Testing procedures for sensors, actuators, electrical circuits, and mechanical systems using appropriate tools and specifications.
Specifications And Tolerances:
Precise measurements, torque values, clearances, and tolerances for all serviced components.
Technical Depth
Depth:
Comprehensive, factory-level detail suitable for professional technicians and experienced DIY mechanics. Covers everything from basic maintenance to complete engine and transmission rebuilds.
Diagnostic Codes:
Coverage of OBD-I/OBD-II diagnostic trouble codes (DTCs) and their interpretation for the relevant model years.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable, enabling quick location of specific topics.
Print Quality
Resolution:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.
Illustrations:
Profusely illustrated with clear, detailed diagrams, schematics, and exploded views.
Binding Type
Binding Original:
N/A (Digital Format)
Paper Type
Paper Original:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Horizontally-opposed (Boxer), turbocharged, intercooled, DOHC
Displacement:
1994 cc (2.0 Liters)
Bore X Stroke:
92.0 mm x 75.0 mm
Compression Ratio:
8.0:1
Horsepower Est:
215-276 hp (Varies by region and specific model designation, e.g., WRX STI)
Torque Est:
208-250 lb-ft (Varies by region and specific model designation)
Performance
Turbocharger Type:
TD04-13G (JDM), TD04H-13G (USDM) or similar
Intercooler:
Top-mount, air-to-air intercooler
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI)
Fuel Type:
Unleaded premium gasoline (91 octane or higher recommended)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission
Optional
Transmission Type:
4-speed Automatic Transmission (less common on WRX models, more on standard Impreza)
Features
AWD Coupling:
Viscous Center Differential (VCD) in conjunction with the manual transmission.
Clutch Type:
Hydraulically actuated, single-plate dry-type
📐 Dimensions
Exterior
Length:
Approx. 4,340 - 4,405 mm (Sedan/Wagon)
Width:
Approx. 1,690 - 1,715 mm
Height:
Approx. 1,400 - 1,445 mm
Wheelbase:
Approx. 2,515 mm
Track Width Front:
Approx. 1,460 mm
Track Width Rear:
Approx. 1,450 mm
Weights
Curb Weight:
Approx. 1,280 - 1,340 kg
Gross Vehicle Weight:
Approx. 1,700 - 1,750 kg
🛡️ Safety Features
Ratings
NHTSA Rating:
Not extensively rated by NHTSA for these specific model years by modern standards. Focus on structural integrity and driver control.
Active Features
ABS:
Anti-lock Braking System (ABS) - often standard on WRX models.
AWD:
Symmetrical All-Wheel Drive provides enhanced traction and stability.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Three-point inertia-reel seatbelts with pre-tensioners for front seats.
Chassis Design:
Reinforced unibody construction, designed for rally homologation.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player (early models) or cassette player. Aftermarket upgrades are common.
Driver Assistance
Traction Control:
Limited or no advanced driver-assistance systems (ADAS) typically found in modern vehicles. Primary safety relies on the AWD system and driver skill.
Connectivity
Connectivity Features:
Basic vehicle connectivity, primarily focused on the internal systems. No modern Bluetooth or smartphone integration from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles or 6 months, depending on driving conditions. Performance driving may necessitate more frequent changes.
Timing Belt Replacement:
Recommended every 60,000-90,000 miles or 5-7 years due to the interference nature of the EJ20 engine. Critical maintenance item.
Spark Plug Replacement:
Approximately every 30,000-60,000 miles (depending on plug type).
Fluid Specifications
Engine Oil:
API SG or higher, SAE 5W-30 or 10W-30 (refer to manual for specific climate/usage recommendations). Synthetic oil highly recommended for performance applications.
Coolant:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 gear oil. Subaru Extra-S or equivalent is often recommended.
Differential Fluid Front Rear:
API GL-5, SAE 80W-90 gear oil.
Power Steering Fluid:
Subaru Genuine Power Steering Fluid or Dexron III/Mercon ATF.
Known Issues
Ring Land Failure:
A known potential issue with EJ20 engines, particularly when subjected to aggressive tuning or poor maintenance. Proper fuel, spark, and boost control are critical.
Head Gasket Leaks:
While more prevalent in later EJ25 engines, older EJ20s can also experience head gasket issues, especially if overheated.
Turbocharger Wear:
Like any turbocharged engine, the turbocharger is subject to wear and requires proper lubrication and cooling. Regular oil changes are vital.
Suspension Bushings:
Rubber suspension bushings can degrade over time, leading to a less precise feel and potential noise issues.
📚 Vehicle History
Brand Heritage
Subaru Rally Heritage:
Subaru's extensive history and success in the World Rally Championship (WRC) heavily influenced the development and appeal of the Impreza WRX.
Model Evolution
Gc8 Generation Introduction:
The GC8 generation (1992-2000) marked Subaru's entry into the performance compact segment, with the WRX variant launched in 1992 in Japan and later introduced to other markets.
Year Specific Updates 1999 2000:
These model years represent later iterations of the GC8 chassis, often featuring engine upgrades (e.g., EJ20G to EJ20K), revised suspension tuning, and minor cosmetic updates compared to earlier models.
Production
Manufacturing Locations:
Primarily manufactured in Japan (Gunma Prefecture).
🏆 Awards & Recognition
Recognitions
Rally Pedigree:
The Impreza WRX (and its STI sibling) are icons in the motorsport world, with a formidable WRC record, contributing to its enthusiast appeal.
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