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Subaru Impreza 2004 (gasoline) WRX STI Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Year: 2004 Trim Level: WRX STI Engine Type: Gasoline Codes Chassis Code: GDB Engine Code: EJ257 👋 Introduction Market Position Segment: Compact Performance Sedan/Hatchback Target Audience: Enthusiast drivers, DIY mechanics, Subaru WRX STI owners Competitive Analysis Competitors: Mitsubishi Lancer Evolution, Ford Focus RS, Volkswagen Golf GTI Key Features Performance Focus: Tuned for high performance, rally heritage All Wheel Drive: Symmetrical All-Wheel Drive system 📋 Manual Details Coverage Areas Primary Coverage: Factory Service Repair Included Sections: Engine, Drivetrain, Chassis, Electrical, Body, HVAC, Maintenance, Troubleshooting Page Count Estimated Pages: Approximately 2000+ Manual Type Type: Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Management: Fuel injection, ignition, emissions control, ECU diagnostics Drivetrain: All-Wheel Drive (AWD) system, differentials, driveshafts, clutch, gearbox Suspension Steering: Front and rear suspension, struts, springs, anti-roll bars, steering rack Brakes: Brake system hydraulics, ABS, rotors, pads, calipers, parking brake Electrical: Wiring diagrams, lighting, power distribution, charging system, starting system, accessories Body Interior: Body panels, doors, windows, seats, interior trim, HVAC system Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, tune-ups, spark plug replacement Diagnostics Troubleshooting: Symptom-based troubleshooting guides, diagnostic trouble codes (DTCs) Repairs: Engine component overhaul, transmission rebuild, brake system repair, suspension component replacement Assembly Disassembly: Detailed steps for removing and installing major components Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds Diagnostic Tools: Includes information for using Subaru Select Monitor (SSM) or equivalent OBD-II scanners 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval Print Quality Quality: High-resolution scans with clear diagrams Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Name: 2.5L Turbocharged Boxer (EJ257) Engine Configuration: Flat-four (Boxer) Displacement: 2457 cc Bore X Stroke: 99.5 mm x 79.0 mm Compression Ratio: 8.0:1 Performance Horsepower Us Spec: 300 hp @ 6000 rpm Torque Us Spec: 300 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI), Sequential Turbocharging Fuel Type: Unleaded Premium (91 octane or higher recommended) Turbocharger Turbocharger Type: Twin-scroll IHI VF39 Intercooler Intercooler Type: Top-mount Air-to-Air 🔧 Transmission Standard Transmission Type: 6-speed Manual Gear Ratios: 1st: 3.600, 2nd: 2.275, 3rd: 1.609, 4th: 1.212, 5th: 0.953, 6th: 0.777, Reverse: 3.500 Optional Transmission Type: N/A for WRX STI model Features Center Differential: Viscous coupling limited-slip center differential Rear Differential: Helical limited-slip rear differential Fluid Type Transmission Fluid: API GL-5, SAE 75W-90 synthetic gear oil 📐 Dimensions Exterior Wheelbase: 103.7 inches (2634 mm) Length: 173.8 inches (4415 mm) Width: 68.3 inches (1735 mm) Height: 56.1 inches (1425 mm) Ground Clearance: 5.5 inches (140 mm) Weights Curb Weight: Approx. 3263 lbs (1480 kg) Wheels Tires Wheel Size: 17 x 7.5 inch alloy Tire Size: 225/45R17 Bolt Pattern: 5x114.3 mm (5x4.5 inches) 🛡️ Safety Features Ratings NHTSA Frontal Driver: 5-star NHTSA Frontal Passenger: 5-star IIHS Front Crash Rating: Good IIHS Side Impact Rating: Acceptable Active Features ABS: Standard Anti-lock Braking System (4-wheel disc) Traction Control: Standard Stability Control: Subaru Vehicle Dynamics Control (VDC) - Standard Passive Features Airbags: Front dual-stage airbags, front side-impact airbags Seatbelts: 3-point front and rear seatbelts with pretensioners 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with 4-6 speakers (upgradeable) Climate Control: Manual or Automatic Climate Control (depending on trim) Driver Assistance Cruise Control: Standard Connectivity Aux Input: N/A (optional accessory or aftermarket modification) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe duty) Engine Oil Type: API SJ or SL, ILSAC GF-3, SAE 10W-30 synthetic recommended (check owner's manual for specific viscosity) Oil Filter Part Number: Subaru 15208AA031 (example, always verify) Spark Plug Replacement: Every 30,000 miles (48,000 km) Timing Belt Replacement: Not Applicable (EJ257 uses a timing chain) Fluid Specifications Coolant Type: Subaru Super Coolant (or equivalent silicate-free, ethylene glycol based coolant) - Blue Brake Fluid Type: DOT 3 or DOT 4 Fluid Capacities Engine Oil Capacity: 4.8 US quarts (4.5 liters) with filter change Known Issues Common Issue 1: Head gasket leaks (though less prevalent on EJ257 than earlier EJ25s) Common Issue 2: Turbocharger failure (often due to poor oil maintenance or hard driving) Common Issue 3: Clutch wear and failure (especially with aggressive driving) Common Issue 4: Catalytic converter failure (can be heat-related) 📚 Vehicle History Brand Heritage Brand Focus: All-wheel drive, rally racing, practical performance vehicles Model Evolution Generation: GD/GG (2000-2007) Updates 2004: Mid-generation refresh including revised styling, updated suspension tuning, and improved interior. Production Production Location: Gunma Prefecture, Japan 🏆 Awards & Recognition Recognitions Performance Awards: Consistently praised by automotive journalists for its performance and handling Rally Heritage: Strong association with World Rally Championship (WRC) success
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Subaru Impreza 2004 (gasoline) WRX STI Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza
Year:
2004
Trim Level:
WRX STI
Engine Type:
Gasoline
Codes
Chassis Code:
GDB
Engine Code:
EJ257
👋 Introduction
Market Position
Segment:
Compact Performance Sedan/Hatchback
Target Audience:
Enthusiast drivers, DIY mechanics, Subaru WRX STI owners
Competitive Analysis
Competitors:
Mitsubishi Lancer Evolution, Ford Focus RS, Volkswagen Golf GTI
Key Features
Performance Focus:
Tuned for high performance, rally heritage
All Wheel Drive:
Symmetrical All-Wheel Drive system
📋 Manual Details
Coverage Areas
Primary Coverage:
Factory Service Repair
Included Sections:
Engine, Drivetrain, Chassis, Electrical, Body, HVAC, Maintenance, Troubleshooting
Page Count
Estimated Pages:
Approximately 2000+
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Management:
Fuel injection, ignition, emissions control, ECU diagnostics
Drivetrain:
All-Wheel Drive (AWD) system, differentials, driveshafts, clutch, gearbox
Suspension Steering:
Front and rear suspension, struts, springs, anti-roll bars, steering rack
Brakes:
Brake system hydraulics, ABS, rotors, pads, calipers, parking brake
Electrical:
Wiring diagrams, lighting, power distribution, charging system, starting system, accessories
Body Interior:
Body panels, doors, windows, seats, interior trim, HVAC system
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, tune-ups, spark plug replacement
Diagnostics Troubleshooting:
Symptom-based troubleshooting guides, diagnostic trouble codes (DTCs)
Repairs:
Engine component overhaul, transmission rebuild, brake system repair, suspension component replacement
Assembly Disassembly:
Detailed steps for removing and installing major components
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
Diagnostic Tools:
Includes information for using Subaru Select Monitor (SSM) or equivalent OBD-II scanners
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval
Print Quality
Quality:
High-resolution scans with clear diagrams
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Name:
2.5L Turbocharged Boxer (EJ257)
Engine Configuration:
Flat-four (Boxer)
Displacement:
2457 cc
Bore X Stroke:
99.5 mm x 79.0 mm
Compression Ratio:
8.0:1
Performance
Horsepower Us Spec:
300 hp @ 6000 rpm
Torque Us Spec:
300 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI), Sequential Turbocharging
Fuel Type:
Unleaded Premium (91 octane or higher recommended)
Turbocharger
Turbocharger Type:
Twin-scroll IHI VF39
Intercooler
Intercooler Type:
Top-mount Air-to-Air
🔧 Transmission
Standard
Transmission Type:
6-speed Manual
Gear Ratios:
1st: 3.600, 2nd: 2.275, 3rd: 1.609, 4th: 1.212, 5th: 0.953, 6th: 0.777, Reverse: 3.500
Optional
Transmission Type:
N/A for WRX STI model
Features
Center Differential:
Viscous coupling limited-slip center differential
Rear Differential:
Helical limited-slip rear differential
Fluid Type
Transmission Fluid:
API GL-5, SAE 75W-90 synthetic gear oil
📐 Dimensions
Exterior
Wheelbase:
103.7 inches (2634 mm)
Length:
173.8 inches (4415 mm)
Width:
68.3 inches (1735 mm)
Height:
56.1 inches (1425 mm)
Ground Clearance:
5.5 inches (140 mm)
Weights
Curb Weight:
Approx. 3263 lbs (1480 kg)
Wheels Tires
Wheel Size:
17 x 7.5 inch alloy
Tire Size:
225/45R17
Bolt Pattern:
5x114.3 mm (5x4.5 inches)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
5-star
NHTSA Frontal Passenger:
5-star
IIHS Front Crash Rating:
Good
IIHS Side Impact Rating:
Acceptable
Active Features
ABS:
Standard Anti-lock Braking System (4-wheel disc)
Traction Control:
Standard
Stability Control:
Subaru Vehicle Dynamics Control (VDC) - Standard
Passive Features
Airbags:
Front dual-stage airbags, front side-impact airbags
Seatbelts:
3-point front and rear seatbelts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with 4-6 speakers (upgradeable)
Climate Control:
Manual or Automatic Climate Control (depending on trim)
Driver Assistance
Cruise Control:
Standard
Connectivity
Aux Input:
N/A (optional accessory or aftermarket modification)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe duty)
Engine Oil Type:
API SJ or SL, ILSAC GF-3, SAE 10W-30 synthetic recommended (check owner's manual for specific viscosity)
Oil Filter Part Number:
Subaru 15208AA031 (example, always verify)
Spark Plug Replacement:
Every 30,000 miles (48,000 km)
Timing Belt Replacement:
Not Applicable (EJ257 uses a timing chain)
Fluid Specifications
Coolant Type:
Subaru Super Coolant (or equivalent silicate-free, ethylene glycol based coolant) - Blue
Brake Fluid Type:
DOT 3 or DOT 4
Fluid Capacities
Engine Oil Capacity:
4.8 US quarts (4.5 liters) with filter change
Known Issues
Common Issue 1:
Head gasket leaks (though less prevalent on EJ257 than earlier EJ25s)
Common Issue 2:
Turbocharger failure (often due to poor oil maintenance or hard driving)
Common Issue 3:
Clutch wear and failure (especially with aggressive driving)
Common Issue 4:
Catalytic converter failure (can be heat-related)
📚 Vehicle History
Brand Heritage
Brand Focus:
All-wheel drive, rally racing, practical performance vehicles
Model Evolution
Generation:
GD/GG (2000-2007)
Updates 2004:
Mid-generation refresh including revised styling, updated suspension tuning, and improved interior.
Production
Production Location:
Gunma Prefecture, Japan
🏆 Awards & Recognition
Recognitions
Performance Awards:
Consistently praised by automotive journalists for its performance and handling
Rally Heritage:
Strong association with World Rally Championship (WRC) success
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