SUBARU 2005 IMPREZA WRX STI Service Workshop Manual STI Engine H4SO Engine H4DOTC Engine Transmission CHASSIS BODY Wiring System

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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STI Year: 2005 Codes Chassis Code: GDB Engine Codes Covered: H4SO, H4DOTC 👋 Introduction Market Position Segment: Performance Compact/Sedan. Key Competitors: Mitsubishi Lancer Evolution, Subaru WRX (non-STI), Mitsubishi Lancer Ralliart. Usp: Symmetrical All-Wheel Drive (SAWD), turbocharged boxer engine, rally-bred heritage, advanced driver-controlled center differential (DCCD). Competitive Analysis Engine Performance Comparison: The EJ257 engine in the 2005 STI offered a strong balance of horsepower and torque, often outperforming competitors in mid-range acceleration and tractability. Drivetrain Comparison: Subaru's Symmetrical AWD system, especially with the DCCD, provided superior traction and cornering stability compared to some front-wheel-drive biased or less sophisticated AWD systems in the class. Key Features Engine Type: EJ257 Turbocharged Boxer-4. Transmission Type: 6-speed manual transmission. All Wheel Drive System: Symmetrical All-Wheel Drive with Driver Controlled Center Differential (DCCD). Suspension Type: Performance-tuned independent suspension. Brakes: High-performance Brembo brakes (front and rear). 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for the 2005 Subaru Impreza WRX STI. Specific Systems: STI Engine, H4SO Engine, H4DOTC Engine, Transmission, Chassis, Body, Wiring System. Page Count Estimated Page Count: Over 3000 pages (typical for full service manuals). Manual Type Type: Service Workshop Repair Manual. Language Language: English. Format Format: PDF Download. 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed diagrams and procedures for STI, H4SO, and H4DOTC engine assemblies, including cylinder head, block, crankshaft, pistons, connecting rods, timing components, lubrication system, cooling system, and fuel system. Engine Performance: Turbocharger system, intercooler, fuel injection, ignition system, engine control module (ECM) diagnostics, emissions control. Transmission Manual: Complete overhaul and repair procedures for the 6-speed manual transmission, including clutch system, gear selection, lubrication, and driveline components. Transmission Differentials: Front, center (DCCD - Driver Controlled Center Differential), and rear differential servicing, including fluid changes and potential rebuilds. Chassis Suspension: Front and rear suspension systems (e.g., MacPherson struts, multi-link), shock absorbers, springs, control arms, sway bars, and alignment specifications. Chassis Steering: Power steering system, steering rack, tie rods, and steering column components. Chassis Brakes: Front and rear brake systems, including ABS, brake calipers, rotors, pads, brake lines, master cylinder, and parking brake. Body Exterior: Body panel removal/installation, door mechanisms, hood, trunk, bumpers, fenders, and aerodynamic components. Body Interior: Dashboard removal, seating, interior trim, airbags, and safety restraint systems. Electrical Lighting: Headlights, taillights, interior lighting, fog lights, and bulb specifications. Electrical Audio: Factory audio system, speaker wiring, and antenna. Wiring Diagrams: Comprehensive wiring diagrams for all vehicle systems, including engine, transmission, chassis, body, lighting, and infotainment. Procedures Included Routine Maintenance: Oil changes, filter replacements, coolant flushes, spark plug replacement, brake fluid changes, transmission fluid changes. Diagnostic Troubleshooting: Step-by-step troubleshooting guides for common and complex issues, including diagnostic trouble codes (DTCs) and symptom-based diagnosis. Component Removal Installation: Detailed instructions for removing and installing virtually every component on the vehicle, from small fasteners to major assemblies. Engine Rebuild: Complete engine rebuilding procedures, including torque specifications, assembly sequences, and piston ring gap measurements. Transmission Rebuild: Detailed steps for the disassembly, inspection, repair, and reassembly of the 6-speed transmission. Suspension Alignment: Wheel alignment specifications and procedures. Brake Service: Brake pad and rotor replacement, caliper servicing, bleeding the brake system. Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, component testing, and multimeter usage. Technical Depth Depth: Factory-level technical detail, suitable for professional mechanics and advanced DIY enthusiasts. Diagnostic Tools: Information on using Subaru Select Monitor (SSM) or equivalent diagnostic scan tools, though specific OBD-II scanner compatibility might vary. Torque Specs: Comprehensive list of torque specifications for all critical fasteners throughout the vehicle. Special Tools: Identification of special tools required for specific repair procedures. 📊 Manual Specifications File Format File Type: PDF. Searchability: Searchable text within the PDF for quick information retrieval. Printability: Printable pages for convenient workshop use. Resolution: High-resolution images and diagrams. Binding Type Binding: N/A (Digital download). Paper Type Paper Quality: N/A (Digital download). ⚙️ Engine Specifications Primary Engine Engine Code: EJ257 (STI specific). Engine Type: 2.5L (2457cc) DOHC 16-valve turbocharged and intercooled horizontally opposed (boxer) 4-cylinder. Performance Horsepower: 320 hp @ 6400 rpm (USDM spec). Torque: 315 lb-ft @ 4000 rpm (USDM spec). Bore X Stroke: 99.5 mm x 79.0 mm. Compression Ratio: 8.0:1. Turbocharger Model: IHI VF39. Fuel System Fuel Delivery: Sequential multi-point fuel injection (S-MPFI) with Denso top-feed fuel injectors. Fuel Type: Premium Unleaded (91 octane or higher recommended). Lubrication Oil Capacity: 4.8 US quarts (4.5 liters) with filter change. Recommended Oil Viscosity: 5W-30 Synthetic. 🔧 Transmission Standard Transmission Type: 6-speed manual transmission (TY856UW3AA). Optional Optional Transmission: None available for STI model. Features Dccd System: Driver Controlled Center Differential (DCCD) with automatic and manual modes for torque distribution adjustment. Differentials: Helical Limited Slip Front Differential, DCCD Center Differential, Viscous Coupling Limited Slip Rear Differential. Fluid Specifications Transmission Fluid Type: API GL-5 SAE 75W-90 Synthetic Gear Oil (Subaru Extra-S recommended). Fluid Capacity...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Impreza WRX STI

Year:

Codes

Chassis Code:

Engine Codes Covered:

H4SO, H4DOTC

👋 Introduction

Market Position

Segment:

Performance Compact/Sedan.

Key Competitors:

Mitsubishi Lancer Evolution, Subaru WRX (non-STI), Mitsubishi Lancer Ralliart.

Symmetrical All-Wheel Drive (SAWD), turbocharged boxer engine, rally-bred heritage, advanced driver-controlled center differential (DCCD).

Competitive Analysis

Engine Performance Comparison:

The EJ257 engine in the 2005 STI offered a strong balance of horsepower and torque, often outperforming competitors in mid-range acceleration and tractability.

Drivetrain Comparison:

Subaru's Symmetrical AWD system, especially with the DCCD, provided superior traction and cornering stability compared to some front-wheel-drive biased or less sophisticated AWD systems in the class.

Key Features

Engine Type:

EJ257 Turbocharged Boxer-4.

Transmission Type:

6-speed manual transmission.

All Wheel Drive System:

Symmetrical All-Wheel Drive with Driver Controlled Center Differential (DCCD).

Suspension Type:

Performance-tuned independent suspension.

Brakes:

High-performance Brembo brakes (front and rear).

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service and repair for the 2005 Subaru Impreza WRX STI.

Specific Systems:

STI Engine, H4SO Engine, H4DOTC Engine, Transmission, Chassis, Body, Wiring System.

Page Count

Estimated Page Count:

Over 3000 pages (typical for full service manuals).

Manual Type

Type:

Service Workshop Repair Manual.

Language

Language:

English.

Format

Format:

PDF Download.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed diagrams and procedures for STI, H4SO, and H4DOTC engine assemblies, including cylinder head, block, crankshaft, pistons, connecting rods, timing components, lubrication system, cooling system, and fuel system.

Engine Performance:

Turbocharger system, intercooler, fuel injection, ignition system, engine control module (ECM) diagnostics, emissions control.

Transmission Manual:

Complete overhaul and repair procedures for the 6-speed manual transmission, including clutch system, gear selection, lubrication, and driveline components.

Transmission Differentials:

Front, center (DCCD - Driver Controlled Center Differential), and rear differential servicing, including fluid changes and potential rebuilds.

Chassis Suspension:

Front and rear suspension systems (e.g., MacPherson struts, multi-link), shock absorbers, springs, control arms, sway bars, and alignment specifications.

Chassis Steering:

Power steering system, steering rack, tie rods, and steering column components.

Chassis Brakes:

Front and rear brake systems, including ABS, brake calipers, rotors, pads, brake lines, master cylinder, and parking brake.

Body Exterior:

Body panel removal/installation, door mechanisms, hood, trunk, bumpers, fenders, and aerodynamic components.

Body Interior:

Dashboard removal, seating, interior trim, airbags, and safety restraint systems.

Electrical Lighting:

Headlights, taillights, interior lighting, fog lights, and bulb specifications.

Electrical Audio:

Factory audio system, speaker wiring, and antenna.

Wiring Diagrams:

Comprehensive wiring diagrams for all vehicle systems, including engine, transmission, chassis, body, lighting, and infotainment.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, coolant flushes, spark plug replacement, brake fluid changes, transmission fluid changes.

Diagnostic Troubleshooting:

Step-by-step troubleshooting guides for common and complex issues, including diagnostic trouble codes (DTCs) and symptom-based diagnosis.

Component Removal Installation:

Detailed instructions for removing and installing virtually every component on the vehicle, from small fasteners to major assemblies.

Engine Rebuild:

Complete engine rebuilding procedures, including torque specifications, assembly sequences, and piston ring gap measurements.

Transmission Rebuild:

Detailed steps for the disassembly, inspection, repair, and reassembly of the 6-speed transmission.

Suspension Alignment:

Wheel alignment specifications and procedures.

Brake Service:

Brake pad and rotor replacement, caliper servicing, bleeding the brake system.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, component testing, and multimeter usage.

Technical Depth

Depth:

Factory-level technical detail, suitable for professional mechanics and advanced DIY enthusiasts.

Diagnostic Tools:

Information on using Subaru Select Monitor (SSM) or equivalent diagnostic scan tools, though specific OBD-II scanner compatibility might vary.

Torque Specs:

Comprehensive list of torque specifications for all critical fasteners throughout the vehicle.

Special Tools:

Identification of special tools required for specific repair procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text within the PDF for quick information retrieval.

Printability:

Printable pages for convenient workshop use.

Resolution:

High-resolution images and diagrams.

Binding Type

Binding:

N/A (Digital download).

Paper Type

Paper Quality:

N/A (Digital download).

⚙️ Engine Specifications

Primary Engine

Engine Code:

EJ257 (STI specific).

Engine Type:

2.5L (2457cc) DOHC 16-valve turbocharged and intercooled horizontally opposed (boxer) 4-cylinder.

Performance

Horsepower:

320 hp @ 6400 rpm (USDM spec).

Torque:

315 lb-ft @ 4000 rpm (USDM spec).

Bore X Stroke:

99.5 mm x 79.0 mm.

Compression Ratio:

8.0:1.

Turbocharger Model:

IHI VF39.

Fuel System

Fuel Delivery:

Sequential multi-point fuel injection (S-MPFI) with Denso top-feed fuel injectors.

Fuel Type:

Premium Unleaded (91 octane or higher recommended).

Lubrication

Oil Capacity:

4.8 US quarts (4.5 liters) with filter change.

Recommended Oil Viscosity:

5W-30 Synthetic.

🔧 Transmission

Standard

Transmission Type:

6-speed manual transmission (TY856UW3AA).

Optional

Optional Transmission:

None available for STI model.

Features

Dccd System:

Driver Controlled Center Differential (DCCD) with automatic and manual modes for torque distribution adjustment.

Differentials:

Helical Limited Slip Front Differential, DCCD Center Differential, Viscous Coupling Limited Slip Rear Differential.

Fluid Specifications

Transmission Fluid Type:

API GL-5 SAE 75W-90 Synthetic Gear Oil (Subaru Extra-S recommended).

Fluid Capacity

Transmission Fluid Capacity:

Approximately 3.7 US quarts (3.5 liters).

📐 Dimensions

Exterior

Length:

173.6 inches (4409 mm).

Width:

69.7 inches (1770 mm).

Height:

57.1 inches (1450 mm).

Wheelbase:

104.0 inches (2642 mm).

Track Width Front:

59.8 inches (1520 mm).

Track Width Rear:

59.6 inches (1515 mm).

Weights

Curb Weight:

Approx. 3263 lbs (1480 kg).

Gross Vehicle Weight Rating:

4400 lbs (1996 kg).

Towing Capacity:

Not Recommended.

Wheels Tires

Standard Wheel Size:

17 x 8.0 inches.

Optional Wheel Size:

18 x 8.0 inches (STI specific).

Wheel Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches).

Standard Tire Size:

225/45R17.

Optional Tire Size:

235/40R18 (for 18-inch wheels).

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Rating:

5-Star.

NHTSA Side Crash Test Rating:

5-Star.

IIHS Frontal Offset Rating:

Good.

Active Features

4-wheel Anti-lock Braking System (ABS).

Electronic Brake-force Distribution (EBD).

Traction Control:

Active Traction Control (ATC).

Passive Features

Airbags:

Driver and front passenger airbags, front side-impact airbags.

Seatbelts:

3-point height-adjustable front seatbelts with pretensioners and load limiters, rear 3-point seatbelts.

Rollover Protection:

Reinforced chassis and body structure designed for rally performance.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD stereo system with 6 speakers.

Display:

Basic LCD display for radio and clock.

Driver Assistance

AWD System Control:

DCCD (Driver Controlled Center Differential) allows driver to manually adjust front-to-rear torque split.

Cruise Control:

Standard electronic cruise control.

Connectivity

Aux Input:

Optional auxiliary audio input jack (location may vary).

Bluetooth:

Not factory equipped.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe driving conditions).

Engine Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed.

Cabin Air Filter:

Replace every 15,000 miles (24,000 km) or 12 months.

Spark Plugs:

Replace at 60,000 miles (96,000 km).

Coolant Flush:

Every 30,000 miles (48,000 km) or 24 months.

Brake Fluid Change:

Every 15,000 miles (24,000 km) or 12 months.

Transmission Fluid Change:

Every 30,000 miles (48,000 km) or 24 months (severe driving).

Differential Fluid Change:

Front/Rear: Every 30,000 miles (48,000 km) or 24 months. Center (DCCD): Every 15,000 miles (24,000 km).

Fluid Specifications

Engine Oil Type:

Full Synthetic 5W-30 (API SN or higher).

Coolant Type:

Subaru Super Coolant (Blue) or equivalent P-HOAT coolant.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Head Gaskets:

While less common on the EJ257 compared to earlier EJ series, internal coolant leaks can occur. Manual provides detailed inspection and repair procedures.

Piston Ringland Failure:

Can occur with aggressive tuning or prolonged detonation. Proper engine management and fuel are critical. Manual covers piston and ring inspection.

Turbocharger Failure:

IHI VF39 turbo is robust but can fail with improper maintenance or oil starvation. Manual details turbo inspection and replacement.

Clutch Wear:

Given the performance nature, clutch wear can be accelerated with aggressive driving. Manual covers clutch inspection and replacement.

Suspension Bushings:

Rubber bushings in suspension components can degrade over time, affecting handling. Manual provides replacement procedures.

📚 Vehicle History

Brand Heritage

Brand Rally Heritage:

Subaru's deep roots in rally racing (WRC) directly influenced the development and tuning of the Impreza WRX STI, making it a homologation special for motorsport.

Model Evolution

Gd Chassis Generation:

The 2005 model year represents the 'Bugeye' (pre-facelift GD) or 'Blobeye' (facelifted GD) generation, depending on the specific market and production date. This manual specifically covers the 2005 model which falls within the facelifted GD chassis.

Sti Development:

The STI (Subaru Tecnica International) models represent the pinnacle of Impreza performance, featuring enhanced engines, transmissions, suspension, brakes, and AWD systems compared to standard WRX models.

Production

Production Location:

Gunma Plant, Japan.

Production Years Gd Sti:

2002-2007 (for the GD chassis WRX STI).

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Impreza WRX and WRX STI models consistently appeared on Car and Driver's 10Best lists during this era, recognized for their performance and value.

Rally Performance Accolades:

Subaru's dominance in WRC during the early 2000s (though the STI model was not always the homologation car) cemented the Impreza's reputation as a rally icon.