SUBARU IMPREZA STI Turbo NON Turbo Service Repair Workshop Manual 2005
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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STI Model Variant: STI (Turbo) / Impreza (Non-Turbo) Year: 2005 Codes Chassis Code: GDB (Impreza chassis) Engine Code Sti: EJ257 Engine Code Non Turbo: EJ204 (commonly found on non-STI Imprezas of this era) 👋 Introduction Market Position Segment: Performance Compact Sedan/Hatchback Usp: Iconic rally heritage, turbocharged performance (STI), symmetrical all-wheel-drive, driver-focused cockpit. Competitive Analysis Competitors: Mitsubishi Lancer Evolution, Honda Civic Si, Volkswagen GTI, Ford Focus SVT. Key Features Performance Focus: Emphasizes track-capable performance and engaging driving dynamics, particularly in the STI variant. AWD Capability: Subaru's renowned Symmetrical All-Wheel Drive system provides superior traction and stability in various conditions. Durability: Known for robust engineering and durability, especially in the boxer engine and AWD drivetrain. 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z for 2005 Subaru Impreza WRX STI and non-turbo Impreza variants. Page Count Estimated Page Count: Approximately 2000+ pages (typical for full factory service manuals of this scope). Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (likely PDF, often with searchable text and high-resolution diagrams) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, torque specifications, cylinder head, crankshaft, pistons, connecting rods, valve train, timing belt/chain, lubrication system, cooling system. Engine Management: Fuel injection system, ignition system, emission control systems (catalytic converter, EVAP), engine control unit (ECU) diagnosis, sensors and actuators, turbocharger system (STI). Transmission Manual: Clutch system, gearbox assembly, disassembly, internal components, gear ratios, shifting mechanisms, driveshafts, differentials. Transmission Automatic: If applicable to specific 2005 Impreza models covered, this would include gearbox assembly, hydraulics, torque converter, electronic controls. Drivetrain: All-Wheel Drive (AWD) system, viscous coupling, differentials (front, center, rear), hubs, wheel bearings. Suspension: Front suspension (struts, control arms, bushings), rear suspension (multi-link design), springs, shock absorbers, sway bars, alignment specifications. Steering: Power steering system, steering column, rack and pinion, tie rods, steering knuckle. Brakes: Hydraulic brake system, brake calipers, rotors, pads, master cylinder, brake booster, ABS system, parking brake. Electrical System: Battery, alternator, starter motor, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams. Body Exterior: Body panel removal and installation, doors, hood, trunk lid, bumpers, glass, seals, trim. Body Interior: Dashboard, seats, upholstery, HVAC system components, interior trim, audio system, airbags. HVAC: Heating, ventilation, and air conditioning system components, refrigerant handling, diagnosis. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake fluid flush, coolant flush. Troubleshooting: Diagnostic procedures for common drivability issues, electrical faults, component failures, including specific symptom-based troubleshooting trees. Component Replacement: Step-by-step instructions for replacing major and minor components across all vehicle systems. Rebuild Procedures: Detailed instructions for the complete disassembly, inspection, repair, and reassembly of engine, transmission, and differential components. Wiring Diagrams: Comprehensive electrical wiring diagrams for all major systems, including engine control, body electronics, and lighting. Torque Specifications: Precise torque values for all critical fasteners, essential for proper assembly and preventing damage. Special Tools: Identification and usage of specialized tools required for specific repairs or diagnostics. Tightening Sequences: Specific sequences for tightening critical components such as cylinder heads and wheel nuts. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Image Quality: High-resolution diagrams and images for clarity. Print Quality Print Readability: Designed for clear readability when printed. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Sti Engine Type: 2.5L EJ257 Flat-Four (Boxer) Sti Aspiration: Turbocharged and Intercooled Sti Horsepower: Approx. 300 hp @ 6000 rpm (factory rating, often underestimated) Sti Torque: Approx. 300 lb-ft @ 4000 rpm (factory rating) Non Turbo Engine Type: 2.0L EJ204 Flat-Four (Boxer) or similar naturally aspirated variant Non Turbo Aspiration: Naturally Aspirated Non Turbo Horsepower: Approx. 150-170 hp (typical for non-STI models) Non Turbo Torque: Approx. 140-150 lb-ft (typical for non-STI models) Performance Compression Ratio Sti: 8.0:1 Bore X Stroke Sti: 92.0 mm x 91.0 mm Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Fuel Type: Premium Unleaded (91 octane or higher recommended for STI) Engine Components Sti Engine Internals: Forged pistons, stronger connecting rods, sodium-filled exhaust valves (STI specific). 🔧 Transmission Standard Sti Transmission Type: 6-speed manual Optional Non Turbo Transmission Type: 5-speed manual or 4-speed automatic (depending on trim/market) Features AWD System: Symmetrical All-Wheel Drive with Driver Controlled Center Differential (DCCD) on STI models. Fluid Specifications Sti Gearbox Fluid: Subaru ExtraS PS Fluid (or equivalent API GL-5 75W-90 synthetic gear oil) AWD Differential Fluid: Subaru ExtraS PS Fluid (or equivalent API GL-5 75W-90 synthetic gear oil) 📐 Dimensions Exterior Wheelbase: Approx. 103.1 inches (2619 mm) Length: Approx. 174.5 inches (4432 mm) Width: Approx. 69.7 inches (1770 mm) Height: Approx. 57.9 inches (1470 mm)...
Fuel injection system, ignition system, emission control systems (catalytic converter, EVAP), engine control unit (ECU) diagnosis, sensors and actuators, turbocharger system (STI).
Good (for comparable 2005 models, specific STI ratings may vary)
NHTSA Front Impact Passenger:
Good (for comparable 2005 models)
IIHS Small Overlap Front:
Not Tested (as this test was not standard for 2005 vehicles)
Active Features
ABS:
Standard Anti-lock Braking System
AWD:
Symmetrical All-Wheel Drive (enhances stability and traction)
Ebd:
Electronic Brake-force Distribution
Passive Features
Airbags:
Front airbags, side curtain airbags (availability may vary by trim).
Seatbelts:
Three-point seatbelts with pre-tensioners.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with premium speaker options available.
Display:
Basic LCD or LED displays for clock, radio information, and climate control.
Driver Assistance
Cruise Control:
Standard cruise control.
Traction Control:
Standard Traction Control System (TCS).
Connectivity
Aux Input:
May be present on later models or as an aftermarket addition.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months, whichever comes first (severe driving conditions), or 7,500 miles/12 months (normal conditions). STI models may require more frequent changes due to performance driving.
Air Filter Replacement:
Every 15,000 miles or 12 months.
Spark Plug Replacement Sti:
Platinum-tipped: 60,000 miles. Iridium-tipped: 100,000 miles (check specific plug type).
Timing Belt Replacement:
Every 90,000 - 105,000 miles (critical maintenance item for EJ engines).
Fluid Specifications
Engine Oil Capacity Sti:
Approx. 5.5 US quarts (5.2 liters) with filter (5W-30 or 10W-30 synthetic recommended).
Engine Oil Capacity Non Turbo:
Approx. 4.5 US quarts (4.3 liters) with filter (5W-30 or 10W-30 recommended).
Coolant Type:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant.
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Head Gasket Failure:
While less common in the EJ257 than earlier versions, head gasket leaks are a potential concern. Vigilant maintenance is key.
Ringland Failure Sti:
Can occur in heavily modified or aggressively driven STI engines due to increased cylinder pressures. Proper tuning and maintenance are crucial.
Clutch Wear:
Performance driving can accelerate clutch wear.
Rear Differential Noise:
Some owners report occasional noise from the rear differential, often related to fluid condition or wear.
📚 Vehicle History
Brand Heritage
Subaru Motorsports:
Deep roots in rallying, with the Impreza WRX STI being a homologation special for WRC competition.
Model Evolution
Generations:
The 2005 model represents the GD chassis generation of the Impreza, specifically the 'Bugeye'/'Blobeye' update.
Sti Launch:
The STI variant, originally a rally homologation special, became a production model offering enhanced performance over the WRX.
Production
Manufacturing Location:
Japan (Ota, Gunma Prefecture)
🏆 Awards & Recognition
Recognitions
Car And Driver Щения:
Often featured on Car and Driver's '10Best' lists for its class and performance capabilities.
Ralley Championships:
The Impreza platform, particularly the STI, has a rich history of World Rally Championship (WRC) victories.