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SUBARU IMPREZA STI (GASOLINE) 2004 Full Service Repair MANUAL

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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STI Year: 2004 Engine Type: Gasoline Codes Chassis Code: GDB Engine Code: EJ207 👋 Introduction Market Position Segment: Performance Compact Sedan/Wagon Niche: Rally-bred performance, all-wheel-drive capability Competitive Analysis Key Competitors: Mitsubishi Lancer Evolution, Ford Focus RS (later models), Volkswagen Golf GTI Key Features Drivetrain: Symmetrical All-Wheel Drive (AWD) Engine: EJ207 turbocharged Boxer engine Transmission: 6-speed manual transmission Suspension: Performance-tuned suspension with DCCD (Driver Controlled Center Differential) Brakes: Brembo performance brake system Aero: Aggressive aerodynamic enhancements including rear wing 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics Page Count Estimated Pages: 1000+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, timing belt, pistons, crankshaft, cylinder heads, valve train Engine Performance: Turbocharger system, fuel injection, ignition system, ECU diagnostics, emissions controls Transmission Drivetrain: Manual transmission (6-speed), clutch, drivetrain components, differentials (front, rear, center DCCD) Suspension Steering: MacPherson struts, multi-link rear, springs, dampers, steering rack, power steering system Brakes: Front Brembo 4-piston calipers, rear 2-piston calipers, ABS, EBD, brake fluid specifications Electrical: Wiring diagrams, fuse box layouts, starter, alternator, battery, lighting, power windows, central locking Bodywork Chassis: Body panel removal/installation, chassis structure, door mechanisms, exterior trim, interior trim HVAC: Air conditioning system, heater core, climate control Fuel System: Fuel tank, fuel pump, fuel injectors, fuel pressure regulator Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement, timing belt replacement intervals Troubleshooting Diagnostics: Fault code interpretation (OBD-II), diagnostic procedures for common issues, wiring harness testing Repair Rebuild: Engine rebuild procedures, transmission overhaul, suspension component replacement, brake caliper overhaul Component Replacement: Turbocharger replacement, clutch replacement, clutch slave cylinder replacement, fuel pump replacement Wheel Alignment: Specifications and procedures for wheel alignment Airbag System: Information on airbag system safety and component replacement Technical Depth Depth: Factory-level diagnostic and repair procedures Diagnostics: Detailed troubleshooting trees and symptom-based diagnostics Specifications: Torque values, clearances, tolerances, fluid capacities Diagrams: Exploded views, wiring diagrams, system schematics 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable Print Quality Quality: High-resolution, printable pages Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Name: EJ207 Configuration: 2.0L Boxer-4 (H4) Aspiration: Twin-Scroll Turbocharged Bore X Stroke: 92.0 mm x 75.0 mm Compression Ratio: 8.0:1 Valvetrain: DOHC, 16 valves Performance Horsepower: 268 hp @ 6000 rpm (JDM spec) Torque: 258 lb-ft @ 4000 rpm (JDM spec) Fuel System Fuel Delivery: Sequential Electronic Fuel Injection (SEFI) Fuel Type: Unleaded gasoline (premium recommended) Ignition System: Electronic ignition with knock sensor Cooling System Type: Liquid-cooled Capacity: Approx. 6.0 Liters Lubrication System Type: Forced lubrication, wet sump Oil Capacity: Approx. 4.5 Liters (w/ filter) Engine Mounts Type: Hydraulic engine mounts 🔧 Transmission Standard Type: 6-speed Manual Gear Ratios: 1st: 3.636, 2nd: 2.053, 3rd: 1.545, 4th: 1.137, 5th: 0.942, 6th: 0.777, Reverse: 3.545 Final Drive Ratio: 3.545 Optional Type: N/A (STI was exclusively manual) Features Dccd: Driver Controlled Center Differential (DCCD) with auto/manual modes Fluid Specifications Manual Transmission Fluid: Subaru Extra-S Gear Oil API GL-5 75W-90 or equivalent Clutch Type: Hydraulically operated, single dry plate clutch 📐 Dimensions Exterior Length: 4415 mm (173.8 in) Width: 1770 mm (69.7 in) Height: 1440 mm (56.7 in) Wheelbase: 2625 mm (103.3 in) Track Width Front: 1530 mm (60.2 in) Track Width Rear: 1535 mm (60.4 in) Ground Clearance: 135 mm (5.3 in) Weights Curb Weight: Approx. 1440 kg (3175 lbs) Wheels Tires Wheel Size: 17 x 7.5 inches Bolt Pattern: 5 x 114.3 mm (5x4.5 inch) Tire Size: 225/45R17 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 Stars (Driver/Passenger - US models) NHTSA Side Impact: 4/4 Stars (Front/Rear - US models) IIHS Frontal Offset: Good Active Features ABS: Standard Anti-lock Braking System Ebd: Standard Electronic Brake-force Distribution AWD: Standard Symmetrical All-Wheel Drive with DCCD Passive Features Airbags: Driver and front passenger airbags Seatbelts: Three-point seatbelts with pretensioners Chassis: Reinforced chassis structure 💡 Technology Features Infotainment Head Unit: Factory-installed AM/FM/CD player (typically basic) Speakers: Standard speaker configuration (4-6 speakers) Driver Assistance Stability Control: Traction Control System (TCS) Cruise Control: Standard Cruise Control Connectivity Auxiliary Input: Rarely standard, often requires aftermarket modification Instrumentation Gauges: Tachometer, speedometer, fuel gauge, coolant temperature, boost gauge (integrated) Climate Control Type: Manual climate control with A/C 🔧 Maintenance Service Intervals Engine Oil Change: Every 3,000-5,000 miles or 6 months, depending on driving conditions (severe service requires more frequent changes) Engine Oil Filter Replacement: With every oil change Air Filter Replacement: Every 15,000-30,000 miles Cabin Air Filter Replacement: Every 15,000-30,000 miles Spark Plug Replacement: Every 60,000 miles (iridium type) Timing Belt Replacement: Every 90,000-105,000 miles or 7 years (critical replacement) Coolant Flush: Every 30,000 miles or 2 years Fluid Specifications Engine Oil Type: Synthetic 5W-30 or 5W-40 (check manual...
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SUBARU IMPREZA STI (GASOLINE) 2004 Full Service Repair MANUAL
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza WRX STI
Year:
2004
Engine Type:
Gasoline
Codes
Chassis Code:
GDB
Engine Code:
EJ207
👋 Introduction
Market Position
Segment:
Performance Compact Sedan/Wagon
Niche:
Rally-bred performance, all-wheel-drive capability
Competitive Analysis
Key Competitors:
Mitsubishi Lancer Evolution, Ford Focus RS (later models), Volkswagen Golf GTI
Key Features
Drivetrain:
Symmetrical All-Wheel Drive (AWD)
Engine:
EJ207 turbocharged Boxer engine
Transmission:
6-speed manual transmission
Suspension:
Performance-tuned suspension with DCCD (Driver Controlled Center Differential)
Brakes:
Brembo performance brake system
Aero:
Aggressive aerodynamic enhancements including rear wing
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Diagnostics
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, timing belt, pistons, crankshaft, cylinder heads, valve train
Engine Performance:
Turbocharger system, fuel injection, ignition system, ECU diagnostics, emissions controls
Transmission Drivetrain:
Manual transmission (6-speed), clutch, drivetrain components, differentials (front, rear, center DCCD)
Suspension Steering:
MacPherson struts, multi-link rear, springs, dampers, steering rack, power steering system
Brakes:
Front Brembo 4-piston calipers, rear 2-piston calipers, ABS, EBD, brake fluid specifications
Electrical:
Wiring diagrams, fuse box layouts, starter, alternator, battery, lighting, power windows, central locking
Bodywork Chassis:
Body panel removal/installation, chassis structure, door mechanisms, exterior trim, interior trim
HVAC:
Air conditioning system, heater core, climate control
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks, spark plug replacement, timing belt replacement intervals
Troubleshooting Diagnostics:
Fault code interpretation (OBD-II), diagnostic procedures for common issues, wiring harness testing
Repair Rebuild:
Engine rebuild procedures, transmission overhaul, suspension component replacement, brake caliper overhaul
Component Replacement:
Turbocharger replacement, clutch replacement, clutch slave cylinder replacement, fuel pump replacement
Wheel Alignment:
Specifications and procedures for wheel alignment
Airbag System:
Information on airbag system safety and component replacement
Technical Depth
Depth:
Factory-level diagnostic and repair procedures
Diagnostics:
Detailed troubleshooting trees and symptom-based diagnostics
Specifications:
Torque values, clearances, tolerances, fluid capacities
Diagrams:
Exploded views, wiring diagrams, system schematics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable
Print Quality
Quality:
High-resolution, printable pages
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Name:
EJ207
Configuration:
2.0L Boxer-4 (H4)
Aspiration:
Twin-Scroll Turbocharged
Bore X Stroke:
92.0 mm x 75.0 mm
Compression Ratio:
8.0:1
Valvetrain:
DOHC, 16 valves
Performance
Horsepower:
268 hp @ 6000 rpm (JDM spec)
Torque:
258 lb-ft @ 4000 rpm (JDM spec)
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (SEFI)
Fuel Type:
Unleaded gasoline (premium recommended)
Ignition System:
Electronic ignition with knock sensor
Cooling System
Type:
Liquid-cooled
Capacity:
Approx. 6.0 Liters
Lubrication System
Type:
Forced lubrication, wet sump
Oil Capacity:
Approx. 4.5 Liters (w/ filter)
Engine Mounts
Type:
Hydraulic engine mounts
🔧 Transmission
Standard
Type:
6-speed Manual
Gear Ratios:
1st: 3.636, 2nd: 2.053, 3rd: 1.545, 4th: 1.137, 5th: 0.942, 6th: 0.777, Reverse: 3.545
Final Drive Ratio:
3.545
Optional
Type:
N/A (STI was exclusively manual)
Features
Dccd:
Driver Controlled Center Differential (DCCD) with auto/manual modes
Fluid Specifications
Manual Transmission Fluid:
Subaru Extra-S Gear Oil API GL-5 75W-90 or equivalent
Clutch
Type:
Hydraulically operated, single dry plate clutch
📐 Dimensions
Exterior
Length:
4415 mm (173.8 in)
Width:
1770 mm (69.7 in)
Height:
1440 mm (56.7 in)
Wheelbase:
2625 mm (103.3 in)
Track Width Front:
1530 mm (60.2 in)
Track Width Rear:
1535 mm (60.4 in)
Ground Clearance:
135 mm (5.3 in)
Weights
Curb Weight:
Approx. 1440 kg (3175 lbs)
Wheels Tires
Wheel Size:
17 x 7.5 inches
Bolt Pattern:
5 x 114.3 mm (5x4.5 inch)
Tire Size:
225/45R17
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 Stars (Driver/Passenger - US models)
NHTSA Side Impact:
4/4 Stars (Front/Rear - US models)
IIHS Frontal Offset:
Good
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brake-force Distribution
AWD:
Standard Symmetrical All-Wheel Drive with DCCD
Passive Features
Airbags:
Driver and front passenger airbags
Seatbelts:
Three-point seatbelts with pretensioners
Chassis:
Reinforced chassis structure
💡 Technology Features
Infotainment
Head Unit:
Factory-installed AM/FM/CD player (typically basic)
Speakers:
Standard speaker configuration (4-6 speakers)
Driver Assistance
Stability Control:
Traction Control System (TCS)
Cruise Control:
Standard Cruise Control
Connectivity
Auxiliary Input:
Rarely standard, often requires aftermarket modification
Instrumentation
Gauges:
Tachometer, speedometer, fuel gauge, coolant temperature, boost gauge (integrated)
Climate Control
Type:
Manual climate control with A/C
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-5,000 miles or 6 months, depending on driving conditions (severe service requires more frequent changes)
Engine Oil Filter Replacement:
With every oil change
Air Filter Replacement:
Every 15,000-30,000 miles
Cabin Air Filter Replacement:
Every 15,000-30,000 miles
Spark Plug Replacement:
Every 60,000 miles (iridium type)
Timing Belt Replacement:
Every 90,000-105,000 miles or 7 years (critical replacement)
Coolant Flush:
Every 30,000 miles or 2 years
Fluid Specifications
Engine Oil Type:
Synthetic 5W-30 or 5W-40 (check manual for specific recommendations)
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Subaru Genuine Power Steering Fluid or Dexron II/III compatible fluid
Clutch Fluid Type:
DOT 3
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free ethylene glycol based coolant
Known Issues
Engine:
Ring land failure (particularly on modified engines), head gasket leaks, turbocharger wear
Drivetrain:
Clutch wear, synchro issues in manual transmission (less common but possible), DCCD unit failure
Suspension:
Worn bushings, premature strut failure
Electrical:
Faulty window regulators, SRS system warning lights
📚 Vehicle History
Brand Heritage
Brand:
Subaru, known for its Boxer engines and All-Wheel Drive systems
Motorsport:
Strong rally racing heritage, directly influencing the STI models
Model Evolution
Generation:
Second Generation Subaru Impreza (GD/GG chassis)
Sti Introduction:
STI variant introduced to homologate for WRC and offer enhanced performance
Sub Models 2004:
STI, WRX
Facelift:
This 2004 model year often refers to the pre-facelift 'Bugeye' or early 'Blobeye' versions depending on market
Production
Production Years:
2000-2007 (GD/GG chassis)
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorsport Titles:
Multiple World Rally Championship (WRC) manufacturer and driver titles for Subaru
Performance Awards:
Frequently recognized by automotive journalists for its handling, performance, and rally-inspired driving dynamics
Ratings
Car And Driver 10Best:
Impreza WRX (non-STI) models often made this list, indicating the platform's merit
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