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Subaru Impreza STI 2004 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STI Year: 2004 Codes Chassis Code: GDB Engine Code: EJ207 👋 Introduction Market Position Positioning: The 2004 Subaru Impreza WRX STI (also known as GDB) is a rally-bred, turbocharged performance sedan, a homologation special designed for motorsport. It is positioned as a premium, high-performance compact car. Competitive Analysis Competitors: Competes with other performance-oriented compacts of its era, such as the Mitsubishi Lancer Evolution, Volkswagen Golf GTI, and Ford Focus RS. Key Features Performance Highlights: Symmetrical All-Wheel Drive (AWD), turbocharged boxer engine, advanced differential systems, potent braking, and a driver-focused chassis. Manual Purpose: Provides authoritative, in-depth technical information for accurate diagnosis, repair, and maintenance, crucial for preserving the performance and longevity of this specialized vehicle. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair and maintenance for the 2004 Subaru Impreza WRX STI. Page Count Total Pages: 3000+ Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drivetrain, Fuel System, Exhaust System. Chassis: Suspension (front and rear), Steering System, Braking System, Wheels and Tires. Electrical: Wiring Diagrams, Ignition System, Starting System, Charging System, Lighting, Instrumentation, ECUs. Body And Interior: Body Panels, Doors, Windows, Seats, Trim, HVAC System, Restraint Systems (Airbags). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, component testing. Repair And Rebuild: Step-by-step repair procedures for major components (engine, transmission, suspension, brakes). Adjustments: Valve clearance adjustments, clutch adjustments, alignment procedures. Technical Depth Depth: Detailed diagnostic procedures, component removal and installation, specifications, tolerances, and torque values for most repairs. 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable PDF with printable pages. Print Quality Printability: Optimized for printing with clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Horizontally Opposed (Boxer), Turbocharged, Intercooled Engine Code: EJ207 Displacement: 2.0 Liters (1994 cc) Performance Horsepower Ps: 265 PS (approx. 261 hp) Torque Nm: 343 Nm (approx. 253 lb-ft) Fuel System Injection Type: Multi-Point Fuel Injection (MPI), Electronic Fuel Injection (EFI) Fuel Type: Premium Unleaded Gasoline (98 RON recommended) Internal Components Pistons: Forged Crankshaft: Cross-plane, forged Cooling System Coolant Type: Subaru Super Coolant or equivalent (Ethylene Glycol based) 🔧 Transmission Standard Transmission Type: 6-Speed Manual Transmission Optional Optional Transmission: N/A (Manual transmission only for STI) Features Drivetrain: Symmetrical All-Wheel Drive (AWD) with Driver-Controlled Center Differential (DCCD) Differentials: Front: Helical LSD, Rear: Viscous LSD Fluid Specifications Transmission Fluid Type: API GL-5, SAE 75W-90 (manual gearbox); Subaru Extra LPS Fluid (transfer case/rear diff, if applicable) 📐 Dimensions Exterior Length Mm: 4405 Width Mm: 1770 Height Mm: 1410 Wheelbase Mm: 2525 Weights Curb Weight Kg: 1430 Gross Vehicle Weight Kg: 1900 Wheels And Tires Wheel Size: 17 x 7.5 inches Tire Size: 225/45R17 Bolt Pattern: 5 x 100 mm Offset: +53mm 🛡️ Safety Features Ratings NHTSA Front Impact: Not rated (historical data may vary) IIHS Front Impact: Good (for 2004 model year Impreza range, STI specific rating may differ) Active Features ABS: Standard (4-wheel ABS) Traction Control: Standard (Symmetrical AWD, DCCD) Passive Features Airbags: Driver and Front Passenger Airbags Seatbelts: 3-point front and rear seatbelts with pretensioners Chassis Design Body Structure: Reinforced chassis with crumple zones and energy-absorbing structure. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD stereo system with basic speaker configuration. Aftermarket upgrades are common. Driver Assistance Stability Control: Not equipped with Electronic Stability Control (ESC) in the modern sense; relies on AWD and differential systems for stability. Connectivity Auxiliary Input: Typically no auxiliary input; older models may have tape decks or limited CD functionality. Instrumentation Dashboard Features: Driver-focused layout with tachometer, speedometer, boost gauge, oil pressure, and temperature gauges. 🔧 Maintenance Service Intervals Oil Change Interval Km: Every 5,000 km or 6 months (severe use), 7,500-10,000 km or 12 months (normal use) Spark Plug Replacement Km: 100,000 km (Iridium type) Timing Belt Replacement Km: 105,000 km or 7 years (whichever comes first) Fluid Specifications Engine Oil Type: API SG/SH/SJ/SL/SM, ACEA A3/B3 or A3/B4, Viscosity: 0W-30, 5W-30, 5W-40, 10W-30, 10W-40 (refer to manual for specific conditions) Engine Oil Capacity Liters: 4.2 L (without filter), 4.5 L (with filter) Coolant Capacity Liters: 7.5 L Brake Fluid Type: DOT 3 or DOT 4 Known Issues Engine Reliability: EJ207 engine is robust but susceptible to ringland failure if consistently abused or poorly tuned. Regular maintenance is critical. Head gasket failures can occur with age/heat cycles. Transmission Wear: The 6-speed transmission is strong, but clutch wear is expected with spirited driving. Synchro wear can occur on high-mileage units. Suspension Components: Worn suspension bushings (control arms, sway bars) are common due to spirited driving and age. Wheel bearings can also wear. Electronics: Intermittent issues with sensors (e.g.,...
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Subaru Impreza STI 2004 Workshop Service Manual for Repair
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza WRX STI
Year:
2004
Codes
Chassis Code:
GDB
Engine Code:
EJ207
👋 Introduction
Market Position
Positioning:
The 2004 Subaru Impreza WRX STI (also known as GDB) is a rally-bred, turbocharged performance sedan, a homologation special designed for motorsport. It is positioned as a premium, high-performance compact car.
Competitive Analysis
Competitors:
Competes with other performance-oriented compacts of its era, such as the Mitsubishi Lancer Evolution, Volkswagen Golf GTI, and Ford Focus RS.
Key Features
Performance Highlights:
Symmetrical All-Wheel Drive (AWD), turbocharged boxer engine, advanced differential systems, potent braking, and a driver-focused chassis.
Manual Purpose:
Provides authoritative, in-depth technical information for accurate diagnosis, repair, and maintenance, crucial for preserving the performance and longevity of this specialized vehicle.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive repair and maintenance for the 2004 Subaru Impreza WRX STI.
Page Count
Total Pages:
3000+
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Drivetrain, Fuel System, Exhaust System.
Chassis:
Suspension (front and rear), Steering System, Braking System, Wheels and Tires.
Electrical:
Wiring Diagrams, Ignition System, Starting System, Charging System, Lighting, Instrumentation, ECUs.
Body And Interior:
Body Panels, Doors, Windows, Seats, Trim, HVAC System, Restraint Systems (Airbags).
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, component testing.
Repair And Rebuild:
Step-by-step repair procedures for major components (engine, transmission, suspension, brakes).
Adjustments:
Valve clearance adjustments, clutch adjustments, alignment procedures.
Technical Depth
Depth:
Detailed diagnostic procedures, component removal and installation, specifications, tolerances, and torque values for most repairs.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable PDF with printable pages.
Print Quality
Printability:
Optimized for printing with clear diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Horizontally Opposed (Boxer), Turbocharged, Intercooled
Engine Code:
EJ207
Displacement:
2.0 Liters (1994 cc)
Performance
Horsepower Ps:
265 PS (approx. 261 hp)
Torque Nm:
343 Nm (approx. 253 lb-ft)
Fuel System
Injection Type:
Multi-Point Fuel Injection (MPI), Electronic Fuel Injection (EFI)
Fuel Type:
Premium Unleaded Gasoline (98 RON recommended)
Internal Components
Pistons:
Forged
Crankshaft:
Cross-plane, forged
Cooling System
Coolant Type:
Subaru Super Coolant or equivalent (Ethylene Glycol based)
🔧 Transmission
Standard
Transmission Type:
6-Speed Manual Transmission
Optional
Optional Transmission:
N/A (Manual transmission only for STI)
Features
Drivetrain:
Symmetrical All-Wheel Drive (AWD) with Driver-Controlled Center Differential (DCCD)
Differentials:
Front: Helical LSD, Rear: Viscous LSD
Fluid Specifications
Transmission Fluid Type:
API GL-5, SAE 75W-90 (manual gearbox); Subaru Extra LPS Fluid (transfer case/rear diff, if applicable)
📐 Dimensions
Exterior
Length Mm:
4405
Width Mm:
1770
Height Mm:
1410
Wheelbase Mm:
2525
Weights
Curb Weight Kg:
1430
Gross Vehicle Weight Kg:
1900
Wheels And Tires
Wheel Size:
17 x 7.5 inches
Tire Size:
225/45R17
Bolt Pattern:
5 x 100 mm
Offset:
+53mm
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not rated (historical data may vary)
IIHS Front Impact:
Good (for 2004 model year Impreza range, STI specific rating may differ)
Active Features
ABS:
Standard (4-wheel ABS)
Traction Control:
Standard (Symmetrical AWD, DCCD)
Passive Features
Airbags:
Driver and Front Passenger Airbags
Seatbelts:
3-point front and rear seatbelts with pretensioners
Chassis Design
Body Structure:
Reinforced chassis with crumple zones and energy-absorbing structure.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD stereo system with basic speaker configuration. Aftermarket upgrades are common.
Driver Assistance
Stability Control:
Not equipped with Electronic Stability Control (ESC) in the modern sense; relies on AWD and differential systems for stability.
Connectivity
Auxiliary Input:
Typically no auxiliary input; older models may have tape decks or limited CD functionality.
Instrumentation
Dashboard Features:
Driver-focused layout with tachometer, speedometer, boost gauge, oil pressure, and temperature gauges.
🔧 Maintenance
Service Intervals
Oil Change Interval Km:
Every 5,000 km or 6 months (severe use), 7,500-10,000 km or 12 months (normal use)
Spark Plug Replacement Km:
100,000 km (Iridium type)
Timing Belt Replacement Km:
105,000 km or 7 years (whichever comes first)
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ/SL/SM, ACEA A3/B3 or A3/B4, Viscosity: 0W-30, 5W-30, 5W-40, 10W-30, 10W-40 (refer to manual for specific conditions)
Engine Oil Capacity Liters:
4.2 L (without filter), 4.5 L (with filter)
Coolant Capacity Liters:
7.5 L
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Reliability:
EJ207 engine is robust but susceptible to ringland failure if consistently abused or poorly tuned. Regular maintenance is critical. Head gasket failures can occur with age/heat cycles.
Transmission Wear:
The 6-speed transmission is strong, but clutch wear is expected with spirited driving. Synchro wear can occur on high-mileage units.
Suspension Components:
Worn suspension bushings (control arms, sway bars) are common due to spirited driving and age. Wheel bearings can also wear.
Electronics:
Intermittent issues with sensors (e.g., MAF, O2) and wiring harnesses can arise due to heat and vibration.
📚 Vehicle History
Brand Heritage
Subaru Rally Heritage:
Subaru's deep roots in World Rally Championship (WRC) with legendary drivers like Colin McRae and Petter Solberg heavily influenced the development and performance of the Impreza STI.
Model Evolution
Gdb Generation:
This 2004 model represents the later part of the 'GDB' (second generation) Impreza, known for significant chassis and engine improvements over earlier versions.
Production
Manufacturing Location:
Japan
Key Market:
Homologation special primarily for European and Japanese markets, with limited availability in North America for specific model years.
🏆 Awards & Recognition
Recognitions
Performance Awards:
Consistently recognized in automotive press for its performance, handling, and rally-inspired driving dynamics.
Ratings
Enthusiast Ratings:
Highly regarded by enthusiasts for its raw performance, tuner-friendliness, and motorsport pedigree.
Certifications
Manual Endorsement:
This workshop manual is essential for any owner or technician seeking to maintain or repair the 2004 Subaru Impreza WRX STI to factory specifications.
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