2004-2005 Subaru impreza WRX STI Service Repair Manual
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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STI Model Code: GDB (Hatchback/Wagon), GGB (Sedan - for some markets, but typically GDB refers to the chassis for this generation) Model Generation: Third Generation (2002-2007, chassis code GDB/GGB), specifically covering the mid-cycle refresh Codes Chassis Code: GDB 👋 Introduction Market Position Positioning: The 2004-2005 Impreza WRX STI represents a pinnacle of rally-inspired performance in a production sedan, targeting enthusiasts and drivers seeking track-capable handling and potent turbocharged power. Competitive Analysis Competitors: Competed against performance variants of models like the Mitsubishi Lancer Evolution, Ford Focus RS, Volkswagen Golf R, and Audi S3 of the era. Key Features Performance Focus: Renowned for its symmetrical All-Wheel Drive system, turbocharged Boxer engine, and track-tuned suspension, offering exceptional grip and acceleration. Rally Heritage: Directly derived from Subaru's World Rally Championship (WRC) heritage, carrying the performance DNA of its motorsport counterparts. Manual Value Value Proposition: Provides official, dealer-level repair and maintenance information, empowering owners and independent shops to perform accurate and efficient servicing. 📋 Manual Details Coverage Areas Covered Years: 2004, 2005 Region Of Origin: Likely North American market based on WRX STI designation, but often includes global specifications. Page Count Estimated Page Count: 1500+ (Typical for comprehensive factory service manuals) Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Format: Digital Download (PDF likely) 📖 Manual Coverage Systems Covered Engine: 2.5L Turbocharged EJ257 Boxer Engine (including timing, lubrication, cooling, fuel injection, ignition, emissions, and engine management) Transmission: 6-speed Manual Transmission (TZ1A3ZG6KA, TY757VW4AA, etc. - specific gearboxes may vary by market and trim) Drivetrain: All-Wheel Drive System (DCCD - Driver's Control Center Differential, center differential, front/rear differentials, driveshafts, axles) Suspension: Front MacPherson strut with lower control arm, Rear multi-link suspension, adjustable components (camber bolts, etc.) Brakes: Front 4-piston Brembo calipers with 325mm ventilated discs, Rear 2-piston Brembo calipers with 300mm ventilated discs, ABS, Brake booster, master cylinder Steering: Power-assisted rack and pinion steering system Electrical: Complete electrical schematics, Body Control Module (BCM), ECU, sensors, lighting, power windows, mirrors, HVAC controls, audio system, airbags Body And Trim: Exterior body panels, interior trim, bumpers, spoilers, doors, hood, trunk, glass HVAC: Heating, Ventilation, and Air Conditioning system operation and repair Fuel System: Fuel tank, fuel pump, fuel lines, fuel injectors, fuel pressure regulator Exhaust System: Manifold, catalytic converter, muffler, O2 sensors Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, fluid flushes (coolant, brake, clutch, transmission, differential), belt inspection/replacement, battery maintenance Diagnostics: Troubleshooting guides for common issues, DTC (Diagnostic Trouble Code) interpretation, sensor testing, circuit testing Repair: Engine overhaul, transmission rebuild, brake component replacement, suspension component replacement, electrical component repair/replacement, body panel repair Disassembly And Assembly: Step-by-step instructions for removing and installing major components and sub-assemblies Specifications And Tolerances: Torque specifications, alignment data, gap measurements, fluid capacities Wiring Diagrams: Detailed electrical schematics for all vehicle systems Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical troubleshooting) 📊 Manual Specifications File Format Format Details: PDF (typically, search functionality, bookmarking, printable pages) Print Quality Quality Description: High-resolution, clear diagrams and text, comparable to original factory documentation Binding Type Binding Description: Not applicable for digital download, but original manuals were typically spiral-bound or perfect-bound. Paper Type Paper Description: Not applicable for digital download, but original manuals were printed on durable paper stock. ⚙️ Engine Specifications Primary Engine Engine Code: EJ257 Configuration: 2.5L (2457cc) turbocharged and intercooled DOHC 16-valve horizontally opposed (Boxer) four-cylinder engine Performance Horsepower: 300 hp @ 6000 rpm (SAE Net) Torque: 300 lb-ft @ 4000 rpm (SAE Net) Bore X Stroke: 99.5 mm x 79.0 mm Compression Ratio: 8.4:1 Fuel System Fuel Delivery: Multi-point fuel injection (MPI), Sequential electronic fuel injection (SEFI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Management ECU Type: Denso ECU (specific part number varies, e.g., 22611AG571 for certain configurations) Cooling System Coolant Capacity: Approx. 7.8 liters (16.4 US pints) Lubrication System Oil Capacity: 5.0 US quarts (4.7 liters) with filter change Oil Type Recommendation: 5W-30 Synthetic (meeting API SN or equivalent) 🔧 Transmission Standard Type: 6-speed Manual Transmission Optional Type: N/A for WRX STI models of this generation; manual was standard. Features Dccd: Driver's Control Center Differential (DCCD) with automatic and manual modes for torque distribution adjustment. Fluid Specs Transmission Fluid Type: Subaru Extra-S Gear Oil or equivalent GL-5 75W-90 Fluid Capacity Transmission Fluid Capacity: Approx. 3.4 liters (7.2 US pints) Differential Fluid Front Differential Fluid Type: GL-5 75W-90 Rear Differential Fluid Type: GL-5 75W-90 📐 Dimensions Exterior Wheelbase: 2629 mm (103.5 in) Length: 4405 mm (173.4 in) Width: 1795 mm (70.7 in) Height: 1445 mm (56.9 in) Front Track: 1530 mm (60.2 in) Rear Track: 1535 mm (60.4 in) Weights Curb Weight: Approx. 1475 kg (3252 lbs) Gross Vehicle Weight Rating: N/A (typically not a primary...
GDB (Hatchback/Wagon), GGB (Sedan - for some markets, but typically GDB refers to the chassis for this generation)
Model Generation:
Third Generation (2002-2007, chassis code GDB/GGB), specifically covering the mid-cycle refresh
Codes
Chassis Code:
GDB
👋 Introduction
Market Position
Positioning:
The 2004-2005 Impreza WRX STI represents a pinnacle of rally-inspired performance in a production sedan, targeting enthusiasts and drivers seeking track-capable handling and potent turbocharged power.
Competitive Analysis
Competitors:
Competed against performance variants of models like the Mitsubishi Lancer Evolution, Ford Focus RS, Volkswagen Golf R, and Audi S3 of the era.
Key Features
Performance Focus:
Renowned for its symmetrical All-Wheel Drive system, turbocharged Boxer engine, and track-tuned suspension, offering exceptional grip and acceleration.
Rally Heritage:
Directly derived from Subaru's World Rally Championship (WRC) heritage, carrying the performance DNA of its motorsport counterparts.
Manual Value
Value Proposition:
Provides official, dealer-level repair and maintenance information, empowering owners and independent shops to perform accurate and efficient servicing.
📋 Manual Details
Coverage Areas
Covered Years:
2004, 2005
Region Of Origin:
Likely North American market based on WRX STI designation, but often includes global specifications.
Page Count
Estimated Page Count:
1500+ (Typical for comprehensive factory service manuals)
Premium Unleaded Gasoline (91 octane or higher recommended)
Engine Management
ECU Type:
Denso ECU (specific part number varies, e.g., 22611AG571 for certain configurations)
Cooling System
Coolant Capacity:
Approx. 7.8 liters (16.4 US pints)
Lubrication System
Oil Capacity:
5.0 US quarts (4.7 liters) with filter change
Oil Type Recommendation:
5W-30 Synthetic (meeting API SN or equivalent)
🔧 Transmission
Standard
Type:
6-speed Manual Transmission
Optional
Type:
N/A for WRX STI models of this generation; manual was standard.
Features
Dccd:
Driver's Control Center Differential (DCCD) with automatic and manual modes for torque distribution adjustment.
Fluid Specs
Transmission Fluid Type:
Subaru Extra-S Gear Oil or equivalent GL-5 75W-90
Fluid Capacity
Transmission Fluid Capacity:
Approx. 3.4 liters (7.2 US pints)
Differential Fluid
Front Differential Fluid Type:
GL-5 75W-90
Rear Differential Fluid Type:
GL-5 75W-90
📐 Dimensions
Exterior
Wheelbase:
2629 mm (103.5 in)
Length:
4405 mm (173.4 in)
Width:
1795 mm (70.7 in)
Height:
1445 mm (56.9 in)
Front Track:
1530 mm (60.2 in)
Rear Track:
1535 mm (60.4 in)
Weights
Curb Weight:
Approx. 1475 kg (3252 lbs)
Gross Vehicle Weight Rating:
N/A (typically not a primary spec for enthusiast vehicles)
Wheels And Tires
Standard Wheel Size:
17x8 inches (later models/special editions may have 18-inch wheels)
Wheel Bolt Pattern:
5x100 mm
Standard Tire Size:
225/45R17
🛡️ Safety Features
Ratings
NHTSA Front Crash Rating:
Not specifically tested for all trims, but generally considered safe for its class.
IIHS Crash Test Ratings:
Good in frontal offset, acceptable/good in side impact depending on testing year and specific configuration.
Active Features
Traction Control:
Subaru Vehicle Dynamics Control (VDC) with AWD integration.
ABS:
4-wheel Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD).
Passive Features
Airbags:
Driver and front passenger airbags, front side-impact airbags, front and rear curtain airbags (depending on trim).
Seatbelts:
3-point front seatbelts with pre-tensioners and load limiters, 3-point rear seatbelts.
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with (optional) subwoofer. Limited connectivity by modern standards.
Climate Control:
Manual or automatic climate control (depending on trim).
Driver Assistance
Cruise Control:
Standard cruise control.
Performance Monitoring:
Driver-controlled center differential (DCCD) for on-the-fly AWD tuning is a key performance technology.
Connectivity
Auxiliary Input:
Optional auxiliary input jack (may require adapter or aftermarket installation).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe duty) or 7,500 miles (12,000 km) or 12 months (normal duty). Synthetic oil is highly recommended.
Engine Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed.
Cabin Air Filter:
Replace annually or every 15,000 miles (24,000 km).
Spark Plugs:
Replace every 60,000 miles (96,000 km). Use Iridium-tipped plugs (e.g., NGK PFR7B or similar).
Coolant Flush:
Every 30,000 miles (48,000 km) or 24 months. Use Subaru Super Coolant or equivalent. Ensure proper mixture (50/50).
Timing Belt:
If equipped with a timing belt (EJ257 uses a belt), replacement is critical at 105,000 miles (168,000 km) or 7 years, including tensioner and idler pulleys.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 compatible brake fluid. High-performance fluid recommended for spirited driving.
Clutch Fluid:
DOT 3 or DOT 4 compatible brake fluid (shared reservoir with brakes).
Known Issues
Piston Ringland Failure:
A known issue with the EJ257 engine, particularly when subjected to aggressive tuning or poor maintenance, leading to ringland damage. Proper fueling and detonation prevention are crucial.
Head Gasket Leaks:
While less prevalent than in earlier EJ engines, head gasket issues can still occur, especially with engine modifications or overheating.
Clutch Wear:
Performance driving can lead to accelerated clutch wear, particularly on the OEM clutch. Upgraded clutches are common.
Suspension Bushings:
Wear and tear on suspension bushings can lead to degraded handling and noise over time.
📚 Vehicle History
Brand Heritage
Heritage Focus:
Subaru's long-standing association with motorsport, particularly in rallying, is the foundation of the WRX and STI lineage, emphasizing AWD and turbocharged performance.
Model Evolution
Generation Context:
This generation (GDB) represented a significant styling and chassis update from the previous GC8 generation, moving to a more modern platform with a longer wheelbase and wider track.
Mid Cycle Refresh:
The 2004 model year marked a significant mid-cycle refresh for the GDB chassis, introducing the new engine (EJ257), updated styling (especially the front fascia and headlights), and revised suspension tuning.
Production
Production Plant:
Ota City, Gunma Prefecture, Japan
Production Years For Generation:
2002-2007
🏆 Awards & Recognition
Recognitions
Performance Magazine Accolades:
Consistently ranked as a top performance car by automotive publications during its production run, lauded for its handling and accessible AWD performance.
Motorsport Success:
The Impreza WRX STI platform has a decorated history in World Rally Championship (WRC), winning multiple driver and manufacturer titles, which significantly bolsters the model's pedigree.
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