2005 Subaru Impreza Service Repair Factory Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza Year: 2005 Codes Chassis Code: GD/GG Platform Code: Subaru Global Platform (predecessor) 👋 Introduction Market Position Positioning: Performance-oriented compact car with rally heritage, targeting enthusiasts and those seeking all-wheel-drive capability. Competitive Analysis Competitors: Mitsubishi Lancer Evolution, Volkswagen GTI, MazdaSpeed3, Ford Focus ST/RS. Key Features Performance Focus: Emphasis on turbocharged engines (STI, H4DOTC) and Subaru's Symmetrical All-Wheel Drive system. Durability Reliability: Known for robust mechanicals, particularly the Boxer engine and AWD system, when properly maintained. Manual Usefulness Target User: DIY mechanics, performance tuners, Subaru owners seeking to maintain or repair their vehicle. Value Proposition: Enables significant cost savings on repairs and maintenance, empowers owners to understand and work on their vehicle. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical, Electrical, Body, Maintenance, Repair, Diagnostics Engine Coverage: STI Engine (EJ257), H4SO Engine (non-turbo EJ20/EJ25), H4DOTC Engine (turbo EJ20/EJ25) Transmission Coverage: Manual and Automatic Transmissions, All-Wheel Drive System Chassis Coverage: Suspension, Steering, Brakes, Wheels, Tires Body Coverage: Exterior Body Panels, Interior Trim, Doors, Glass, Safety Restraints Electrical Coverage: Wiring Diagrams, Lighting, Instrumentation, Powertrain Control, Body Electronics, Audio System Technical Systems Covered: Engine Management, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Climate Control, Power Steering, ABS, SRS Page Count Estimated Page Count: 1500-2000 (estimated based on typical factory manuals of this era and scope) Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: PDF (Electronic Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshafts, timing belts/chains, seals, gaskets, lubrication system, cooling system, fuel delivery, intake system, exhaust system. Engine Performance: Engine tuning, performance modifications, turbocharger systems (STI and H4DOTC), intercooler systems, emission controls. Transmission Drivetrain: Manual transmission (5-speed/6-speed for STI), automatic transmission, clutch system, drive shafts, differentials (front, center, rear), AWD system operation and service. Chassis Suspension: Front suspension (MacPherson struts), rear suspension (multi-link), springs, shock absorbers, control arms, bushings, wheel bearings, alignment specifications. Chassis Steering: Power steering system (hydraulic), steering rack, tie rods, steering column, alignment specifications. Chassis Brakes: Front disc brakes (ventilated for STI), rear disc brakes, ABS system components, brake lines, master cylinder, parking brake, brake fluid specifications and bleeding procedures. Body Structural: Body panel removal/installation, door mechanisms, hood, trunk, bumpers, glass replacement, rust prevention, chassis rigidity components. Electrical Powertrain: ECU (Engine Control Unit) functions, sensors (MAP, MAF, O2, knock), actuators, ignition system components, fuel injectors, starter motor, alternator, battery. Electrical Body: Interior and exterior lighting, horn, wipers, power windows, central locking, mirrors, instrument cluster, HVAC controls, SRS airbag system wiring. Wiring Diagrams: Comprehensive, color-coded wiring schematics for all major systems, component identification and location. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, tune-ups, inspections. Engine Repair: Engine rebuilds, head gasket replacement, piston ring replacement, bearing replacement, timing belt/chain service, turbocharger overhaul. Transmission Repair: Transmission fluid changes, clutch replacement, manual transmission rebuild, automatic transmission service and repair, differential service. Suspension Steering Repair: Strut replacement, shock absorber replacement, ball joint replacement, tie rod end replacement, power steering pump replacement, wheel alignment adjustments. Brake System Repair: Brake pad and rotor replacement, brake caliper service, brake line replacement, master cylinder replacement, brake bleeding procedures, ABS module diagnostics and replacement. Electrical Troubleshooting: Diagnostic procedures for electrical faults, component testing, fuse and relay identification and testing, wiring harness repair, ECU diagnostic connector (OBD-II) usage. Body Work: Door hinge adjustment, panel alignment, bumper repair/replacement, glass installation, interior trim panel removal/installation. Diagnostic Procedures: Troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs), component testing procedures, using diagnostic tools. Installation Procedures: Installation procedures for common replacement parts and some aftermarket components (where applicable). Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and chassis component overhaul. Diagnostic Capability: Detailed diagnostic flowcharts, component resistance and voltage specifications, sensor data interpretation. Rebuild Procedures: Detailed step-by-step instructions for rebuilding major components like engines and transmissions, including torque specifications and clearances. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text (OCR'd) for efficient information retrieval. Compatibility: Compatible with all versions of Windows and Mac OS. Software Requirements: Adobe PDF Reader, WinZip (for potential archive extraction). Print Quality Quality Description: Digital format allows for high-resolution viewing and printing, zoom capability for detailed inspection of diagrams and text. Diagram Clarity: High clarity of diagrams, schematics, and illustrations due to digital zoom. Binding Type Binding Type: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Sti Engine Code: EJ257 Sti Engine Type: 2.5L turbocharged and intercooled DOHC 16-valve flat-four (Boxer) engine Sti Bore X Stroke: 99.5 mm x 79.0 mm Sti Compression Ratio: 8.2:1 Sti Horsepower: 300 hp @ 6000 rpm (SAE net) Sti Torque: 300 lb-ft @ 4000 rpm (SAE net) H4So Engine Non Turbo Engine Codes: EJ20, EJ25 (depending...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Impreza

Year:

Codes

Chassis Code:

GD/GG

Platform Code:

Subaru Global Platform (predecessor)

👋 Introduction

Market Position

Positioning:

Performance-oriented compact car with rally heritage, targeting enthusiasts and those seeking all-wheel-drive capability.

Competitive Analysis

Competitors:

Mitsubishi Lancer Evolution, Volkswagen GTI, MazdaSpeed3, Ford Focus ST/RS.

Key Features

Performance Focus:

Emphasis on turbocharged engines (STI, H4DOTC) and Subaru's Symmetrical All-Wheel Drive system.

Durability Reliability:

Known for robust mechanicals, particularly the Boxer engine and AWD system, when properly maintained.

Manual Usefulness

Target User:

DIY mechanics, performance tuners, Subaru owners seeking to maintain or repair their vehicle.

Value Proposition:

Enables significant cost savings on repairs and maintenance, empowers owners to understand and work on their vehicle.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical, Electrical, Body, Maintenance, Repair, Diagnostics

Engine Coverage:

STI Engine (EJ257), H4SO Engine (non-turbo EJ20/EJ25), H4DOTC Engine (turbo EJ20/EJ25)

Transmission Coverage:

Manual and Automatic Transmissions, All-Wheel Drive System

Chassis Coverage:

Suspension, Steering, Brakes, Wheels, Tires

Body Coverage:

Exterior Body Panels, Interior Trim, Doors, Glass, Safety Restraints

Electrical Coverage:

Wiring Diagrams, Lighting, Instrumentation, Powertrain Control, Body Electronics, Audio System

Technical Systems Covered:

Engine Management, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Climate Control, Power Steering, ABS, SRS

Page Count

Estimated Page Count:

1500-2000 (estimated based on typical factory manuals of this era and scope)

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

PDF (Electronic Download)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, pistons, crankshaft, camshafts, timing belts/chains, seals, gaskets, lubrication system, cooling system, fuel delivery, intake system, exhaust system.

Engine Performance:

Engine tuning, performance modifications, turbocharger systems (STI and H4DOTC), intercooler systems, emission controls.

Transmission Drivetrain:

Manual transmission (5-speed/6-speed for STI), automatic transmission, clutch system, drive shafts, differentials (front, center, rear), AWD system operation and service.

Chassis Suspension:

Front suspension (MacPherson struts), rear suspension (multi-link), springs, shock absorbers, control arms, bushings, wheel bearings, alignment specifications.

Chassis Steering:

Power steering system (hydraulic), steering rack, tie rods, steering column, alignment specifications.

Chassis Brakes:

Front disc brakes (ventilated for STI), rear disc brakes, ABS system components, brake lines, master cylinder, parking brake, brake fluid specifications and bleeding procedures.

Body Structural:

Body panel removal/installation, door mechanisms, hood, trunk, bumpers, glass replacement, rust prevention, chassis rigidity components.

Electrical Powertrain:

ECU (Engine Control Unit) functions, sensors (MAP, MAF, O2, knock), actuators, ignition system components, fuel injectors, starter motor, alternator, battery.

Electrical Body:

Interior and exterior lighting, horn, wipers, power windows, central locking, mirrors, instrument cluster, HVAC controls, SRS airbag system wiring.

Wiring Diagrams:

Comprehensive, color-coded wiring schematics for all major systems, component identification and location.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, tune-ups, inspections.

Engine Repair:

Engine rebuilds, head gasket replacement, piston ring replacement, bearing replacement, timing belt/chain service, turbocharger overhaul.

Transmission Repair:

Transmission fluid changes, clutch replacement, manual transmission rebuild, automatic transmission service and repair, differential service.

Suspension Steering Repair:

Strut replacement, shock absorber replacement, ball joint replacement, tie rod end replacement, power steering pump replacement, wheel alignment adjustments.

Brake System Repair:

Brake pad and rotor replacement, brake caliper service, brake line replacement, master cylinder replacement, brake bleeding procedures, ABS module diagnostics and replacement.

Electrical Troubleshooting:

Diagnostic procedures for electrical faults, component testing, fuse and relay identification and testing, wiring harness repair, ECU diagnostic connector (OBD-II) usage.

Body Work:

Door hinge adjustment, panel alignment, bumper repair/replacement, glass installation, interior trim panel removal/installation.

Diagnostic Procedures:

Troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs), component testing procedures, using diagnostic tools.

Installation Procedures:

Installation procedures for common replacement parts and some aftermarket components (where applicable).

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics, and chassis component overhaul.

Diagnostic Capability:

Detailed diagnostic flowcharts, component resistance and voltage specifications, sensor data interpretation.

Rebuild Procedures:

Detailed step-by-step instructions for rebuilding major components like engines and transmissions, including torque specifications and clearances.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely searchable text (OCR'd) for efficient information retrieval.

Compatibility:

Compatible with all versions of Windows and Mac OS.

Software Requirements:

Adobe PDF Reader, WinZip (for potential archive extraction).

Print Quality

Quality Description:

Digital format allows for high-resolution viewing and printing, zoom capability for detailed inspection of diagrams and text.

Diagram Clarity:

High clarity of diagrams, schematics, and illustrations due to digital zoom.

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Sti Engine Code:

EJ257

Sti Engine Type:

2.5L turbocharged and intercooled DOHC 16-valve flat-four (Boxer) engine

Sti Bore X Stroke:

99.5 mm x 79.0 mm

Sti Compression Ratio:

8.2:1

Sti Horsepower:

300 hp @ 6000 rpm (SAE net)

Sti Torque:

300 lb-ft @ 4000 rpm (SAE net)

H4So Engine

Non Turbo Engine Codes:

EJ20, EJ25 (depending on market/trim)

Non Turbo Engine Type:

2.0L or 2.5L SOHC or DOHC naturally aspirated flat-four (Boxer) engine

Non Turbo Horsepower Range:

120-170 hp (estimated, varies by specific engine and market)

Non Turbo Torque Range:

130-165 lb-ft (estimated, varies by specific engine and market)

H4Dotc Engine

Turbo Engine Codes:

EJ20, EJ25 (turbocharged variants)

Turbo Engine Type:

2.0L or 2.5L turbocharged and intercooled DOHC flat-four (Boxer) engine

Turbo Horsepower Range:

220-250 hp (estimated, WRX models)

Turbo Torque Range:

240-260 lb-ft (estimated, WRX models)

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPI)

Fuel Type:

Unleaded gasoline, Premium unleaded required for STI and turbocharged models.

🔧 Transmission

Standard

Sti Transmission:

6-speed close-ratio manual transmission (TY856)

Wrx Transmission:

5-speed manual transmission

Non Turbo Transmission:

5-speed manual transmission or 4-speed automatic transmission

Optional

Optional Transmission:

4-speed automatic transmission (available on non-turbo and some WRX models in certain markets)

Features

AWD System:

Subaru Symmetrical All-Wheel Drive (permanent)

Center Differential Sti:

Driver-controlled center differential (DCCD) on STI models.

Transmission Fluid Manual:

Gear oil (e.g., Subaru Extra-S Gear Oil or equivalent GL-5 specification, viscosity depends on ambient temperature, typically 75W-90).

Transmission Fluid Automatic:

Subaru ATF HP or equivalent.

📐 Dimensions

Exterior

Wheelbase:

2525 mm (99.4 in)

Length:

4405 mm (173.4 in)

Width:

1740 mm (68.5 in)

Height:

1445 mm (56.9 in) (Sedan) / 1425 mm (56.1 in) (Wagon)

Weights

Curb Weight Range:

1300-1500 kg (2866-3307 lbs) (varies by trim and drivetrain)

Gross Vehicle Weight Rating Gvwr:

Approx. 1850 kg (4079 lbs) (estimate, consult specific model)

Towing Capacity:

Not recommended or specified for most performance variants; typically around 450 kg (1000 lbs) for non-turbo models if equipped.

Wheel Bolt Pattern:

5x100 mm

Wheel Size Sti:

17x8.0 inches

Tire Size Sti:

225/45R17

Wheel Size Wrx Non Turbo:

16x7.0 inches (common for WRX), 15x6.0 inches (common for non-turbo)

Tire Size Wrx Non Turbo:

205/50R16 (common for WRX), 195/60R15 (common for non-turbo)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-star (driver and passenger) for 2005 models with side airbags.

IIHS Frontal Offset:

Good (for models tested)

Active Features

Active Safety:

All-Wheel Drive, Anti-lock Braking System (ABS), Traction Control System (TCS) (available on some models).

Passive Features

Passive Safety:

Front airbags, optional side airbags, front seatbelt pretensioners, crumple zones.

Airbag System:

SRS (Supplemental Restraint System) with front and optional side impact airbags.

💡 Technology Features

Infotainment

Infotainment System:

Basic factory-installed audio systems with CD player, AM/FM radio. Limited connectivity options compared to modern vehicles.

Speaker Configuration:

Typically 4 or 6 speakers.

Driver Assistance

Driver Assistance Features:

Limited by modern standards; ABS and optional Traction Control were primary features. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.

Connectivity

Connectivity Options:

Auxiliary input jack might be present on some models, but Bluetooth and USB connectivity are generally absent.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 6 months (severe service) or 7,500 miles or 12 months (normal service), consult manual for specifics based on engine and driving conditions.

Timing Belt Replacement:

105,000 miles or 105 months for EJ25 engines (check manual, some sources cite 60,000-105,000 miles depending on engine and specific manual).

Spark Plug Replacement:

Approx. 60,000 miles (Iridium spark plugs) or 30,000 miles (Platinum spark plugs, if applicable).

Coolant Flush:

Every 30,000 miles or 2 years.

Transmission Fluid Change:

Manual: Every 30,000-60,000 miles. Automatic: Every 30,000-50,000 miles. AWD center differential: Every 30,000 miles.

Fluid Specifications

Engine Oil Type:

5W-30 or 10W-30 (API SG/SH/SJ/SL) synthetic or conventional, depending on climate and specific engine.

Engine Oil Capacity:

4.5 US quarts (4.3 L) with filter for 2.5L engines, 4.2 US quarts (4.0 L) for 2.0L engines.

Coolant Type:

Subaru Super Coolant (blue) or equivalent silicate-free, long-life coolant.

Brake Fluid Type:

DOT 3 or DOT 4.

Known Issues

Engine Issues:

Head gasket leaks (particularly on older EJ25 SOHC engines, less common on DOHC), ringland failure on early EJ257 STI engines under extreme use, turbocharger failure (if not properly maintained or pushed too hard).

Suspension Issues:

Worn struts and bushings due to performance driving and AWD system load.

Transmission Issues:

Synchro wear in manual transmissions, particularly on the 6-speed STI transmission with hard shifting.

Electrical Issues:

Occasional sensor failures (e.g., MAF, O2 sensors), wiring harness issues.

Filter Part Numbers

Oil Filter:

Subaru Part Number 15208AA100 (or equivalent) is a common example for EJ engines.

Air Filter:

Subaru Part Number 16546AA120 (or equivalent).

📚 Vehicle History

Brand Heritage

Heritage:

Subaru has a long history of producing durable vehicles with a focus on All-Wheel Drive technology, stemming from their success in motorsports, particularly the World Rally Championship (WRC).

Model Evolution

Generation:

Second generation (GD/GG), introduced in 2000 and facelifted in 2002 for the 2003 model year. The 2005 model represents a refinement of this generation.

Trim Levels:

Key trims include the naturally aspirated 2.5i (often with a 2.5L SOHC engine), the turbocharged WRX (with 2.0L or 2.5L turbo engines), and the high-performance WRX STI (with the 2.5L EJ257 turbo engine).

Production

Manufacturing Location:

Japan

Production Years For Generation:

2000-2007

🏆 Awards & Recognition

Recognitions

Ralley Heritage:

The Impreza WRX and STI models have a strong lineage in motorsports, particularly in the World Rally Championship (WRC), earning multiple driver and manufacturer titles, which significantly boosted their global recognition.

Performance Awards:

Consistently praised by automotive journalists for handling, performance, and AWD capability.

Ratings

Consumer Reports Ratings:

Ratings varied by model year and specific trim; typically good in performance and handling, but could be mixed in reliability depending on engine and year.

Certifications

Emissions Certification:

Meets EPA and California ARB emissions standards for the respective model year.