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2004 SUBARU IMPREZA WRX sti Service Repair Manual

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$133.00
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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STI Year: 2004 Codes Chassis Code: GDB Engine Code Primary: EJ257 Trim Level: STI 👋 Introduction Market Position Positioning: Performance sedan/coupe, rally-bred homologation special, enthusiast vehicle. Competitive Analysis Competitors: Mitsubishi Lancer Evolution, Subaru WRX (non-STI variants), Ford Focus RS, VW Golf R. Key Features Performance Focus: Turbocharged Boxer engine, Symmetrical All-Wheel Drive, advanced differential systems. Driving Dynamics: Legendary handling, driver-focused cockpit, responsive steering. Manual Value Target Audience: Enthusiast owners, independent repair shops, performance tuners. Distinctiveness: Provides dealership-level technical data not typically available to the public. 📋 Manual Details Coverage Areas Primary Coverage: Vehicle Service and Repair Secondary Coverage: Diagnostics, Troubleshooting, Maintenance, Overhaul Page Count Estimated Pages: 2000+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, component replacement (pistons, rods, crankshaft, valves, camshafts), timing belt/chain system, lubrication system, cooling system. Engine Management: ECU diagnostics, fuel injection system, ignition system, emission control systems (catalytic converter, EGR, secondary air injection), sensors and actuators. Transmission Manual: Driveshaft, differential, gearbox overhaul, clutch replacement, shift linkage. Transmission Automatic: Not applicable for this STI model. Drivetrain AWD: Center differential, viscous coupling, rear differential, hub assemblies, CV joints. Suspension: Front and rear suspension components (struts, springs, control arms, bushings, sway bars), alignment specifications. Brakes: Brake system hydraulics, ABS system, rotor and pad replacement, caliper overhaul, brake bleeding procedures. Steering: Power steering system, steering rack, tie rods, wheel alignment. Electrical System: Battery, charging system, starting system, lighting, instrumentation, power windows, locks, HVAC controls, audio system. Body And Interior: Body panel removal and installation, door mechanisms, interior trim, seats, dashboard components, glass replacement. HVAC: Air conditioning system, heating system, blower motor, climate controls, refrigerant handling. Procedures Included Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and changes, brake inspections. Troubleshooting: Diagnostic flowcharts for common issues, symptom-based problem diagnosis. Repair: Step-by-step instructions for component replacement, system repair, and adjustments. Diagnostics: OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, scan tool usage. Rebuilds: Detailed procedures for engine and transmission rebuilding, including torque specifications and clearances. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. Technical Depth Depth: Expert level, suitable for professional technicians and advanced DIY enthusiasts. Scope: Full vehicle service and repair, from routine maintenance to complete engine rebuilds. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content Printability: Printable pages Print Quality Quality: High-resolution scans for clear text and diagrams Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Horizontally Opposed Turbocharged (Boxer) Displacement: 2.5 Liters (2457 cc) Engine Code: EJ257 Performance Horsepower Est: 300 hp @ 6000 rpm (SAE Net) Torque Est: 300 lb-ft @ 4000 rpm (SAE Net) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI), Electronic Throttle Control (ETC) Turbocharger: IHI VF30 (or similar depending on market), Intercooled Engine Components Cylinder Head: Dual Overhead Camshaft (DOHC), 16 valves Compression Ratio: 8.0:1 Fluid Specifications Oil Type: SAE 5W-30 Synthetic (API SG or SH) Oil Capacity: 4.5 US quarts (4.3 L) with filter Coolant Type: Subaru Super Coolant (Blue) 🔧 Transmission Standard Transmission Type: 6-Speed Manual Transmission Features Driver Control: Driver Controlled Center Differential (DCCD) with automatic and manual modes. Fluid Type: GL-5 75W-90 Gear Oil (Transmission and Front Differential) Gear Ratios Primary 1St Gear: 3.636 2Nd Gear: 2.063 3Rd Gear: 1.448 4Th Gear: 1.094 5Th Gear: 0.970 6Th Gear: 0.777 Reverse: 3.545 Final Drive: 3.545 Drivetrain Spec AWD System: Symmetrical All-Wheel Drive with DCCD and Helical Front/Limited Slip Rear Differentials. 📐 Dimensions Exterior Length: 173.8 in (4415 mm) Width: 69.7 in (1770 mm) Height: 56.1 in (1425 mm) Wheelbase: 103.0 in (2615 mm) Front Track: 60.0 in (1525 mm) Rear Track: 59.4 in (1510 mm) Weights Curb Weight Est: 3329 lbs (1510 kg) Gross Weight Rating Est: 4343 lbs (1970 kg) Wheel And Tire Wheel Size: 17 x 8.0 inches Bolt Pattern: 5 x 100 mm Tire Size Std: 225/45R17 Fuel Capacity Fuel Tank Capacity: 15.6 US gallons (59 L) 🛡️ Safety Features Ratings NHTSA Front Crash Rating: 4/5 Stars (Driver/Passenger) NHTSA Side Impact Rating: 4/5 Stars (Front/Rear Passenger) IIHS Crashworthiness: Good (Frontal Offset) Active Features ABS: Standard Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD). Traction Control: Standard Traction Control System (TCS) and Vehicle Stability Control (VDC). Passive Features Airbags Front: Driver and front passenger airbags Airbags Side: Optional front side-impact airbags (market dependent) Seatbelts: 3-point seatbelts with pretensioners and load limiters. Body Structure: Reinforced unibody construction with front and rear crumple zones. 💡 Technology Features Infotainment Head Unit: Factory AM/FM/CD player, optional premium audio system. Display: Basic digital display for clock, temperature, and audio information. Driver Assistance Cruise Control: Standard electronic cruise control. Dccd: Driver Controlled Center Differential provides advanced AWD torque management. Connectivity Bluetooth:...
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2004 SUBARU IMPREZA WRX sti Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza WRX STI
Year:
2004
Codes
Chassis Code:
GDB
Engine Code Primary:
EJ257
Trim Level:
STI
👋 Introduction
Market Position
Positioning:
Performance sedan/coupe, rally-bred homologation special, enthusiast vehicle.
Competitive Analysis
Competitors:
Mitsubishi Lancer Evolution, Subaru WRX (non-STI variants), Ford Focus RS, VW Golf R.
Key Features
Performance Focus:
Turbocharged Boxer engine, Symmetrical All-Wheel Drive, advanced differential systems.
Driving Dynamics:
Legendary handling, driver-focused cockpit, responsive steering.
Manual Value
Target Audience:
Enthusiast owners, independent repair shops, performance tuners.
Distinctiveness:
Provides dealership-level technical data not typically available to the public.
📋 Manual Details
Coverage Areas
Primary Coverage:
Vehicle Service and Repair
Secondary Coverage:
Diagnostics, Troubleshooting, Maintenance, Overhaul
Page Count
Estimated Pages:
2000+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, component replacement (pistons, rods, crankshaft, valves, camshafts), timing belt/chain system, lubrication system, cooling system.
Engine Management:
ECU diagnostics, fuel injection system, ignition system, emission control systems (catalytic converter, EGR, secondary air injection), sensors and actuators.
Transmission Manual:
Driveshaft, differential, gearbox overhaul, clutch replacement, shift linkage.
Transmission Automatic:
Not applicable for this STI model.
Drivetrain AWD:
Center differential, viscous coupling, rear differential, hub assemblies, CV joints.
Suspension:
Front and rear suspension components (struts, springs, control arms, bushings, sway bars), alignment specifications.
Brakes:
Brake system hydraulics, ABS system, rotor and pad replacement, caliper overhaul, brake bleeding procedures.
Steering:
Power steering system, steering rack, tie rods, wheel alignment.
Electrical System:
Battery, charging system, starting system, lighting, instrumentation, power windows, locks, HVAC controls, audio system.
Body And Interior:
Body panel removal and installation, door mechanisms, interior trim, seats, dashboard components, glass replacement.
HVAC:
Air conditioning system, heating system, blower motor, climate controls, refrigerant handling.
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and changes, brake inspections.
Troubleshooting:
Diagnostic flowcharts for common issues, symptom-based problem diagnosis.
Repair:
Step-by-step instructions for component replacement, system repair, and adjustments.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, scan tool usage.
Rebuilds:
Detailed procedures for engine and transmission rebuilding, including torque specifications and clearances.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
Technical Depth
Depth:
Expert level, suitable for professional technicians and advanced DIY enthusiasts.
Scope:
Full vehicle service and repair, from routine maintenance to complete engine rebuilds.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content
Printability:
Printable pages
Print Quality
Quality:
High-resolution scans for clear text and diagrams
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Horizontally Opposed Turbocharged (Boxer)
Displacement:
2.5 Liters (2457 cc)
Engine Code:
EJ257
Performance
Horsepower Est:
300 hp @ 6000 rpm (SAE Net)
Torque Est:
300 lb-ft @ 4000 rpm (SAE Net)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI), Electronic Throttle Control (ETC)
Turbocharger:
IHI VF30 (or similar depending on market), Intercooled
Engine Components
Cylinder Head:
Dual Overhead Camshaft (DOHC), 16 valves
Compression Ratio:
8.0:1
Fluid Specifications
Oil Type:
SAE 5W-30 Synthetic (API SG or SH)
Oil Capacity:
4.5 US quarts (4.3 L) with filter
Coolant Type:
Subaru Super Coolant (Blue)
🔧 Transmission
Standard
Transmission Type:
6-Speed Manual Transmission
Features
Driver Control:
Driver Controlled Center Differential (DCCD) with automatic and manual modes.
Fluid Type:
GL-5 75W-90 Gear Oil (Transmission and Front Differential)
Gear Ratios Primary
1St Gear:
3.636
2Nd Gear:
2.063
3Rd Gear:
1.448
4Th Gear:
1.094
5Th Gear:
0.970
6Th Gear:
0.777
Reverse:
3.545
Final Drive:
3.545
Drivetrain Spec
AWD System:
Symmetrical All-Wheel Drive with DCCD and Helical Front/Limited Slip Rear Differentials.
📐 Dimensions
Exterior
Length:
173.8 in (4415 mm)
Width:
69.7 in (1770 mm)
Height:
56.1 in (1425 mm)
Wheelbase:
103.0 in (2615 mm)
Front Track:
60.0 in (1525 mm)
Rear Track:
59.4 in (1510 mm)
Weights
Curb Weight Est:
3329 lbs (1510 kg)
Gross Weight Rating Est:
4343 lbs (1970 kg)
Wheel And Tire
Wheel Size:
17 x 8.0 inches
Bolt Pattern:
5 x 100 mm
Tire Size Std:
225/45R17
Fuel Capacity
Fuel Tank Capacity:
15.6 US gallons (59 L)
🛡️ Safety Features
Ratings
NHTSA Front Crash Rating:
4/5 Stars (Driver/Passenger)
NHTSA Side Impact Rating:
4/5 Stars (Front/Rear Passenger)
IIHS Crashworthiness:
Good (Frontal Offset)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD).
Traction Control:
Standard Traction Control System (TCS) and Vehicle Stability Control (VDC).
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Optional front side-impact airbags (market dependent)
Seatbelts:
3-point seatbelts with pretensioners and load limiters.
Body Structure:
Reinforced unibody construction with front and rear crumple zones.
💡 Technology Features
Infotainment
Head Unit:
Factory AM/FM/CD player, optional premium audio system.
Display:
Basic digital display for clock, temperature, and audio information.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Dccd:
Driver Controlled Center Differential provides advanced AWD torque management.
Connectivity
Bluetooth:
Not standard, aftermarket integration common.
Instrumentation
Gauge Cluster:
Includes tachometer, speedometer, fuel gauge, coolant temperature gauge, and multi-function display.
Boost Gauge:
Integrated factory boost gauge in the center console or dashboard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (under severe driving conditions).
Engine Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed.
Cabin Air Filter:
Replace every 15,000 miles (24,000 km) or 12 months.
Spark Plugs:
Iridium type: 105,000 miles (168,000 km).
Timing Belt:
Not applicable. Uses a timing chain.
Coolant Flush:
Every 30,000 miles (48,000 km) or 24 months.
Transmission Fluid Change:
Every 30,000 miles (48,000 km) or 24 months (for performance use).
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Subaru Genuine ATF-HP or Dexron III compatible
Differential Fluid Type:
GL-5 75W-90 Gear Oil (Front and Rear)
Known Issues
Head Gaskets:
Less prone to failure than earlier EJ series engines, but still a potential concern under high heat/stress.
Ringland Failure:
Common issue on EJ257 engines, especially if modified or run with improper fueling/tuning, leading to piston ringland damage.
Clutch Wear:
Can wear prematurely with aggressive driving or repeated launches.
Turbocharger Failure:
Can occur due to lack of oil changes or improper warm-up/cool-down procedures.
📚 Vehicle History
Brand Heritage
Subaru Rally:
Strong lineage from Subaru's extensive World Rally Championship (WRC) success.
Model Evolution
Generation:
Second Generation Impreza (GD/GG) - Introduced 2000, facelifted in 2002 and 2005.
Gdb Sti Introduction:
The 2004 model year marked the introduction of the GDB chassis STI to the North American market.
Production
Manufacturing Location:
Gunma Prefecture, Japan
Production Years:
2004-2007 (for this specific chassis generation STI variant)
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Impreza WRX (non-STI) was a frequent recipient of Car and Driver's 10Best list, highlighting its performance-to-value ratio.
Sports Car International World Performance Car:
The STI variant received accolades for its rally-bred performance and handling capabilities.
Ratings
Jdpowers Initial Quality:
Generally average to below average for initial quality during its production years, typical for performance vehicles.
Certifications
Emissions Standards:
Compliant with EPA and CARB emissions standards for its model year.
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