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2004 Subaru Sti Service/Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STI Year: 2004 Chassis Code: GDB-F Generation: GD Generation Variant: GD/GG (2nd Generation, 'F' model year update) 👋 Introduction Market Position Vehicle Segment: Compact Performance Sedan/Wagon (WRC Homologation Special) Target Audience: Enthusiasts, Owners Seeking In-depth Maintenance and Repair Information Competitive Analysis Key Competitors 2004: Mitsubishi Lancer Evolution VIII, Ford Focus RS, Honda Civic Type R (EP3), Volkswagen Golf GTI Key Features Performance Focus: Tuned turbocharged engine, Symmetrical All-Wheel Drive, Driver-focused chassis tuning Rally Heritage: Direct lineage from WRC success, providing rally-bred performance Manual Value Proposition: Enables owners to perform complex maintenance and repairs, enhancing vehicle longevity and performance potential. 📋 Manual Details Coverage Areas Main Coverage: Complete Service and Repair Manual Engine Coverage: EJ257 Turbocharged Boxer Engine Transmission Coverage: 6-speed Manual Transmission (TY856WR1JJ) Chassis Coverage: Suspension, Steering, Brakes, Drivetrain (AWD System) Body Coverage: Exterior and Interior Body Panels, Doors, Glass, Bumpers, Trim Electrical Coverage: Wiring Diagrams, Fuses, Relays, Lighting, ECUs, Sensors Acoustics Coverage: Noise, Vibration, and Harshness (NVH) Control Page Count Estimated Pages: Over 2000 Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format Delivery Format: Downloadable Digital File Archival Format: WinRAR Archive (.rar) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Ignition System, Exhaust System, Turbocharger System, Drivetrain, Transmission, Differentials (Front, Center, Rear) Chassis And Suspension: Front and Rear Suspension, Steering System, Brake System (ABS, Brake Booster, Master Cylinder, Calipers, Rotors, Lines), Wheel Hubs, Bearings Body And Interior: Body Panel Removal/Installation, Doors, Hood, Trunk, Seats, Interior Trim, Glass Replacement, HVAC System Electrical And Electronics: Engine Control Unit (ECU), Body Control Module (BCM), Powertrain Control Module (PCM), Wiring Diagrams, Fuses, Relays, Lighting Systems (Headlights, Taillights, Interior), Audio System, Power Accessories, SRS (Airbag) System Procedures Included Diagnostics: Troubleshooting Charts, Diagnostic Trouble Codes (DTCs), Symptom-based Diagnostics, Component Testing Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Spark Plug Replacement, Belt Inspection and Replacement Repair: Engine Overhaul, Turbocharger Rebuild/Replacement, Transmission Overhaul/Replacement, Clutch Replacement, Brake Pad/Rotor Replacement, Suspension Component Replacement, Electrical Component Repair, Body Panel Repair Installation: Component Installation and Removal (e.g., Engine, Transmission, Turbocharger, Suspension Components, Body Panels) Adjustment: Valve Clearance Adjustment, Clutch Pedal Adjustment, Handbrake Adjustment Technical Depth Depth Level: Comprehensive (from basic checks to full engine/transmission rebuilds) Diagnostic Capability: Advanced Diagnostic Procedures, Component Resistance and Voltage Checks, Sensor Signal Analysis Rebuild Specifications: Detailed Torque Specifications, Clearances, Assembly Procedures for Major Components 📊 Manual Specifications File Format Digital Format: PDF (likely extracted from original FSM) Searchability: Likely searchable text within PDF, depending on scan quality Print Quality Visual Quality: Variable (dependent on original source scans/creation) Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: EJ257 Engine Type: Horizontally-Opposed (Boxer), 4-Cylinder, 16-Valve, DOHC, Turbocharged Displacement: 2.5 Liters (2457 cc) Bore X Stroke: 99.5 mm x 79.0 mm Performance Horsepower Usdm: 300 hp @ 6000 rpm Torque Usdm: 300 lb-ft @ 4000 rpm Compression Ratio: 8.2:1 Turbocharger Model: IHI VF39 Intercooler Type: Air-to-Air Top-Mount Intercooler Fuel System Fuel Delivery: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Premium Gasoline (91+ Octane Recommended) Fuel Pump: High-flow electric fuel pump Fluid Capacity Engine Oil Capacity: 4.8 US quarts (4.5 liters) with filter change Fluid Specifications Engine Oil Viscosity: 5W-30 (API SG or SH grade, or equivalent) Engine Management ECU Type: Engine Control Unit (ECU) with specific STI calibration 🔧 Transmission Standard Type: 6-Speed Manual Transmission Model Code: TY856WR1JJ Optional Availability: N/A (STI model exclusively 6MT) Features Drivetrain Layout: Symmetrical All-Wheel Drive (AWD) with Driver Controlled Center Differential (DCCD) Front Differential: Open Differential Rear Differential: Viscous Limited Slip Differential (VLSD) Fluid Capacity Transmission Fluid Capacity: 2.2 US quarts (2.1 liters) Fluid Specifications Transmission Fluid Type: API GL-5, SAE 75W-90 Gear Oil (Subaru Extra-S recommended) Clutch Type: Hydraulically operated, single dry plate, diaphragm spring clutch 📐 Dimensions Exterior Length: 173.8 inches (4415 mm) Width: 69.7 inches (1770 mm) Height: 57.7 inches (1465 mm) Wheelbase: 104.7 inches (2659 mm) Front Track: 59.8 inches (1519 mm) Rear Track: 59.3 inches (1506 mm) Weights Curb Weight: 3285 lbs (1490 kg) approx. Gross Vehicle Weight Rating: 4299 lbs (1950 kg) Towing Capacity: Not Recommended/Specified Cargo Trunk Volume: 11.3 cubic feet (Sedan) Wheels And Tires Standard Wheel Size: 17 x 7.5 inches Standard Tire Size: 225/45R17 Bolt Pattern: 5 x 114.3 mm (5 x 4.5 inches) Wheel Offset: +53 mm 🛡️ Safety Features Ratings NHTSA Frontal Driver: 5-Star (for 2004 model year Impreza) NHTSA Frontal Passenger: 5-Star (for 2004 model year Impreza) IIHS Moderate Overlap Frontal: Good (for comparable 2nd Gen Impreza models) Active Features ABS: Standard Anti-lock Braking System (ABS) E-Brake: Rear Drum Parking Brake Passive Features Airbags: Driver and Passenger Frontal Airbags, Side Airbags (optional on some trims) Seatbelts: 3-point Front and Rear Seatbelts with pretensioners Body Structure: Ring-shaped reinforcement frame, reinforced...
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2004 Subaru Sti Service/Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza WRX STI
Year:
2004
Chassis Code:
GDB-F
Generation:
GD
Generation Variant:
GD/GG (2nd Generation, 'F' model year update)
👋 Introduction
Market Position
Vehicle Segment:
Compact Performance Sedan/Wagon (WRC Homologation Special)
Target Audience:
Enthusiasts, Owners Seeking In-depth Maintenance and Repair Information
Competitive Analysis
Key Competitors 2004:
Mitsubishi Lancer Evolution VIII, Ford Focus RS, Honda Civic Type R (EP3), Volkswagen Golf GTI
Key Features
Performance Focus:
Tuned turbocharged engine, Symmetrical All-Wheel Drive, Driver-focused chassis tuning
Rally Heritage:
Direct lineage from WRC success, providing rally-bred performance
Manual Value Proposition:
Enables owners to perform complex maintenance and repairs, enhancing vehicle longevity and performance potential.
📋 Manual Details
Coverage Areas
Main Coverage:
Complete Service and Repair Manual
Engine Coverage:
EJ257 Turbocharged Boxer Engine
Transmission Coverage:
6-speed Manual Transmission (TY856WR1JJ)
Chassis Coverage:
Suspension, Steering, Brakes, Drivetrain (AWD System)
Body Coverage:
Exterior and Interior Body Panels, Doors, Glass, Bumpers, Trim
Electrical Coverage:
Wiring Diagrams, Fuses, Relays, Lighting, ECUs, Sensors
Acoustics Coverage:
Noise, Vibration, and Harshness (NVH) Control
Page Count
Estimated Pages:
Over 2000
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
Delivery Format:
Downloadable Digital File
Archival Format:
WinRAR Archive (.rar)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Ignition System, Exhaust System, Turbocharger System, Drivetrain, Transmission, Differentials (Front, Center, Rear)
Chassis And Suspension:
Front and Rear Suspension, Steering System, Brake System (ABS, Brake Booster, Master Cylinder, Calipers, Rotors, Lines), Wheel Hubs, Bearings
Body And Interior:
Body Panel Removal/Installation, Doors, Hood, Trunk, Seats, Interior Trim, Glass Replacement, HVAC System
Electrical And Electronics:
Engine Control Unit (ECU), Body Control Module (BCM), Powertrain Control Module (PCM), Wiring Diagrams, Fuses, Relays, Lighting Systems (Headlights, Taillights, Interior), Audio System, Power Accessories, SRS (Airbag) System
Procedures Included
Diagnostics:
Troubleshooting Charts, Diagnostic Trouble Codes (DTCs), Symptom-based Diagnostics, Component Testing
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Replacements, Spark Plug Replacement, Belt Inspection and Replacement
Repair:
Engine Overhaul, Turbocharger Rebuild/Replacement, Transmission Overhaul/Replacement, Clutch Replacement, Brake Pad/Rotor Replacement, Suspension Component Replacement, Electrical Component Repair, Body Panel Repair
Installation:
Component Installation and Removal (e.g., Engine, Transmission, Turbocharger, Suspension Components, Body Panels)
Adjustment:
Valve Clearance Adjustment, Clutch Pedal Adjustment, Handbrake Adjustment
Technical Depth
Depth Level:
Comprehensive (from basic checks to full engine/transmission rebuilds)
Diagnostic Capability:
Advanced Diagnostic Procedures, Component Resistance and Voltage Checks, Sensor Signal Analysis
Rebuild Specifications:
Detailed Torque Specifications, Clearances, Assembly Procedures for Major Components
📊 Manual Specifications
File Format
Digital Format:
PDF (likely extracted from original FSM)
Searchability:
Likely searchable text within PDF, depending on scan quality
Print Quality
Visual Quality:
Variable (dependent on original source scans/creation)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EJ257
Engine Type:
Horizontally-Opposed (Boxer), 4-Cylinder, 16-Valve, DOHC, Turbocharged
Displacement:
2.5 Liters (2457 cc)
Bore X Stroke:
99.5 mm x 79.0 mm
Performance
Horsepower Usdm:
300 hp @ 6000 rpm
Torque Usdm:
300 lb-ft @ 4000 rpm
Compression Ratio:
8.2:1
Turbocharger Model:
IHI VF39
Intercooler Type:
Air-to-Air Top-Mount Intercooler
Fuel System
Fuel Delivery:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Premium Gasoline (91+ Octane Recommended)
Fuel Pump:
High-flow electric fuel pump
Fluid Capacity
Engine Oil Capacity:
4.8 US quarts (4.5 liters) with filter change
Fluid Specifications
Engine Oil Viscosity:
5W-30 (API SG or SH grade, or equivalent)
Engine Management
ECU Type:
Engine Control Unit (ECU) with specific STI calibration
🔧 Transmission
Standard
Type:
6-Speed Manual Transmission
Model Code:
TY856WR1JJ
Optional
Availability:
N/A (STI model exclusively 6MT)
Features
Drivetrain Layout:
Symmetrical All-Wheel Drive (AWD) with Driver Controlled Center Differential (DCCD)
Front Differential:
Open Differential
Rear Differential:
Viscous Limited Slip Differential (VLSD)
Fluid Capacity
Transmission Fluid Capacity:
2.2 US quarts (2.1 liters)
Fluid Specifications
Transmission Fluid Type:
API GL-5, SAE 75W-90 Gear Oil (Subaru Extra-S recommended)
Clutch
Type:
Hydraulically operated, single dry plate, diaphragm spring clutch
📐 Dimensions
Exterior
Length:
173.8 inches (4415 mm)
Width:
69.7 inches (1770 mm)
Height:
57.7 inches (1465 mm)
Wheelbase:
104.7 inches (2659 mm)
Front Track:
59.8 inches (1519 mm)
Rear Track:
59.3 inches (1506 mm)
Weights
Curb Weight:
3285 lbs (1490 kg) approx.
Gross Vehicle Weight Rating:
4299 lbs (1950 kg)
Towing Capacity:
Not Recommended/Specified
Cargo
Trunk Volume:
11.3 cubic feet (Sedan)
Wheels And Tires
Standard Wheel Size:
17 x 7.5 inches
Standard Tire Size:
225/45R17
Bolt Pattern:
5 x 114.3 mm (5 x 4.5 inches)
Wheel Offset:
+53 mm
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
5-Star (for 2004 model year Impreza)
NHTSA Frontal Passenger:
5-Star (for 2004 model year Impreza)
IIHS Moderate Overlap Frontal:
Good (for comparable 2nd Gen Impreza models)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
E-Brake:
Rear Drum Parking Brake
Passive Features
Airbags:
Driver and Passenger Frontal Airbags, Side Airbags (optional on some trims)
Seatbelts:
3-point Front and Rear Seatbelts with pretensioners
Body Structure:
Ring-shaped reinforcement frame, reinforced passenger compartment
💡 Technology Features
Infotainment
Head Unit:
Factory AM/FM/CD player
Speakers:
Typically 6-speaker system
Driver Assistance
Traction Control:
No explicit Traction Control System (TCS) but AWD and DCCD provide significant traction benefits.
Cruise Control:
Standard electronic cruise control
Connectivity
Aux Input:
N/A (typically no standard auxiliary input)
Instrumentation
Gauge Cluster:
Includes tachometer, speedometer, fuel gauge, coolant temperature, oil pressure warning light, DCCD indicator.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3.75 months (severe driving) / 7,500 miles or 7.5 months (normal driving), based on Subaru recommendations and oil type.
Air Filter Replacement:
Every 15,000 miles or 15 months
Cabin Air Filter Replacement:
Every 15,000 miles or 15 months
Spark Plug Replacement:
Every 30,000 miles (NGK PFR7B or equivalent)
Timing Belt Replacement:
Not Applicable (EJ257 uses a timing chain)
Coolant Flush:
Every 30,000 miles or 30 months
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (Subaru DOT3 recommended)
Power Steering Fluid:
Subaru ATF-HP or Dexron III equivalent
Coolant:
Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant
Known Issues
Engine Failure Risk:
Piston ring land failure (ringland failure), connecting rod bearing wear, head gasket failure (less common on EJ257 than earlier EJ25s but still a concern).
Turbocharger Failures:
Bearing wear in VF39 turbo due to oil contamination or lack of lubrication.
Clutch Wear:
Early clutch wear or failure, especially with aggressive driving or modifications.
Susceptibility To Oil Sludge:
Requires diligent adherence to oil change intervals and using quality oil to prevent sludge buildup.
Differential Failure:
Potential for center and rear differential failure under extreme stress or poor maintenance.
📚 Vehicle History
Brand Heritage
Subaru Rally Success:
Dominant presence in World Rally Championship (WRC) with multiple manufacturer and driver titles, directly influencing STI models.
Model Evolution
Impreza Development:
Introduced in 1992, the STI (Subaru Tecnica International) variants were developed for homologation and performance.
Gd Generation:
Second generation (GD/GG) launched in 2000, with significant updates in 2002 and 2004 (affecting bodywork, suspension, and engine management).
2004 Update:
Introduction of the 'F' model year for the GD chassis, featuring revised front-end styling (grille, headlights, bumper), wider track, and updated DCCD controls.
Production
Manufacturing Location:
Ota City, Gunma Prefecture, Japan
Production Years Gdb:
2000-2007
🏆 Awards & Recognition
Recognitions
Sport Compact Car Achievement:
Often recognized by automotive publications like Sport Compact Car for performance and handling.
Car And Driver 10Best:
While not consistently on 10Best, the Impreza line often received nods for its performance and value.
Certifications
Wrc Homologation:
STI models are WRC homologation specials, meeting FIA requirements for rally competition.
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