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(317 MB) 2004 Subaru Impreza STI WRX-Official Factory Service Manual (FSM)/Repair Manual/Workshop Manual 04 (ZIP-PDF Format)

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Welcome to the factory service manual for the 2004 Subaru Impreza WRX STI, a high-performance compact sedan renowned for its rally-bred heritage and exceptional all-wheel-drive capabilities. This model, part of...
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(317 MB) 2004 Subaru Impreza STI WRX-Official Factory Service Manual (FSM)/Repair Manual/Workshop Manual 04 (ZIP-PDF Format)
Welcome to the factory service manual for the 2004 Subaru Impreza WRX STI, a high-performance compact sedan renowned for its rally-bred heritage and exceptional all-wheel-drive capabilities. This model, part of the GDB generation, is celebrated for its potent 2.5L turbocharged Boxer engine, delivering approximately 300 horsepower and 300 lb-ft of torque, paired with a precise 6-speed manual transmission and Subaru's signature Symmetrical All-Wheel Drive system featuring a Driver Controlled Center Differential (DCCD). Its engineering emphasizes agile handling and a direct connection to the road, making it a standout in its class and a favorite among driving enthusiasts. This comprehensive manual provides in-depth coverage for all repairs, from routine maintenance to complex overhauls. You will find detailed procedures for the engine, transmission (both manual and automatic variants), drivetrain, suspension, brakes, steering, and electrical systems, including extensive wiring diagrams. The manual also covers body interior and exterior components, climate control, and safety restraint systems. With step-by-step instructions, diagnostic guides, and exploded diagrams, this resource is an indispensable tool for owners and technicians seeking to maintain, troubleshoot, and repair the 2004 Subaru Impreza WRX STI with accuracy and efficiency.
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Impreza WRX STI
Year:
2004
Generation
Generation Code:
GDB (GD)
Codes
Chassis Code:
GDB
👋 Introduction
Market Position
Positioning:
High-performance compact sedan/hatchback, rally-bred heritage
Competitive Analysis
Competitors:
Mitsubishi Lancer Evolution, Subaru WRX (non-STI), Honda Civic Si, Volkswagen GTI, MazdaSpeed3
Key Features
Performance Orientation:
Emphasis on turbocharged engine, all-wheel drive (AWD), and agile handling
Rally Heritage:
Direct lineage from Subaru's World Rally Championship (WRC) success
📋 Manual Details
Coverage Areas
Primary Coverage:
All models and all repairs A-Z
Specific Systems Covered:
Engine, Transmission, Chassis, Body, Electrical System
Page Count
Estimated Page Count:
High (typical FSMs are 1000+ pages)
Manual Type
Type:
Official Factory Service Manual (FSM) / Repair Manual / Workshop Manual
Language
Language:
English
Format
Digital Format:
PDF
Compatibility
Operating Systems:
Windows & Mac
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Mechanical parts, diagnostics, cooling, lubrication, ignition, starting
Engine Fuel Air Exhaust:
Fuel injection, air intake, exhaust systems
Transmission Manual:
5-speed manual (5MT) and 6-speed manual (6MT) transmissions
Transmission Automatic:
4-speed automatic transmission (4AT) (less common for STI, but often included in comprehensive FSMs for model range)
Drivetrain:
Transfer case, driveshaft, differentials, clutch
Suspension:
Front and rear suspension systems
Brakes:
Antilock Braking System (ABS), brake system components, parking brake
Steering:
Steering system components
Body Exterior:
Body panels, glass, windows, mirrors, lighting, wipers/washers
Body Interior:
Instrument panel, seats, locks, security, sunroof, interior finishing
Climate Control:
HVAC system, climate system components
Safety Restraints:
Airbags, seatbelts
Electrical General:
General diagnosis, component locations
Electrical Wiring:
Comprehensive wiring diagrams, signals
Procedures Included
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements
Diagnostics:
Dedicated troubleshooting guides, diagnostic procedures for various systems
Repair:
Step-by-step repair instructions for all major components
Disassembly Assembly:
Exploded diagrams for component disassembly and reassembly
Wiring Diagrams Detail:
High level of detail in wiring schematics, showing component connections and routing.
Technical Depth
Depth:
Comprehensive (covers maintenance to major overhauls and diagnostics)
📊 Manual Specifications
File Format
Format:
ZIP archive containing PDF files
Print Quality
Printability:
Printable pages (user can print selectively)
Binding Type
Binding Type:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format)
File Size
Size Mb:
317 MB
⚙️ Engine Specifications
Primary Engine
Engine Code:
EJ257
Engine Type:
2.5L Boxer-4 Turbocharged (EJ257)
Performance
Horsepower Hp:
300 hp @ 6000 RPM (approximate, US spec)
Torque Lb Ft:
300 lb-ft @ 4000 RPM (approximate, US spec)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Recommended Fuel:
Premium Unleaded (91+ Octane)
Engine Management
ECU Type:
Subaru Select Monitor (SSM)
🔧 Transmission
Standard
Type:
6-speed Manual Transmission (6MT)
Optional
Type:
4-speed Automatic Transmission (4AT) (less common for STI, often not specified for STI models)
Features
All Wheel Drive:
Symmetrical All-Wheel Drive (AWD) with Driver Controlled Center Differential (DCCD) on 6MT models
📐 Dimensions
Exterior
Length In:
173.8 in
Width In:
69.7 in
Height In:
56.1 in
Weights
Curb Weight Lbs:
3263 lbs (approximate for 6MT sedan)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for driver and passenger, typical for this era)
NHTSA Side Impact:
5-Star (typical for this era)
Active Features
Traction Control:
Yes (often linked to AWD system)
Electronic Stability Control:
Subaru Vehicle Dynamics Control (VDC) system
Passive Features
Airbags:
Front airbags, side-impact airbags
Seatbelts:
Front pre-tensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, premium sound system (optional)
Driver Assistance
ABS:
Standard Antilock Braking System (ABS)
AWD Control:
Driver Controlled Center Differential (DCCD) for manual transmission models, allowing variable front/rear torque split adjustment.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3.75 months, or 7,500 miles/7.5 months with synthetic oil (check specific recommendations)
Timing Belt Replacement:
105,000 miles (for EJ257 engine)
Fluid Specifications
Engine Oil Type:
SAE 0W-30 or 5W-30 Synthetic (refer to manual for specific viscosity based on temperature)
Coolant Type:
Subaru Super Coolant (Blue) or equivalent
Transmission Fluid Type 6Mt:
Subaru Extra-S Gear Oil or equivalent SAE 75W-90 GL-5
Known Issues
Head Gaskets:
Less prone to blown head gaskets than earlier EJ20/EJ25 engines due to improved design, but still a potential failure point under high stress.
Ring Lands:
Susceptible to ring land failure on pistons, especially with aggressive tuning or detonation, common in high-mileage or abused EJ257 engines.
Clutch Wear:
Clutch wear can be accelerated with aggressive driving and frequent launches.
📚 Vehicle History
Brand Heritage
Brand Focus:
AWD technology, horizontally-opposed engines, rally racing
Model Evolution
Generation 2004:
Part of the second generation (GDB) Impreza, representing a significant performance uplift and distinct STI styling
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Performance Awards:
Consistently praised by automotive journalists for its performance, handling, and AWD system, often featured in 'best performance car' lists.
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