2004 SUBARU IMPREZA WRX STI Service & Repair Manual-PDF

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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX STI Year: 2004 Chassis Code: GDB Engine Code: EJ257 Generation Generation Designation: Second Generation (GDB) Generation Years: 2002-2007 Codes Vin Drivetrain...

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Mots clés: 2004 Car Cars IMPREZA WRX STI Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Impreza WRX STI

Year:

Chassis Code:

Engine Code:

EJ257

Generation

Generation Designation:

Second Generation (GDB)

Generation Years:

2002-2007

Codes

Vin Drivetrain Code:

H (for AWD)

👋 Introduction

Market Position

Performance Segment:

Compact Performance Sedan/Wagon

Rally Heritage:

Directly influenced by Subaru's World Rally Championship (WRC) success

Competitive Analysis

Key Competitors:

Mitsubishi Lancer Evolution, Ford Focus RS, Volkswagen Golf R

Key Features

Drivetrain Philosophy:

Symmetrical All-Wheel Drive (AWD) system with Driver Controlled Center Differential (DCCD)

Engine Philosophy:

Performance-tuned turbocharged Boxer engine

Suspension Tuning:

Performance-oriented suspension setup for enhanced handling

Braking System:

Upgraded Brembo braking system for superior stopping power

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete vehicle service and repair

Engine Coverage:

All engines (specifically EJ257 for WRX STI)

Drivetrain Coverage:

All-Wheel Drive (AWD) system, differentials, transmission

Body Coverage:

Exterior panels, interior trim, chassis components

Electrical Coverage:

Wiring diagrams, component testing, ECU diagnostics

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Official Service and Repair Manual

Language

Language:

English

Format

Format:

File Type:

Digital (Searchable PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine teardown, assembly, cylinder head, pistons, crankshaft, lubrication, cooling

Engine Management:

Fuel injection, ignition system, emissions control, ECU diagnostics, sensors

Transmission:

6-speed manual transmission (TY756VW4CA), clutch system, driveline components

Suspension:

Front struts, rear multi-link, springs, shocks, anti-roll bars, alignment procedures

Brakes:

Front Brembo 4-piston calipers, rear 2-piston calipers, ABS system, brake fluid

Steering:

Power assisted rack and pinion, steering column

Electrical System:

Starting and charging system, lighting, instrumentation, audio system, power windows, airbags

HVAC:

Air conditioning, heating, ventilation, refrigerant handling

Body And Chassis:

Frame, body panels, doors, hood, trunk, glass, interior trim

Procedures Included

Preventative Maintenance:

Oil changes, filter replacements, fluid checks, spark plug replacement, belt inspection

Troubleshooting:

Diagnostic flowcharts for common and uncommon issues, symptom-based troubleshooting

Repair And Rebuild:

Detailed step-by-step instructions for component removal, disassembly, repair, and reassembly

Diagnostics:

OBD-II diagnostics, sensor testing, actuator testing, ECU relearning procedures

Specifications And Tolerances:

Torque specifications, measurement tolerances, clearances

Wiring Diagrams:

Comprehensive electrical schematics for all vehicle systems

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to full engine/transmission rebuilds)

Diagnostic Capability:

Advanced diagnostic procedures, component-level testing

Wiring Detail:

Pinouts, wire colors, connector diagrams

📊 Manual Specifications

File Format

File Format Type:

PDF (Portable Document Format)

Searchability:

Text-searchable, allowing quick access to specific information

Printability:

Printable pages for workshop use

Digital Features:

Hyperlinked sections for easy navigation (typical for professional PDFs)

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Horizontally-opposed turbocharged Boxer 4-cylinder

Displacement:

2.0 Liters (1994 cc)

Bore X Stroke:

92.0 mm x 75.0 mm

Compression Ratio:

8.4:1

Valve Train:

DOHC, 16 valves (4 valves per cylinder)

Performance

Horsepower:

300 hp @ 6000 rpm (SAE Net)

Torque:

290 lb-ft @ 4000 rpm (SAE Net)

Fuel System

Fuel Delivery:

Sequential multi-port fuel injection (MPI)

Fuel Type:

Premium Unleaded Gasoline (91 octane or higher recommended)

Turbocharger:

IHI VF30 (or similar, depending on market)

Intercooler:

Top-mounted air-to-air intercooler

🔧 Transmission

Standard

Transmission Type:

6-speed manual

Transmission Model:

TY756VW4CA

Optional

Optional Transmission:

N/A (6-speed manual was standard on WRX STI)

Features

Dccd:

Driver Controlled Center Differential (DCCD) with automatic and manual modes

Differential Type:

Front: Helical LSD; Rear: Active Torque Split DCCD with Viscous LSD

📐 Dimensions

Exterior

Length:

4415 mm (173.8 inches)

Width:

1770 mm (69.7 inches)

Height:

1440 mm (56.7 inches)

Wheelbase:

2625 mm (103.3 inches)

Front Track:

1515 mm (59.6 inches)

Rear Track:

1505 mm (59.3 inches)

Weights

Curb Weight:

Approx. 1460 kg (3219 lbs)

Gross Vehicle Weight Rating:

Approx. 1900 kg (4189 lbs)

Cargo

Trunk Volume:

Approx. 0.33 m³ (11.8 cu ft) (Sedan)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

4/5 Stars (Driver/Passenger)

NHTSA Side Impact Test:

4/5 Stars (Front/Rear Passenger)

IIHS Moderate Overlap Front:

Active Features

4-wheel Anti-lock Braking System (ABS)

E Brake Force Distribution:

Electronic Brake-force Distribution (EBD)

Traction Control:

Standard Traction Control System (TCS)

Passive Features

Airbags:

Front driver and passenger airbags, front side-impact airbags

Seatbelts:

3-point seatbelts with pretensioners and load limiters

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system

💡 Technology Features

Infotainment

Head Unit:

Factory-installed CD player with AM/FM radio. Higher trims may have premium audio systems.

Speaker System:

Standard 4-speaker or optional 6-speaker audio system (e.g., Clarion).

Driver Assistance

Cruise Control:

Standard electronic cruise control

Anti Theft System:

Factory immobilizer and alarm system

Connectivity

Auxiliary Input:

Optional or aftermarket auxiliary input for audio devices

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 6 months (severe conditions), or 7,500 miles or 12 months (normal conditions)

Air Filter Replacement Interval:

Every 15,000-30,000 miles, or as needed based on inspection

Cabin Air Filter Replacement Interval:

Every 15,000-30,000 miles, or annually

Spark Plug Replacement Interval:

Every 30,000-60,000 miles (depending on plug type - iridium recommended)

Timing Belt Replacement Interval:

Not applicable (uses a timing chain)

Fluid Specifications

Engine Oil Type:

5W-30 Synthetic (API SN or higher recommended)

Engine Oil Capacity:

4.5 US quarts (4.3 L) with filter

Coolant Type:

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

Coolant Capacity:

Approx. 7.5 US quarts (7.1 L)

Transmission Fluid Type:

API GL-4 Gear Oil (e.g., Subaru Extra-S or equivalent high-quality 75W-90)

Transmission Fluid Capacity:

Approx. 3.0 US quarts (2.8 L)

Rear Differential Fluid Type:

API GL-5 Gear Oil (75W-90)

Rear Differential Fluid Capacity:

Approx. 0.9 US quarts (0.85 L)

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Power Steering Fluid Type:

Subaru Automatic Transmission Fluid (ATF) - Type WS (or equivalent)

Known Issues

Head Gasket Failures:

While less common than earlier models, early GDB EJ25 engines can still be susceptible to head gasket failure, especially if not maintained or if modified.

Piston Ringland Failure:

Can occur with aggressive tuning or detonation. Regular use of premium fuel and proper engine management is crucial.

Clutch Wear:

High-performance nature of the STI can lead to faster clutch wear, especially with aggressive driving.

Turbocharger Wear:

The IHI VF30 turbo can develop wear over time, leading to reduced boost pressure or failure.

Oil Consumption:

Some EJ25 engines exhibit higher than average oil consumption, necessitating regular oil level checks.

📚 Vehicle History

Brand Heritage

Subaru Rally Heritage:

Subaru's long-standing success and association with the World Rally Championship (WRC) heavily influenced the Impreza WRX STI lineage.

Model Evolution

Gc8 To Gdb Transition:

The 2004 model marks the transition to the second generation (GDB) chassis, offering significant upgrades in styling, technology, and performance over the previous GC8 generation.

Sti Evolution:

The STI (Subaru Tecnica International) variant represents the pinnacle of the Impreza line, featuring enhanced engines, transmissions, suspensions, and braking systems derived from rally technology.

Production

Production Period:

Second generation (GDB) produced from 2002 to 2007

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The Impreza WRX (non-STI) was frequently recognized on Car and Driver's 10Best lists during this era, highlighting the model's performance credentials.

Ratings

Sport Compact Of The Year:

The WRX STI often received 'Sport Compact of the Year' awards from various automotive publications.

Certifications

Engine Certification:

Meets EPA and CARB emissions standards for the model year