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2004 Subaru WRX STI Workshop Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: Subaru Model: WRX STI Year: 2004 Generation Generation Code: GDB (2nd Generation, "Blobeye" revision) Codes Chassis Code: GDB Engine Code: EJ257 ๐ Introduction Market Position...
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๐ท๏ธ Basic Information
Identification
Make:
Subaru
Model:
WRX STI
Year:
2004
Generation
Generation Code:
GDB (2nd Generation, "Blobeye" revision)
Codes
Chassis Code:
GDB
Engine Code:
EJ257
๐ Introduction
Market Position
Market Segment:
Performance Sedan / Rally-Bred Sport Compact
Target Audience:
Enthusiasts, DIY mechanics, professional automotive technicians specializing in Subaru performance vehicles.
Competitive Analysis
Key Competitors 2004:
Mitsubishi Lancer Evolution VIII, Ford Focus SVT, Volkswagen Golf GTI, Acura RSX Type-S.
Key Features
Vehicle Highlight 1:
Symmetrical All-Wheel Drive (AWD) with DCCD.
Vehicle Highlight 2:
Legendary EJ257 Boxer Engine with Turbocharging.
Vehicle Highlight 3:
Performance-tuned suspension and braking systems.
Manual Value Proposition
Value To Owner:
Enables owners to perform all maintenance and repairs, saving money and ensuring optimal performance.
Value To Technician:
Provides authoritative, factory-level information for efficient and accurate servicing.
๐ Manual Details
Coverage Areas
Coverage Scope:
Complete service and repair coverage for all aspects of the 2004 Subaru WRX STI.
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Type:
Workshop Service Repair Manual (WSRM)
Language
Language:
English
Format
Format:
Digital (Likely PDF, Print-On-Demand)
๐ Manual Coverage
Systems Covered
Engine Mechanical:
Detailed breakdown of EJ257 engine: disassembly, assembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication, cooling systems.
Engine Performance:
Fuel injection system (ECU control, injectors, fuel pump, pressure regulator), ignition system, emissions control, turbocharger (assembly, wastegate, blow-off valve).
Transmission Drivetrain:
Manual transmission (TY856), clutch system, propeller shaft, front/rear differentials, DCCD (Driver's Control Centre Differential) system.
Suspension Steering:
Front and rear suspension (struts, control arms, stabilizer bars), power steering system, steering column.
Brakes:
Front and rear brake systems (calipers, rotors, pads), ABS (Anti-lock Braking System), brake hydraulics, parking brake.
Electrical Systems:
Wiring diagrams, power distribution, starting/charging system, lighting, instrumentation, body electronics, ECUs (Engine Control Unit, Transmission Control Unit, etc.).
Body Chassis:
Body panel removal/installation, interior trim, exterior trim, chassis components, corrosion protection.
Procedures Included
Maintenance:
Routine maintenance schedules, oil changes, filter replacements, spark plug replacement, coolant service, brake fluid service.
Repair Overhaul:
Complete engine overhaul, transmission rebuild, suspension component replacement, brake caliper/rotor replacement, turbocharger service.
Diagnostics:
Troubleshooting guides, fault code interpretation, diagnostic procedures for various systems, use of Subaru Select Monitor (SSM).
Specifications Data:
Torque specifications, clearances, fluid capacities, technical data for all components.
Technical Depth
Depth:
Comprehensive, from basic fluid checks to complete engine and transmission rebuilds, including ECU tuning parameter descriptions.
๐ Manual Specifications
File Format
File Format:
PDF
Searchable Text:
Yes (Assumed for digital format)
Print Quality
Print Quality Recommendation:
High-resolution for clear diagrams and text.
Binding Type
Binding Type:
N/A (Digital), Professional binding recommended if printed.
Paper Type
Paper Type Recommendation:
Durable, matte finish paper for workshop use if printed.
โ๏ธ Engine Specifications
Primary Engine
Engine Code:
EJ257
Engine Type:
2.5L DOHC turbocharged flat-four boxer engine
Performance
Horsepower Hp:
260 hp @ 5600 rpm (USDM specification)
Torque Lb Ft:
290 lb-ft @ 3600 rpm (USDM specification)
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI), Sequential Electronic Fuel Injection (SEFI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Induction
Turbocharger:
IHI VF39
Compression Ratio
Compression Ratio:
8.2:1
๐ง Transmission
Standard
Transmission Type:
6-speed manual transmission
Transmission Model:
TY856
Optional
Optional Transmission:
N/A for WRX STI
Features
Dccd:
Driver's Control Centre Differential (DCCD) with manual/auto modes
Fluid Specifications
Manual Transmission Fluid:
Subaru Extra S Gear Oil (or equivalent API GL-5 75W-90)
Clutch
Clutch Type:
Hydraulically operated, multi-plate, dry type
๐ Dimensions
Exterior
Wheelbase In:
104.0
Length In:
173.8
Width In:
69.7
Height In:
57.1
Weights
Curb Weight Lbs:
3263
Wheels Tires
Wheel Size:
17 x 7.5 inches
Tire Size:
225/45R17
Bolt Pattern:
5x100mm
๐ก๏ธ Safety Features
Ratings
NHTSA Frontal Driver:
5-Star
NHTSA Frontal Passenger:
5-Star
IIHS Moderate Overlap Frontal:
Good
Active Features
ABS:
Yes, 4-wheel disc brakes with ABS
Traction Control:
Yes, Subaru's Symmetrical AWD system
Passive Features
Airbags:
Frontal airbags, Front side-impact airbags
Seatbelts:
3-point front and rear seatbelts with pretensioners
๐ก Technology Features
Infotainment
Head Unit:
Basic AM/FM/CD stereo system, optional CD changer. Analog climate controls.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Dccd:
Electronically controlled center differential for torque distribution adjustment.
Connectivity
Auxiliary Input:
Limited to aftermarket integrations; no standard USB or Bluetooth.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3 months (severe conditions) / 7,500 miles or 7.5 months (normal conditions) - Consult manual for specifics.
Engine 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 PFR7G recommended).
Timing Belt Replacement:
N/A - EJ257 uses a timing chain, not a belt.
Fluid Specifications
Engine Oil Capacity:
5.5 US quarts (with filter) of 5W-30 synthetic oil.
Coolant Type:
Subaru Super Coolant (Blue) or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Ring Land Failure:
Common issue on EJ257 engines, particularly with aggressive tuning or poor fueling. Manual provides insights into engine assembly and tolerances.
Turbocharger Failures:
IHI VF39 can be prone to wear; manual details inspection and replacement procedures.
Clutch Wear:
High-performance nature can lead to accelerated clutch wear; manual covers clutch inspection and replacement.
Suspension Bushings:
Wear can affect handling; manual details replacement of various suspension bushings.
๐ Vehicle History
Brand Heritage
Subaru Rally History:
Subaru's long and successful history in World Rally Championship (WRC) directly influences the WRX and STI models.
Model Evolution
Gc8 To Gdb Transition:
The 2004 model represents the second generation (GDB) 'Blobeye' revision, following the 'Bugeye' and preceding the 'Hawkeye'.
Production
Production Location:
Japan
Production Years Gdb Gen:
2002-2007
๐ Awards & Recognition
Recognitions
Car And Driver ุงูุนุดุฑุฉ ุงูุฃูุถู:
2004 Subaru WRX STI was often praised in contemporary reviews for its performance and rally-bred capabilities, though not specifically awarded '10 Best' by Car and Driver in 2004.
Ratings
Autoguide Review:
Praised for AWD grip, turbocharged power, and raw driving experience.
Certifications
Emissions Certification:
Meets EPA and CARB emissions standards for 2004.