Subaru Impreza WRX 2005 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Impreza WRX Year: 2005 Codes Chassis Code: GDB Engine Code Primary: EJ205 👋 Introduction Market Position Vehicle Segment: Compact/Performance Sedan/Wagon Target Audience: Enthusiasts,...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Impreza WRX

Year:

Codes

Chassis Code:

Engine Code Primary:

EJ205

👋 Introduction

Market Position

Vehicle Segment:

Compact/Performance Sedan/Wagon

Target Audience:

Enthusiasts, performance-oriented drivers, rally-inspired consumers.

Competitive Analysis

Key Competitors:

Mitsubishi Lancer Evolution, Honda Civic Si, Volkswagen GTI, Ford Focus SVT.

Key Features

Drivetrain Philosophy:

Symmetrical All-Wheel Drive (AWD) as standard, emphasizing traction and handling.

Engine Technology:

Turbocharged Boxer engine for a low center of gravity and distinctive sound.

Performance Focus:

Tuned for sporty driving, acceleration, and handling characteristics, often associated with rally racing heritage.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format Primary:

Digital (likely PDF)

Page Count

Estimated Page Count:

1000+

Format

File Format:

Digital PDF (typically, though physical copies may exist)

Searchability:

Searchable text within the PDF for quick access to specific information.

Printability:

Printable pages for workshop use.

Illustrations Diagrams:

Includes diagrams, schematics, and illustrations to aid understanding.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of all engine components including block, cylinder heads, pistons, crankshaft, camshafts, timing system.

Engine Performance:

Detailed specifications for engine tuning, performance upgrades, ECU mapping basics, turbocharger system diagnostics and repair.

Fuel System:

Fuel injectors, fuel pump, fuel filter, fuel pressure regulator, EVAP system diagnostics and repair.

Ignition System:

Spark plugs, ignition coils, crankshaft position sensor, camshaft position sensor diagnostics and replacement.

Cooling System:

Radiator, thermostat, water pump, coolant hoses, fan system diagnostics and repair.

Lubrication System:

Oil pump, oil pan, oil filter, oil cooler (if applicable), oil pressure diagnostics and repair.

Transmission Manual:

Clutch system, gearbox disassembly, inspection, repair, and reassembly, shift linkages, driveshafts, differential.

Transmission Automatic:

Diagnostics, fluid checks, minor repairs (if applicable for specific WRX trims).

Drivetrain:

All-Wheel Drive (AWD) system, center differential, viscous coupling, rear differential diagnostics and repair.

Suspension Front:

MacPherson struts, control arms, sway bar, bushings, wheel bearings diagnostics and replacement.

Suspension Rear:

Multi-link suspension, shock absorbers, springs, trailing arms, bushings, wheel bearings diagnostics and replacement.

Steering System:

Power steering pump, steering rack, tie rods, steering column diagnostics and repair.

Brake System:

Front and rear brake calipers, rotors, pads, brake lines, master cylinder, ABS system diagnostics and repair.

Electrical System General:

Wiring diagrams, fuse box locations, relay functions, battery, charging system (alternator, starter).

Lighting System:

Headlights, taillights, interior lights, fog lights diagnostics and repair.

Instrument Panel:

Gauges, warning lights, warning chimes diagnostics and repair.

Comfort Control:

HVAC system, blower motor, heater core, A/C compressor, refrigerant system diagnostics and repair.

Body Exterior:

Body panel removal and installation, door mechanisms, hood, trunk, bumpers, glass replacement.

Body Interior:

Seat removal, dashboard disassembly, trim panel replacement, interior components.

Diagnostics:

OBD-II diagnostic trouble codes (DTCs), diagnostic procedures, scan tool usage, troubleshooting flowcharts.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, tire rotations.

Component Replacement:

Detailed step-by-step instructions for replacing virtually all major and minor components.

Troubleshooting Fault Finding:

Systematic approach to identifying and resolving common and uncommon vehicle issues.

Engine Rebuild:

Comprehensive guide for engine overhaul, including machining specifications and assembly procedures.

Transmission Repair:

Detailed instructions for manual gearbox repair, clutch replacement, and AWD system service.

Brake Service:

Pad and rotor replacement, caliper service, brake bleeding, ABS system troubleshooting.

Suspension Alignment:

Specifications and procedures for suspension alignment adjustments.

Electrical Diagnostics:

Using wiring diagrams to trace circuits, test components, and diagnose electrical faults.

Body Repair:

Procedures for minor body panel repairs, dent removal, and replacement of exterior trim.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics.

Diagnostic Tools Required:

Standard hand tools, specialized engine tools (e.g., timing belt tools, piston ring compressor), OBD-II scanner, multimeter.

Torque Specifications:

Detailed torque values for all critical fasteners across all vehicle systems.

Clearances Tolerances:

Precise measurements for component clearances and wear tolerances required during rebuilding.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Horizontally Opposed (Boxer), Turbocharged, Intercooled, DOHC

Displacement:

2.0 Liters (1994 cc)

Bore X Stroke:

92.0 mm x 75.0 mm

Compression Ratio:

8.0:1

Valvetrain:

DOHC, 4 valves per cylinder

Performance

Horsepower Peak:

227 hp @ 6400 RPM

Torque Peak:

217 lb-ft @ 4400 RPM

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Premium (91 octane or higher recommended)

Turbocharger:

Mitsubishi TD04L-13T or similar (specific turbo may vary slightly by region)

Intercooler:

Air-to-air top-mount intercooler

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission (TY754VN)

Optional

Transmission Type:

4-speed Automatic Transmission (4EAT) - Less common for WRX models, more prevalent in standard Impreza.

Features

AWD System:

Symmetrical All-Wheel Drive with a viscous coupling center differential.

Gear Ratios Manual:

Specific ratios vary, but typically geared for performance. (e.g., 1st: 3.167, 2nd: 1.947, 3rd: 1.370, 4th: 1.063, 5th: 0.825)

Differential Type:

Front: Open, Rear: Limited Slip Differential (LSD) - often helical or viscous for WRX.

📐 Dimensions

Exterior

Wheelbase:

2525 mm (99.4 inches)

Length:

4415 mm (173.8 inches)

Width:

1700 mm (66.9 inches)

Height:

1445 mm (56.9 inches)

Ground Clearance:

135 mm (5.3 inches)

Weights

Curb Weight:

1370 kg (3020 lbs) - approximate, varies by trim and options

Gross Vehicle Weight Rating:

Approx. 1850 kg (4079 lbs)

Cargo

Trunk Volume:

Sedan: ~0.37 m³ (13.0 cu ft), Wagon: ~0.37 m³ (13.0 cu ft) with seats up

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not directly rated in 2005 model year by NHTSA for WRX specifically in all configurations. General Impreza models received good ratings.

Active Features

Standard Anti-lock Braking System

E Brake:

Hand-operated parking brake

Passive Features

Airbags Front:

Driver and front passenger airbags

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

Rollover Protection:

Reinforced chassis and A-pillars designed to minimize cabin intrusion during rollovers, a key feature of Subaru's AWD platform.

💡 Technology Features

Infotainment

Head Unit:

Base single-DIN or double-DIN aftermarket stereo systems were common. Factory units were typically basic AM/FM/CD players.

Speaker System:

Standard 4-speaker or optional 6-speaker system.

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Traction Control:

Not typically equipped with electronic traction control (like VDC) as standard on the WRX models of this era; AWD and driver skill were primary traction aids.

Connectivity

Auxiliary Input:

Not standard. Aftermarket head unit upgrades often provided aux input or USB connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions (severe vs. normal).

Engine Oil Filter Interval:

Replace with oil change.

Air Filter Interval:

Inspect every 15,000 miles (24,000 km), replace as needed.

Cabin Air Filter Interval:

Inspect every 15,000 miles (24,000 km), replace as needed.

Spark Plug Replacement:

Every 30,000-45,000 miles (48,000-72,000 km) with specific platinum or iridium plugs.

Timing Belt Replacement:

Crucial: Every 90,000-105,000 miles (145,000-170,000 km) or 7-10 years, includes idlers and tensioner.

Coolant Flush:

Every 30,000 miles (48,000 km) or 2-3 years.

Transmission Fluid Change:

Manual: Every 30,000-50,000 miles (48,000-80,000 km). Automatic: More frequent, typically 20,000-30,000 miles (32,000-48,000 km).

Differential Fluid Change:

Front & Rear: Every 30,000-50,000 miles (48,000-80,000 km).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 Synthetic (API SG, SH, SJ, SL or ILSAC GF-2, GF-3 certified)

Engine Oil Capacity:

4.8 US quarts (4.5 liters) with filter change.

Coolant Type:

Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant.

Transmission Fluid Type Manual:

API GL-5, SAE 75W-90 (Hypoid gear oil)

Transmission Fluid Type Automatic:

Subaru ATF-HP (Highly Recommended)

Differential Fluid Type:

API GL-5, SAE 75W-90 (Hypoid gear oil)

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid Type:

Subaru Genuine Power Steering Fluid or Dexron III/Mercon compatible ATF.

Known Issues

Short Block Failure:

EJ205 engines are known for potential ringland failure, especially if subjected to detonation or excessive boost. Regular use of high-octane fuel and proper tuning is crucial.

Clutch Wear:

Performance driving can lead to accelerated clutch wear. Clutch replacement is a common maintenance item.

Rear Main Seal Leaks:

Common on many Subaru models, including this generation, leading to oil leaks at the transmission mating surface.

Suspension Bushings:

Worn control arm bushings, sway bar bushings, and subframe bushings can lead to a vague steering feel and clunking noises.

Turbo Oil Feed Line:

The banjo bolt on the turbo oil feed line can become clogged with debris, starving the turbo of oil and leading to premature failure. Regular inspection and cleaning are advised.

Catalytic Converter:

Can become clogged over time, affecting performance and emissions. Requires replacement if functionality is compromised.

📚 Vehicle History

Brand Heritage

Subaru Motorsports:

Deep roots in World Rally Championship (WRC) with Colin McRae and Richard Burns, influencing the WRX's design and performance focus.

Model Evolution

Gc8 Platform:

The 2005 WRX is part of the second generation (GD/GG chassis), often referred to as 'GC8' by enthusiasts, which saw significant chassis and powertrain refinements over the first generation.

Subtle Facelift 2004:

The 2005 model year saw a significant facelift (often called 'Hawkeye') with new headlights, bumper, grille, and hood, improving aerodynamics and styling.

Production

Production Years Gen2:

2000-2007 (GD/GG chassis)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Subaru Impreza WRX models have frequently appeared on Car and Driver's 10Best lists in various years for their performance and value.

Wrc Success:

The continuous success of Subaru in the World Rally Championship directly bolsters the credibility and appeal of the road-going WRX.