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Subaru WRX STi 2004 Workshop Manual

Download Subaru WRX STi 2004 Workshop Manual


Subaru WRX STi 2004 Workshop Manual
Sedan, Wagon, Outback, STi

2.0L Turbo

2.5L

STi

CONTAINS FULLY ILLUSTRATED & CONCISE SECTIONS ON:-

ENGINE

TRANSMISSION

CHASSIS

GENERAL SERVICING

ELECTRICAL

And much more

1. GENERAL INFORMATION

01. FOREWORD
02. HOW TO USE THIS MANUAL
03. SPECIFICATIONS
04. PRECAUTION
05. NOTE
06. IDENTIFICATION
07. RECOMMENDED MATERIALS
08. PRE-DELIVERY INSPECTION
09. PERIODIC MAINTENANCE SERVICES
01. General Description.
02. Schedule.
03. Engine Oil.
04. Engine Oil Filter.
05. Spark Plugs.
06. V-belt.
07. Timing Belt.
08. Fuel Line.
09. Fuel Filter.
10. Air Cleaner Element.
11. Cooling System.
12. Coolant.
13. Clutch System.
14. Transmission Gear Oil.
15. ATF.
16. Front & Rear Differential Gear Oil.
17. Brake Line.
18. Brake Fluid.
19. Disc Brake Pads and Discs.
20. Parking Brake.
21. Suspension.
22. Wheel Bearing.
23. Axle Boots & Joints.
24. Tire Rotation.
25. Steering System

26. Supplemental Restraint System.

2. ENGINE SECTION (STi)

01. FUEL INJECTION (FUEL SYSTEMS)
01. General Description.
02. Throttle Body.
03. Intake Manifold.
04. Engine Coolant Temperature Sensor.
05. Crankshaft Position Sensor.
06. Camshaft Position Sensor.
07. Knock Sensor.
08. Mass Air Flow and Intake Air Temperature Sensor.
09. Manifold Absolute Pressure Sensor.
10. Fuel Injector.
11. Tumble Generator Valve Assembly.
12. Tumble Generator Valve Actuator.
13. Wastegate Control Solenoid Valve.
14. Front Oxygen (A-F) Sensor.
15. Rear Oxygen Sensor.
16. Engine Control Module (ECM).
17. Main Relay.
18. Fuel Pump Relay.
19. Fuel Pump Control Unit.
20. Fuel.
21. Fuel Tank.
22. Fuel Filler Pipe.
23. Fuel Pump.
24. Fuel Level Sensor.
25. Fuel Sub Level Sensor.
26. Fuel Filter.
27. Fuel Cut Valve.
28. Fuel Damper Valve.
29. Fuel Delivery, Return and Evaporation Lines.
30. Fuel System Trouble in General.
02. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)
01. General Description.
02. Front Catalytic Converter.
03. Rear Catalytic Converter.
04. Canister.
05. Purge Control Solenoid Valve.
06. Main Fuel Level Sensor.
07. Fuel Temperature Sensor.
08. Fuel Sub Level Sensor.
09. Fuel Tank Pressure Sensor.
10. Fuel Tank Sensor Control Valve.
11. Pressure Control Solenoid.
12. Drain Filter.
13. Vent Valve.
14. Shut Valve.
15. Drain Valve.
16. PCV Hose Assembly.
03. INTAKE (INDUCTION)

01. General Description.
02. Air Cleaner.
03. Air Intake Duct.
04. Intake Duct.
05. Intercooler.
06. Turbocharger.
07. Air By-pass Valve.
08. Resonator Chamber.
09. Intercooler Water Spray Tank.
10. Intercooler Water Spray Nozzle.
04. MECHANICAL
01. General Description.
02. Compression.
03. Idle Speed.
04. Ignition Timing.
05. Intake Manifold Vacuum.
06. Engine Oil Pressure.
07. Fuel Pressure.
08. Valve Clearance.
09. Engine Assembly.
10. Engine Mounting.
11. Preparation for Overhaul.
12. V-belt.
13. Crankshaft Pulley.
14. Timing Belt Cover.
15. Timing Belt Assembly.
16. Camshaft Sprocket.
17. Crankshaft Sprocket.
18. Camshaft.
19. Cylinder Head Assembly.
20. Cylinder Block.
21. Intake and Exhaust Valve.
22. Piston.
23. Connecting Rod.
24. Crankshaft.
25. Engine Trouble in General.
26. Engine Noise.
05. EXHAUST

01. General Description.
06. COOLING
01. General Description.
07. LUBRICATION
01. General Description.
02. Oil Pressure System.
03. Engine Oil.
04. Oil Pump.
05. Oil Pan and Strainer.
06. Oil Pressure Switch.
07. Engine Oil Cooler.
08. Engine Oil Filter.
09. Engine Lubrication System Trouble in General.
08. SPEED CONTROL SYSTEMS
01. General Description.
02. Accelerator Pedal.
09. IGNITION
01. General Description.
02. Spark Plug.
03. Ignition Coil & Ignitor Assy.
10. STARTING-CHARGING SYSTEMS
01. General Description.
11. ENGINE (DIAGNOSTICS)
01. Basic Diagnostic Procedure.
02. Check List for Interview.
03. General Description.
04. Electrical Components Location.
05. Engine Control Module (ECM) I-O Signal.
06. Engine Condition Data.
07. Data Link Connector.
08. OBD-II General Scan Tool.
09. Subaru Select Monitor.
10. Read Diagnostic Trouble Code (DTC).
11. Inspection Mode.
12. Drive Cycle.
13. Clear Memory Mode.
14. Compulsory Valve Operation Check Mode.
15. Malfunction Indicator Light.
16. Diagnostics for Engine Starting Failure.
17. List of Diagnostic Trouble Code (DTC).
18. Diagnostic Procedure with Diagnostic Trouble Code (DTC).
19. General Diagnostic Table.
12. GENERAL DESCRIPTION
01. List of Diagnostic Trouble Code (DTC).
02. Diagnostic Trouble Code (DTC) Detecting Criteria.

GENERAL DESCRIPTION SECTION

01. General Description H4 SO
01. List of Diagnostic Trouble Code (DTC).
02. Diagnostic Trouble Code (DTC) Detecting Criteria.
02. General Description H4 DOTC
01. List of Diagnostic Trouble Code (DTC).
02. Diagnostic Trouble Code (DTC) Detecting Criteria.
03. General Description Sti
01. List of Diagnostic Trouble Code (DTC).
02. Diagnostic Trouble Code (DTC) Detecting Criteria.
4. TRANSMISSION

01. CONTROL SYSTEMS
01. General Description.
02. AT Shift Lock System.
03. Select Lever.
04. Select Cable.
05. AT Shift Lock Solenoid .
06. Body Integrated Unit.
07. MT Gear Shift Lever.
08. Reverse Check Cable.
09. General Diagnostic Table.
02. AUTOMATIC TRANSMISSION
01. General Description.
02. Automatic Transmission Fluid.
03. Differential Gear Oil.
04. Road Test.
05. Stall Test.
06. Time Lag Test.
07. Line Pressure Test.
08. Transfer Clutch Pressure Test.
09. Automatic Transmission Assembly.
10. Transmission Mounting System.
11. Extension Case Oil Seal.
12. Inhibitor Switch.
13. Front Vehicle Speed Sensor.
14. Rear Vehicle Speed Sensor.
15. Torque Converter Turbine Speed

16. Control Valve Body.
17. Shift Solenoids, Duty Solenoids and ATF Temperature Sensor.
18. Transfer Duty Solenoid and Valve Body.
19. ATF Filter.
20. Transmission Control Module (TCM).
21. Dropping Resistor.
22. ATF Cooler Pipe and Hose.
23. Air Breather Hose.
24. Oil Charger Pipe.
25. Torque Converter Clutch Assembly.
26. Extension Case.
27. Transfer Clutch.
28. Multi-plate Clutch.
29. Rear Drive Shaft.
30. Reduction Driven Gear.
31. Reduction Drive Gear.
32. Center Differential Carrier.
33. Parking Pawl.
34. Torque Converter Clutch Case.
35. Oil Pump Housing.
36. Drive Pinion Shaft.
37. Front Differential.
38. AT Main Case.
39. Transmission Control Device.

03. AUTOMATIC TRANSMISSION (DIAGNOSTICS)
01. Basic Diagnostic Procedure.
02. Check List for Interview.
03. General Description.
04. Electrical Components Location.
05. Transmission Control Module (TCM) IO Signal.
06. Subaru Select Monitor.
07. Read Diagnostic Trouble Code (DTC).
08. Inspection Mode.
09. Clear Memory Mode.
10. AT OIL TEMP Warning Light Display.
11. List of Diagnostic Trouble Code (DTC).
12. Diagnostic Procedure for AT OIL TEMP Warning Light.
13. Diagnostic Procedure for Select Monitor Communication.
14. Diagnostic Procedure with Diagnostic Trouble Code (DTC).
15. Diagnostic Procedure without Diagnostic Trouble Code (DTC).
16. Symptom Related Diagnostic.
04. MANUAL TRANSMISSION AND DIFFERENTIAL (5MT)
01. General Description.
02. Transmission Gear Oil.
03. Manual Transmission Assembly.
04. Transmission Mounting System.
05. Oil Seal.
06. Switches and Harness.
07. Vehicle Speed Sensor.
08. Preparation for Overhaul.

09. Transfer Case and Extension Case Assembly.
10. Transfer Drive Gear.
11. Transfer Driven Gear.
12. Center Differential.
13. Reverse Check Sleeve.
14. Transmission Case.
15. Main Shaft Assembly.
16. Drive Pinion Shaft Assembly.
17. Front Differential Assembly.
18. Speedometer Gear.
19. Reverse Idler Gear.
20. Shifter Fork and Rod.
21. General Diagnostic.

05. MANUAL TRANSMISSION AND DIFFERENTIAL (6MT)
01. General Description.
02. Transmission Gear Oil.
03. Oil Seal.
04. Vehicle Speed Sensor.
05. Transmission Mounting System.
06. Manual Transmission Assembly.
07. Preparation for Overhaul.
08. Air Breather Hose.
CHASSIS

01. FRONT SUSPENSION
01. General Description.
02. Wheel Alignment.
03. Front Transverse Link.
04. Front Ball Joint.
05. Front Strut.
06. Front Stabilizer.
07. Front Crossmember.
08. Sub Frame.
09. Front Support Arm.
10. General Diagnostic Table.
02. REAR SUSPENSION
01. General Description.
02. Wheel Alignment.
03. Rear Stabilizer.
04. Rear Trailing Link.
05. Rear Strut.
06. Lateral link.
07. Rear Crossmember.
08. General Diagnostic Table.
03. WHEEL AND TIRE SYSTEM
01. General Description.
02. Tire.
03. Steel Wheel.
04. Aluminum Wheel.
05. Wheel Balancing.
06. T-type Tire.
07. Full Wheel Cap.
08. General Diagnostics Table.
04. DIFFERENTIALS
01. General Description.
02. Differential Gear Oil.
03. Front Differential.
04. Rear Differential.
05. Rear Differential Front Oil Seal.
06. Rear Differential Front Oil Seal.
07. Rear Differential Member.
08. General Diagnostic Table.
05. TRANSFER CASE
01. General Description.
02. Transfer Case and Extension (MT).
03. Transfer Clutch and Extension (4AT).
04. Oil Seal.
05. Transfer Drive Gear (MT).
06. Transfer Driven Gear (MT).
07. Reduction Drive Gear (4AT without VTD).
08. Reduction Drive Gear (4AT with VTD).
09. Reduction Driven Gear (4AT without VTD).
10. Reduction Driven Gear (4AT with VTD).
11. Center Differential.
12. Transfer Clutch Pressure Test.
13. Transfer Duty Solenoid and Valve Body.

06. DRIVE SHAFT SYSTEM
01. General Description.
02. Propeller Shaft.
03. Front Axle.
04. Rear Axle.
05. Front Drive Shaft.
06. Rear Drive Shaft.
07. General Diagnostic Table.
07. ABS
01. General Description.
02. ABS Control Module and Hydraulic Control Unit.
03. ABS Sequence Control.
04. Front ABS Wheel Speed Sensor.
05. Rear ABS Wheel Speed Sensor.
06. Front Tone Wheel.
07. Rear Tone Wheel.
08. G Sensor.
09. Lateral G Sensor.
08. ABS (DIAGNOSTICS)
01. Basic Diagnostic Procedure.
02. Check List for Interview.
03. General Description.
04. Electrical Components Location.
05. Control Module IO Signal.
06. Subaru Select Monitor.
07. Read Diagnostic Trouble Code (DTC).
08. Inspection Mode.
09. Clear Memory Mode.
10. ABS Warning Light-Brake Warning Light Illumination Pattern.
11. List of Diagnostic Trouble Code (DTC).
12. Diagnostics Procedure without Subaru Select Monitor.
13. Diagnostics Procedure with Subaru Select Monitor.
14. General Diagnostics Table.
09. BRAKE
01. General Description.
02. Front Brake Pad.
03. Front Disc Rotor.
04. Front Disc Brake Assembly.
05. Rear Brake Pad.
06. Rear Disc Rotor.
07. Rear Disc Brake Assembly.
08. Master Cylinder.
09. Brake Booster.
10. Brake Fluid
11. Air Bleeding.
12. Brake Hose.
13. Brake Pipe.
14. Brake Pedal.
15. Stop Light Switch.
16. General Diagnostics.

10. PARKING BRAKE
01. General Description.
02. Parking Brake Lever.
03. Parking Brake Cable.
04. Parking Brake Assembly (Rear Disc Brake).
05. General Diagnostic Table.
11. POWER ASSISTED SYSTEM (POWER STEERING)
01. General Description.
02. Steering Wheel.
03. Universal Joint.
04. Tilt Steering Column.
05. Steering Gearbox.
06. Pipe Assembly.
07. Oil Pump.
08. Reservoir Tank.
09. Power Steering Fluid.
10. General Diagnostic Table.
6. BODY

01. HVAC SYSTEM (HEATER, VENTILATOR AND AC)
01. General Description.
02. Refrigerant Pressure with Manifold Gauge.
03. Refrigerant Recovery Procedure.
04. Refrigerant Charging Procedure.
05. Refrigerant Leak Check.
06. Compressor Oil.
07. Blower Motor Unit Assembly.
08. Power Transistor (Auto AC Model).
09. Blower Resistor (Manual AC Model).
10. Heater Core.
11. Control Unit (Manual AC Model).
12. Control Unit (Auto AC Model).
13. Compressor.
14. Condenser.
15. Heater and Cooling Unit.
16. Evaporator.
17. Hose and Tube.
18. Relay and Fuse.
19. Pressure Switch (Dual Switch).
20. Ambient Sensor (Auto AC Model).
21. Sunload Sensor (Auto AC Model).
22. Air Vent Grille.
23. Heater Duct.
24. Heater Vent Duct.
25. General Diagnostic Table.
02. HVAC SYSTEM (AUTO AC) (DIAGNOSTICS)
01. Basic Diagnostic Procedure.
02. General Description.
03. Electrical Components Location.
04. AC Control Module IO Signal.
05. Diagnostics Chart for Self-diagnosis.
06. Diagnostics for AC System Malfunction.
07. Diagnostic Procedure for Actuators.
08. Diagnostic Procedure for Sensors.
09. Symptom Related Diagnostic.
03. AIRBAG SYSTEM
01. General Description.
02. Airbag Connector.
03. Inspection Locations After a Collision.
04. Drivers Airbag Module.
05. Passengers Airbag Module.
06. Side Airbag Module.
07. Airbag Control Module.
08. Side Airbag Sensor.
09. Roll Connector.
10. Front Sub Sensor.

04. AIRBAG SYSTEM (DIAGNOSTICS)

01. Basic Diagnostic Procedure.
02. Check List for Interview.
03. General Description.
04. Electrical Components Location.
05. Airbag Control Module IO Signal.
06. Airbag Connector.
07. Airbag Warning Light Illumination Pattern.
08. Read Diagnostic Trouble Code (DTC).
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