SUBARU FORESTER 2003 2004 2005 2006 2007 2008 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation: Second Generation (SG) Codes Chassis Code: SG5, SG9 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Target Audience: Families, outdoor enthusiasts, individuals seeking practicality and AWD capability Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Nissan X-Trail (Rogue), Mazda CX-5 (later years), Ford Escape Key Features All Wheel Drive: Standard Symmetrical All-Wheel Drive system, a hallmark of Subaru vehicles Practicality: Spacious interior, versatile cargo area, elevated ride height for light off-roading and adverse weather Reliability: Generally considered a reliable vehicle, especially with proper maintenance Safety: Good safety ratings and standard AWD contributing to active safety 📋 Manual Details Coverage Areas Years Covered: 2003, 2004, 2005, 2006, 2007, 2008 Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Workshop Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: 2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255/EJ257) Transmission: 5-Speed Manual, 4-Speed Automatic Drivetrain: Symmetrical All-Wheel Drive (AWD) System, Differentials (Front, Center, Rear), Driveshafts, CV Joints Suspension: Front MacPherson Struts, Rear Multi-link Suspension, Springs, Dampers, Bushings, Control Arms Brakes: Front Ventilated Discs, Rear Solid Discs (or Ventilated on Turbo), ABS System, Parking Brake Steering: Power Assisted Rack and Pinion Electrical: 12V Battery System, Charging System (Alternator), Starting System (Starter), Ignition System, Lighting, Fuses, Relays, Wiring Diagrams Body And Chassis: Frame and Body Structure, Doors, Hood, Tailgate, Bumpers, Windows, Interior Trim, Seats HVAC: Heating, Ventilation, Air Conditioning System, Compressor, Condenser, Evaporator, Refrigerant Fuel System: Fuel Tank, Fuel Pump, Fuel Injectors, Fuel Filter, Evaporative Emission Control (EVAP) Cooling System: Radiator, Water Pump, Thermostat, Coolant Hoses, Cooling Fan Exhaust System: Exhaust Manifolds, Catalytic Converter, Muffler, Oxygen Sensors Safety Systems: Airbags, Seatbelt Systems, ABS/Traction Control Module Procedures Included Routine Maintenance: Oil Changes, Filter Replacements, Fluid Checks and Top-offs, Spark Plug Replacement, Belt Inspections Engine Repair: Engine Disassembly and Reassembly, Piston and Connecting Rod Installation, Cylinder Head Gasket Replacement, Timing Belt/Chain Service (if applicable - check specific engine type), Valve Adjustment Transmission Repair: Transmission Fluid and Filter Service, Clutch Replacement (Manual), Valve Body Diagnostics and Repair (Automatic), Torque Converter Service Brake Service: Brake Pad and Rotor Replacement, Brake Fluid Flush and Bleed, Caliper and Wheel Cylinder Service Suspension And Steering Repair: Shock Absorber and Strut Replacement, Ball Joint and Tie Rod End Replacement, Power Steering Pump and Hose Service Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, Component testing, ECU diagnosis Body And Interior Repair: Panel Replacement, Door Mechanism Repair, Window Regulator Service, Interior Trim Removal and Installation HVAC Service: Refrigerant Recharge, Component Replacement (Compressor, Dryer, Expansion Valve), Heater Core Service Troubleshooting: Diagnostic fault codes (DTCs), Symptoms and probable causes, Step-by-step diagnostic procedures Torque Specifications: Essential torque values for critical fasteners across all systems Technical Depth Depth Level: Comprehensive Workshop Level Repair Scope: From basic scheduled maintenance to complete engine and transmission overhauls Diagnostic Capabilities: Detailed diagnostic flowcharts and procedures for identifying and resolving complex issues 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick information retrieval Print Quality Image Resolution: High-resolution illustrations and diagrams for clarity Printable: Yes, pages can be printed for easier on-site use Binding Type Binding Type Digital: N/A (Digital format) Paper Type Paper Type Digital: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Naturally Aspirated Engine: 2.5L EJ253 SOHC Flat-4 (Boxer) Turbocharged Engine: 2.5L EJ255 DOHC Turbocharged Flat-4 (WRX/XT models), EJ257 DOHC Turbocharged Flat-4 (STI/XT models) Performance Naturally Aspirated Horsepower: 165-173 hp @ 5600-6000 rpm (depending on year and emissions standards) Naturally Aspirated Torque: 166-177 lb-ft @ 3600-4400 rpm Turbocharged Horsepower: 210-230 hp @ 5600 rpm (EJ255), 250-300 hp @ 5600 rpm (EJ257) Turbocharged Torque: 235-250 lb-ft @ 3600 rpm (EJ255), 270-350 lb-ft @ 3600 rpm (EJ257) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) for EJ253, Sequential Electronic Fuel Injection for Turbo models Fuel Type: Unleaded Gasoline (Premium recommended for Turbo models) Engine Management ECU Type: Subaru ECM (Engine Control Module) with OBD-II diagnostics 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Transmission (TY757VWAA / TY757VDAD) Optional Optional Transmission Type: 4-Speed Automatic Transmission (4EAT) Features AWD System Coupling: Manual: Viscous coupling center differential; Automatic: Electronically controlled multi-plate clutch AWD Fluid Specifications Manual Transmission Fluid: Subaru Manual Transmission Fluid (API GL-5) or equivalent 75W-90 Automatic Transmission Fluid: Subaru ATF HP (High Performance) or Dexron III/Mercon compatible fluid 📐 Dimensions Exterior Length: Approximately 179.5 inches (4560 mm) Width: Approximately 69.7 inches (1770 mm) Height: Approximately 63.4 inches (1610 mm) Wheelbase: Approximately 101.8 inches (2585 mm) Interior Passenger Volume: Approximately 97.1 cu ft (2749 L) Cargo Cargo Volume Behind Rear Seats: Approximately 32.1 cu ft (909 L) Cargo Volume With Rear Seats Folded: Approximately 63.0 cu ft (1784 L) Weights Curb Weight: Approximately 3200-3500 lbs (1450-1590 kg), depending on trim and drivetrain Towing Capacity: Up to 2400 lbs (1089 kg) (check specific model...

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Typ: Car

Anbieter:

Art.-Nr: 474897

Sammlungen: ALL Subaru

Verfügbarkeit: Auf Lager

Stichworte: 2003 2004 2005 2006 2007 2008 Car Cars FORESTER Misc Subaru

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Generation:

Second Generation (SG)

Codes

Chassis Code:

SG5, SG9

👋 Introduction

Market Position

Vehicle Segment:

Compact Crossover SUV

Target Audience:

Families, outdoor enthusiasts, individuals seeking practicality and AWD capability

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Nissan X-Trail (Rogue), Mazda CX-5 (later years), Ford Escape

Key Features

All Wheel Drive:

Standard Symmetrical All-Wheel Drive system, a hallmark of Subaru vehicles

Practicality:

Spacious interior, versatile cargo area, elevated ride height for light off-roading and adverse weather

Reliability:

Generally considered a reliable vehicle, especially with proper maintenance

Safety:

Good safety ratings and standard AWD contributing to active safety

📋 Manual Details

Coverage Areas

Years Covered:

2003, 2004, 2005, 2006, 2007, 2008

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255/EJ257)

Transmission:

5-Speed Manual, 4-Speed Automatic

Drivetrain:

Symmetrical All-Wheel Drive (AWD) System, Differentials (Front, Center, Rear), Driveshafts, CV Joints

Suspension:

Front MacPherson Struts, Rear Multi-link Suspension, Springs, Dampers, Bushings, Control Arms

Brakes:

Front Ventilated Discs, Rear Solid Discs (or Ventilated on Turbo), ABS System, Parking Brake

Steering:

Power Assisted Rack and Pinion

Electrical:

12V Battery System, Charging System (Alternator), Starting System (Starter), Ignition System, Lighting, Fuses, Relays, Wiring Diagrams

Body And Chassis:

Frame and Body Structure, Doors, Hood, Tailgate, Bumpers, Windows, Interior Trim, Seats

HVAC:

Heating, Ventilation, Air Conditioning System, Compressor, Condenser, Evaporator, Refrigerant

Fuel System:

Fuel Tank, Fuel Pump, Fuel Injectors, Fuel Filter, Evaporative Emission Control (EVAP)

Cooling System:

Radiator, Water Pump, Thermostat, Coolant Hoses, Cooling Fan

Exhaust System:

Exhaust Manifolds, Catalytic Converter, Muffler, Oxygen Sensors

Safety Systems:

Airbags, Seatbelt Systems, ABS/Traction Control Module

Procedures Included

Routine Maintenance:

Oil Changes, Filter Replacements, Fluid Checks and Top-offs, Spark Plug Replacement, Belt Inspections

Engine Repair:

Engine Disassembly and Reassembly, Piston and Connecting Rod Installation, Cylinder Head Gasket Replacement, Timing Belt/Chain Service (if applicable - check specific engine type), Valve Adjustment

Transmission Repair:

Transmission Fluid and Filter Service, Clutch Replacement (Manual), Valve Body Diagnostics and Repair (Automatic), Torque Converter Service

Brake Service:

Brake Pad and Rotor Replacement, Brake Fluid Flush and Bleed, Caliper and Wheel Cylinder Service

Suspension And Steering Repair:

Shock Absorber and Strut Replacement, Ball Joint and Tie Rod End Replacement, Power Steering Pump and Hose Service

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams, Component testing, ECU diagnosis

Body And Interior Repair:

Panel Replacement, Door Mechanism Repair, Window Regulator Service, Interior Trim Removal and Installation

HVAC Service:

Refrigerant Recharge, Component Replacement (Compressor, Dryer, Expansion Valve), Heater Core Service

Troubleshooting:

Diagnostic fault codes (DTCs), Symptoms and probable causes, Step-by-step diagnostic procedures

Torque Specifications:

Essential torque values for critical fasteners across all systems

Technical Depth

Depth Level:

Comprehensive Workshop Level

Repair Scope:

From basic scheduled maintenance to complete engine and transmission overhauls

Diagnostic Capabilities:

Detailed diagnostic flowcharts and procedures for identifying and resolving complex issues

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable for quick information retrieval

Print Quality

Image Resolution:

High-resolution illustrations and diagrams for clarity

Printable:

Yes, pages can be printed for easier on-site use

Binding Type

Binding Type Digital:

N/A (Digital format)

Paper Type

Paper Type Digital:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Naturally Aspirated Engine:

2.5L EJ253 SOHC Flat-4 (Boxer)

Turbocharged Engine:

2.5L EJ255 DOHC Turbocharged Flat-4 (WRX/XT models), EJ257 DOHC Turbocharged Flat-4 (STI/XT models)

Performance

Naturally Aspirated Horsepower:

165-173 hp @ 5600-6000 rpm (depending on year and emissions standards)

Naturally Aspirated Torque:

166-177 lb-ft @ 3600-4400 rpm

Turbocharged Horsepower:

210-230 hp @ 5600 rpm (EJ255), 250-300 hp @ 5600 rpm (EJ257)

Turbocharged Torque:

235-250 lb-ft @ 3600 rpm (EJ255), 270-350 lb-ft @ 3600 rpm (EJ257)

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI) for EJ253, Sequential Electronic Fuel Injection for Turbo models

Fuel Type:

Unleaded Gasoline (Premium recommended for Turbo models)

Engine Management

ECU Type:

Subaru ECM (Engine Control Module) with OBD-II diagnostics

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual Transmission (TY757VWAA / TY757VDAD)

Optional

Optional Transmission Type:

4-Speed Automatic Transmission (4EAT)

Features

AWD System Coupling:

Manual: Viscous coupling center differential; Automatic: Electronically controlled multi-plate clutch AWD

Fluid Specifications

Manual Transmission Fluid:

Subaru Manual Transmission Fluid (API GL-5) or equivalent 75W-90

Automatic Transmission Fluid:

Subaru ATF HP (High Performance) or Dexron III/Mercon compatible fluid

📐 Dimensions

Exterior

Length:

Approximately 179.5 inches (4560 mm)

Width:

Approximately 69.7 inches (1770 mm)

Height:

Approximately 63.4 inches (1610 mm)

Wheelbase:

Approximately 101.8 inches (2585 mm)

Interior

Passenger Volume:

Approximately 97.1 cu ft (2749 L)

Cargo

Cargo Volume Behind Rear Seats:

Approximately 32.1 cu ft (909 L)

Cargo Volume With Rear Seats Folded:

Approximately 63.0 cu ft (1784 L)

Weights

Curb Weight:

Approximately 3200-3500 lbs (1450-1590 kg), depending on trim and drivetrain

Towing Capacity:

Up to 2400 lbs (1089 kg) (check specific model and regional regulations)

🛡️ Safety Features

Ratings

NHTSA Front Driver Impact:

5 Stars (for models equipped with side airbags)

NHTSA Front Passenger Impact:

5 Stars (for models equipped with side airbags)

IIHS Side Impact:

Good (for models equipped with side airbags)

Active Features

Standard Safety Features:

Symmetrical All-Wheel Drive, Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD)

Passive Features

Standard Passive Safety:

Front Airbags, Side Curtain Airbags (optional on some trims), Front Seatbelt Pretensioners

Optional Safety Features:

Side Airbags (for front seats), Traction Control System (TCS), Vehicle Stability Control (VSC) - availability varies by year and trim

💡 Technology Features

Infotainment

Infotainment System:

Base models typically featured a 120-watt AM/FM/CD stereo with 4 speakers. Higher trims offered optional premium audio systems with more speakers and a subwoofer, and in-dash CD changers or MP3 capability.

Driver Assistance

Driver Assistance Features:

Limited by modern standards. Available features included Cruise Control and a basic trip computer. Traction Control and Stability Control were optional on some trims and became more prevalent in later years of this generation.

Connectivity

Connectivity Options:

Basic auxiliary input jack for audio devices became available on some later models. Bluetooth connectivity was not a standard factory offering for this period.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used (consult manual for specific recommendation)

Engine Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection

Cabin Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or annually

Spark Plug Replacement:

100,000 miles (160,000 km) for iridium-tipped plugs (standard on later models)

Transmission Fluid Change:

Manual: Inspect annually, change every 30,000-60,000 miles. Automatic: Every 30,000-60,000 miles (severe use may require more frequent changes).

Fluid Specifications

Engine Oil Type:

SAE 5W-30 Synthetic (API SM or higher)

Coolant Type:

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

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Head Gasket Leaks:

Commonly cited issue in EJ25 engines (both NA and Turbo) requiring significant repair. Newer OEM or aftermarket gaskets are often recommended for replacement.

Turbocharger Wear:

On turbocharged models (XT), turbocharger longevity can be impacted by heat and maintenance. Regular oil changes are crucial.

Oil Consumption:

Some EJ25 engines may exhibit higher oil consumption, especially with age and mileage. Monitoring oil level is important.

Susceptibility To Overheating:

Can occur if the cooling system is not properly maintained, especially on turbocharged models.

📚 Vehicle History

Brand Heritage

Subaru Heritage:

Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a history rooted in aviation and a strong reputation for All-Wheel Drive technology and boxer engines.

Model Evolution

Forester Introduction:

The Subaru Forester was first introduced in 1997 as a compact crossover SUV, blending SUV utility with car-like driving dynamics.

Sg Generation Launch:

The second generation (SG) was launched for the 2003 model year, featuring a more refined design, improved interior, and updated powertrains.

Facelift Midcycle:

A significant facelift occurred for the 2006 model year, with updated styling (front grille, headlights, bumpers), interior enhancements, and powertrain revisions for certain models.

Production

Production Location:

Primarily manufactured in Gunma, Japan.

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

Forester models from this generation often received 'Good' ratings in IIHS crash tests, contributing to its reputation for safety.

Kbb Best Resale Value:

Subaru vehicles, including the Forester, have historically held strong resale values due to their AWD and perceived reliability.

Certifications

Emissions Certifications:

Meets U.S. EPA and California Air Resources Board (CARB) emissions standards for its respective model years.