Subaru Forester 2003 2004 2005 Workshop Service Repair Manual Pdf

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🏷️ Basic Information Identification Make: Subaru Model: Forester Model Years Covered: 2003, 2004, 2005 Generation: Second Generation (SG) 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience: Families, outdoor enthusiasts, individuals seeking practicality and all-weather capability. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Mazda CX-5 (though CX-5 is later generation). Key Features Drivetrain Advantage: Standard Symmetrical All-Wheel Drive across all trims, a significant differentiator in its class. Ground Clearance: Higher than many competitors, enhancing off-road and foul-weather capability. Practicality: Spacious interior, versatile cargo area, and a reputation for durability and reliability. Engine Options: Availability of naturally aspirated and turbocharged (GT/XT) engine variants. 📋 Manual Details Coverage Areas Engine Coverage: 2.5L Naturally Aspirated EJ253, 2.5L Turbocharged EJ255 (XT models) Transmission Coverage: 5-Speed Manual (TY754VB/TY754VC), 4-Speed Automatic (TZ1A2ZDBAA/TZ1A2ZDBAZ) Drivetrain Coverage: All-Wheel Drive (Symmetrical AWD) Chassis Coverage: Suspension, Steering, Brakes, Body Structure, Exterior Components Electrical Coverage: Engine Control Unit (ECU), Body Control Module (BCM), Lighting, Audio System, HVAC Controls, Power Accessories, Wiring Diagrams Page Count Estimated Pages: Over 2000 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head overhaul, piston/ring replacement, crankshaft/bearing service, camshaft timing, valve train maintenance, lubrication system, cooling system Engine Performance: Fuel injection system diagnosis and repair, ignition system troubleshooting, emission control systems (EVAP, EGR), turbocharger system service (XT models), engine diagnostics with scan tools Transmission Manual: Clutch system, transmission removal/installation, internal component repair, gear shift linkage adjustment Transmission Automatic: Transmission fluid and filter change, valve body diagnosis, torque converter service, transmission removal/installation, electronic controls Drivetrain: Front and rear differential service, driveshaft and axle shaft repair, AWD system maintenance and diagnosis Suspension: Front and rear strut/shock absorber replacement, control arm service, stabilizer bar maintenance, wheel bearing replacement Steering: Power steering system diagnosis and repair, steering rack and pinion service, tie rod end replacement, steering column adjustment Brakes: Front and rear brake pad/rotor replacement, caliper service, brake line and hose inspection/replacement, ABS system diagnosis and repair, parking brake adjustment Body And Exterior: Door panel removal, bumper repair, fender replacement, glass replacement, sunroof service, exterior trim repair Interior: Seat removal, dashboard disassembly, HVAC ducting service, interior trim panel replacement, airbag system precautions Electrical Components: Headlight/taillight bulb replacement, fuse and relay identification, battery testing and replacement, starter and alternator service, power window/lock diagnosis Climate Control: HVAC system diagnosis, refrigerant recharge, blower motor replacement, heater core service, A/C compressor diagnosis Procedures Included Maintenance: Routine scheduled maintenance (oil changes, filter replacements, fluid checks), spark plug replacement, drive belt inspection/replacement, coolant flushes Diagnostics: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation, electrical system testing procedures, fuel system pressure testing Repair: Step-by-step repair instructions for all major vehicle systems, including component replacement and adjustment Wiring Diagrams: Detailed electrical schematics for all major systems, aiding in troubleshooting and repair of electrical faults Specifications: Torque specifications for critical fasteners, fluid capacities and types, alignment specifications, diagnostic parameters Technical Depth Depth: Comprehensive, covering from basic preventative maintenance to advanced engine and transmission overhauls. Suitable for professional technicians and skilled DIY enthusiasts. 📊 Manual Specifications File Format Searchability: Searchable text within the PDF for quick information retrieval. Printability: Printable pages, allowing for physical copies of specific sections or the entire manual. Print Quality Quality: High-resolution images and diagrams ensure clarity for technical procedures. Binding Type Format Type: Digital Download (PDF) Paper Type Digital Format: PDF ⚙️ Engine Specifications Primary Engine Naturally Aspirated Engine: 2.5L (2457cc) EJ253 SOHC Flat-4 Boxer Engine Turbocharged Engine: 2.5L (2457cc) EJ255 DOHC Turbocharged Flat-4 Boxer Engine (GT/XT models) Performance Naturally Aspirated Horsepower: 165 hp @ 5,600 rpm (2003-2004), 173 hp @ 5,600 rpm (2005) Naturally Aspirated Torque: 166 lb-ft @ 4,000 rpm (2003-2004), 166 lb-ft @ 4,000 rpm (2005) Turbocharged Horsepower: 210 hp @ 5,600 rpm (2004-2005) Turbocharged Torque: 235 lb-ft @ 3,600 rpm (2004-2005) Fuel System Injection Type: Electronic Fuel Injection (MPI - Multi-Point Injection) Fuel Type Fuel Requirement: Unleaded gasoline (87 octane minimum recommended for NA, 91 octane recommended for Turbocharged) Engine Design Configuration: Horizontally opposed (Boxer) engine 🔧 Transmission Standard Manual Transmission: 5-Speed Manual (TY754VB/TY754VC) Optional Automatic Transmission: 4-Speed Automatic (TZ1A2ZDBAA/TZ1A2ZDBAZ) Features AWD System: Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled transfer clutch (automatic) Fluid Specifications Manual Transmission Fluid: SAE 75W-90 Gear Oil (API GL-5) Automatic Transmission Fluid: Subaru ATF-HP (or equivalent DEXRON III/MERCON compliant fluid) 📐 Dimensions Exterior Length: Approx. 177.8 inches (4516 mm) Width: Approx. 70.1 inches (1781 mm) Height: Approx. 65.5 inches (1664 mm) Wheelbase: Approx. 103.1 inches (2619 mm) Ground Clearance: Approx. 8.0 inches (203 mm) Weights Curb Weight Min Manual: Approx. 3,252 lbs (1475 kg) Curb Weight Max Auto: Approx. 3,443 lbs (1562 kg) Towing Capacity: 2,400 lbs (1089 kg) (when properly equipped with trailer brakes) Cargo Cargo Volume Behind...

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Typ: Car

Anbieter:

Art.-Nr: 298721

Sammlungen: ALL Subaru

Verfügbarkeit: Auf Lager

Stichworte: 2003 2004 2005 Car Cars Forester Misc Subaru

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Model Years Covered:

2003, 2004, 2005

Generation:

Second Generation (SG)

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Target Audience:

Families, outdoor enthusiasts, individuals seeking practicality and all-weather capability.

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Mazda CX-5 (though CX-5 is later generation).

Key Features

Drivetrain Advantage:

Standard Symmetrical All-Wheel Drive across all trims, a significant differentiator in its class.

Ground Clearance:

Higher than many competitors, enhancing off-road and foul-weather capability.

Practicality:

Spacious interior, versatile cargo area, and a reputation for durability and reliability.

Engine Options:

Availability of naturally aspirated and turbocharged (GT/XT) engine variants.

📋 Manual Details

Coverage Areas

Engine Coverage:

2.5L Naturally Aspirated EJ253, 2.5L Turbocharged EJ255 (XT models)

Transmission Coverage:

5-Speed Manual (TY754VB/TY754VC), 4-Speed Automatic (TZ1A2ZDBAA/TZ1A2ZDBAZ)

Drivetrain Coverage:

All-Wheel Drive (Symmetrical AWD)

Chassis Coverage:

Suspension, Steering, Brakes, Body Structure, Exterior Components

Electrical Coverage:

Engine Control Unit (ECU), Body Control Module (BCM), Lighting, Audio System, HVAC Controls, Power Accessories, Wiring Diagrams

Page Count

Estimated Pages:

Over 2000

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF (Portable Document Format)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine removal/installation, cylinder head overhaul, piston/ring replacement, crankshaft/bearing service, camshaft timing, valve train maintenance, lubrication system, cooling system

Engine Performance:

Fuel injection system diagnosis and repair, ignition system troubleshooting, emission control systems (EVAP, EGR), turbocharger system service (XT models), engine diagnostics with scan tools

Transmission Manual:

Clutch system, transmission removal/installation, internal component repair, gear shift linkage adjustment

Transmission Automatic:

Transmission fluid and filter change, valve body diagnosis, torque converter service, transmission removal/installation, electronic controls

Drivetrain:

Front and rear differential service, driveshaft and axle shaft repair, AWD system maintenance and diagnosis

Suspension:

Front and rear strut/shock absorber replacement, control arm service, stabilizer bar maintenance, wheel bearing replacement

Steering:

Power steering system diagnosis and repair, steering rack and pinion service, tie rod end replacement, steering column adjustment

Brakes:

Front and rear brake pad/rotor replacement, caliper service, brake line and hose inspection/replacement, ABS system diagnosis and repair, parking brake adjustment

Body And Exterior:

Door panel removal, bumper repair, fender replacement, glass replacement, sunroof service, exterior trim repair

Interior:

Seat removal, dashboard disassembly, HVAC ducting service, interior trim panel replacement, airbag system precautions

Electrical Components:

Headlight/taillight bulb replacement, fuse and relay identification, battery testing and replacement, starter and alternator service, power window/lock diagnosis

Climate Control:

HVAC system diagnosis, refrigerant recharge, blower motor replacement, heater core service, A/C compressor diagnosis

Procedures Included

Maintenance:

Routine scheduled maintenance (oil changes, filter replacements, fluid checks), spark plug replacement, drive belt inspection/replacement, coolant flushes

Diagnostics:

Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) interpretation, electrical system testing procedures, fuel system pressure testing

Repair:

Step-by-step repair instructions for all major vehicle systems, including component replacement and adjustment

Wiring Diagrams:

Detailed electrical schematics for all major systems, aiding in troubleshooting and repair of electrical faults

Specifications:

Torque specifications for critical fasteners, fluid capacities and types, alignment specifications, diagnostic parameters

Technical Depth

Depth:

Comprehensive, covering from basic preventative maintenance to advanced engine and transmission overhauls. Suitable for professional technicians and skilled DIY enthusiasts.

📊 Manual Specifications

File Format

Searchability:

Searchable text within the PDF for quick information retrieval.

Printability:

Printable pages, allowing for physical copies of specific sections or the entire manual.

Print Quality

Quality:

High-resolution images and diagrams ensure clarity for technical procedures.

Binding Type

Format Type:

Digital Download (PDF)

Paper Type

Digital Format:

⚙️ Engine Specifications

Primary Engine

Naturally Aspirated Engine:

2.5L (2457cc) EJ253 SOHC Flat-4 Boxer Engine

Turbocharged Engine:

2.5L (2457cc) EJ255 DOHC Turbocharged Flat-4 Boxer Engine (GT/XT models)

Performance

Naturally Aspirated Horsepower:

165 hp @ 5,600 rpm (2003-2004), 173 hp @ 5,600 rpm (2005)

Naturally Aspirated Torque:

166 lb-ft @ 4,000 rpm (2003-2004), 166 lb-ft @ 4,000 rpm (2005)

Turbocharged Horsepower:

210 hp @ 5,600 rpm (2004-2005)

Turbocharged Torque:

235 lb-ft @ 3,600 rpm (2004-2005)

Fuel System

Injection Type:

Electronic Fuel Injection (MPI - Multi-Point Injection)

Fuel Type

Fuel Requirement:

Unleaded gasoline (87 octane minimum recommended for NA, 91 octane recommended for Turbocharged)

Engine Design

Configuration:

Horizontally opposed (Boxer) engine

🔧 Transmission

Standard

Manual Transmission:

5-Speed Manual (TY754VB/TY754VC)

Optional

Automatic Transmission:

4-Speed Automatic (TZ1A2ZDBAA/TZ1A2ZDBAZ)

Features

AWD System:

Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled transfer clutch (automatic)

Fluid Specifications

Manual Transmission Fluid:

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

Automatic Transmission Fluid:

Subaru ATF-HP (or equivalent DEXRON III/MERCON compliant fluid)

📐 Dimensions

Exterior

Length:

Approx. 177.8 inches (4516 mm)

Width:

Approx. 70.1 inches (1781 mm)

Height:

Approx. 65.5 inches (1664 mm)

Wheelbase:

Approx. 103.1 inches (2619 mm)

Ground Clearance:

Approx. 8.0 inches (203 mm)

Weights

Curb Weight Min Manual:

Approx. 3,252 lbs (1475 kg)

Curb Weight Max Auto:

Approx. 3,443 lbs (1562 kg)

Towing Capacity:

2,400 lbs (1089 kg) (when properly equipped with trailer brakes)

Cargo

Cargo Volume Behind Rear Seats:

Approx. 30.1 cubic feet (853 liters)

Cargo Volume With Rear Seats Folded:

Approx. 67.7 cubic feet (1917 liters)

Wheels And Tires

Standard Wheel Size:

16-inch steel or alloy

Optional Wheel Size:

17-inch alloy (XT models)

Standard Tire Size:

215/60R16

Optional Tire Size:

215/55R17 (XT models)

Bolt Pattern:

5 x 100 mm

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-star (for 2003-2005 models)

NHTSA Front Impact Passenger:

5-star (for 2003-2005 models)

NHTSA Side Impact Front Driver:

5-star (for 2003-2005 models)

NHTSA Side Impact Front Passenger:

5-star (for 2003-2005 models)

NHTSA Side Impact Rear Driver:

5-star (for 2003-2005 models)

NHTSA Side Impact Rear Passenger:

5-star (for 2003-2005 models)

IIHS Frontal Offset Score:

Good (for applicable years)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Available Vehicle Stability Control (VSC)

Passive Features

Airbags:

Standard front airbags, available front side-impact airbags

Seatbelts:

3-point seatbelts with pretensioners and load limiters

Child Seats:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD stereo with optional premium sound system and subwoofer.

Navigation:

Optional factory navigation system available on some trim levels.

Driver Assistance

Cruise Control:

Standard cruise control.

Keyless Entry:

Available keyless entry system.

Connectivity

Auxiliary Input:

Available auxiliary audio input jack.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 6 months (severe driving) / 7,500 miles or 12 months (normal driving) - consult manual for specific conditions.

Engine Air Filter Replacement:

Every 30,000 miles or 30 months

Cabin Air Filter Replacement:

Every 15,000 miles or 15 months

Spark Plug Replacement Na:

Every 60,000 miles (NGK ILFR5B or equivalent)

Spark Plug Replacement Turbo:

Every 30,000 miles (NGK SILFR5A-11 or equivalent)

Coolant Replacement:

First at 30,000 miles/30 months, then every 30,000 miles/30 months thereafter (Subaru Super Coolant or equivalent).

Fluid Specifications

Engine Oil Type:

0W-20 (preferred), 5W-30 (API SN or higher, ILSAC GF-5 or higher)

Engine Oil Capacity:

4.8 quarts (4.5 liters) with filter (EJ253), 5.2 quarts (4.9 liters) with filter (EJ255)

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

Head Gaskets:

While less prevalent than in earlier generations, Subaru head gasket leaks can still occur, particularly in higher-mileage naturally aspirated engines. The manual provides procedures for diagnosis and repair.

Turbocharger Wear Xt Models:

Turbocharged models (XT) may experience wear on the turbocharger seals or wastegate actuators, often related to maintenance neglect. The manual details turbo system inspection.

Automatic Transmission Longevity:

Regular fluid and filter changes are crucial for the longevity of the 4-speed automatic transmission. The manual emphasizes these procedures.

Suspension Components:

Worn bushings and struts are common wear items due to the vehicle's utility and often spirited driving. The manual details replacement procedures.

📚 Vehicle History

Brand Heritage

Subaru Identity:

Known for its Symmetrical All-Wheel Drive, horizontally opposed boxer engines, and focus on utility and safety.

Model Evolution

Second Generation Launch:

Introduced for the 2003 model year, representing a significant redesign over the first generation.

Design Changes:

Larger dimensions, updated styling, improved interior comfort and features compared to the previous model.

Powertrain Updates:

Introduction of the turbocharged GT/XT model for enhanced performance.

Production

Manufacturing Location:

Gunma Manufacturing Plant, Japan

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

Subaru Forester models have historically been recognized by Car and Driver, often praised for their AWD system and practicality, though specific placement for these model years would need verification.

Ratings

Consumers Reports Reliability:

Generally rated as average to above average for reliability, with specific model years and powertrain configurations impacting overall scores.

Certifications

Epa Fuel Economy Na Auto:

Approx. 20 MPG city / 26 MPG highway (2005 model)

Epa Fuel Economy Na Manual:

Approx. 19 MPG city / 25 MPG highway (2005 model)

Epa Fuel Economy Xt Auto:

Approx. 18 MPG city / 22 MPG highway (2005 model)

Epa Fuel Economy Xt Manual:

Approx. 15 MPG city / 20 MPG highway (2005 model)