SUBARU FORESTER 2005-2008 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2005-2008 Codes Chassis Code: SG Engine Codes Covered: EJ253 (2.5L SOHC NA), EJ255 (2.5L DOHC Turbo) Transmission Codes Covered: TZ1A3ZD3AA (5MT), TZ1B3ZD3AA (5MT), 43700SA060 (4AT), 43700SA080 (4AT) 👋 Introduction Market Position Positioning: The Subaru Forester of this generation (SG) was positioned as a versatile compact SUV/crossover, known for its standard Symmetrical All-Wheel Drive, practical utility, and Subaru's reputation for durability and safety. It competed against vehicles like the Honda CR-V, Toyota RAV4, and Ford Escape. Competitive Analysis Strengths: Standard AWD, good visibility, comfortable ride, robust build quality, available turbocharged engine (XT models) providing strong performance. Weaknesses: Interior materials could be basic compared to some rivals, fuel economy was average, base engine lacked punch. Key Features Standard Features: Symmetrical All-Wheel Drive, Boxer engine, independent suspension, power windows/locks/mirrors, cruise control, air conditioning, anti-lock braking system (ABS). Optional Features: Sunroof, leather upholstery, premium audio system, heated front seats, automatic climate control, body-colored cladding (on some trims). 📋 Manual Details Coverage Areas Region: USA and Canada Page Count Estimated Pages: 2000+ Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and assembly of all engine components. Includes timing belt replacement, piston/ring service, cylinder head and valve train, crankshaft and bearing service, oil pump, water pump, and cooling system. Engine Performance: Fuel injection system (EFI), ignition system, emissions control systems (EVAP, EGR), turbocharger system (if applicable), engine control module (ECM) diagnostics and programming. Transmission Manual: Clutch system, gearbox internal inspection and repair, shift linkage, driveshafts, differentials. Transmission Automatic: Torque converter, valve body, planetary gear sets, hydraulic control system, transmission control module (TCM) diagnostics and programming, fluid and filter service. Drivetrain: All-Wheel Drive (AWD) system, viscous coupling, center differential, rear differential service, CV joints and boots, propeller shaft. Suspension: Front and rear suspension components, struts, shock absorbers, control arms, bushings, wheel bearings, alignment specifications. Brakes: Front and rear brake systems (disc brakes), hydraulic lines, calipers, rotors, brake pads, parking brake system, ABS system diagnostics and component testing. Steering: Power steering system (hydraulic pump, reservoir, lines, rack and pinion), steering column, tie rod ends. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior lights), horn, fuses, relays, wiring diagrams for all circuits. Body And Chassis: Body panel removal and installation, door mechanisms, glass replacement, interior trim, exterior trim, frame and chassis repair, corrosion protection. HVAC: Air conditioning system (refrigerant cycle, compressor, condenser, evaporator), heating system, climate control unit, blower motor, ductwork. Safety Systems: Airbag system (SRS), seatbelt mechanisms, pre-tensioners, SRS control unit diagnostics. Diagnostics: OBD-II (On-Board Diagnostics II) procedures, diagnostic trouble codes (DTCs), live data stream interpretation, specific diagnostic tools and procedures for each system. Procedures Included Maintenance: Scheduled maintenance intervals, oil and filter changes, fluid checks and top-offs, filter replacements (air, fuel, cabin), spark plug replacement, coolant flushes. Troubleshooting: Diagnostic flowcharts for common drivability issues, electrical faults, HVAC problems, brake system anomalies, and more. Repair Procedures: Step-by-step instructions for component replacement and repair, including detailed torque specifications and special tool requirements. Component Testing: Testing procedures for sensors, actuators, electrical components, and mechanical assemblies using multimeters, oscilloscopes, and specialized diagnostic equipment. Engine Rebuild: Comprehensive instructions for complete engine overhauls, including cylinder head resurfacing, valve seat grinding, and piston ring gap adjustment. Transmission Overhaul: Detailed steps for the complete disassembly, inspection, and reassembly of both automatic and manual transmissions. Body Repair: Procedures for collision repair, panel alignment, welding, and rust repair, with emphasis on structural integrity. Electrical Diagnostics: Detailed wiring diagrams, component location charts, and step-by-step troubleshooting guides for electrical issues. Technical Depth Depth: Factory-level diagnostic and repair procedures, including advanced diagnostics, component-level repair, and complete system overhauls. Suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Format: PDF Searchability: Fully searchable text content for quick access to information. Compatibility: Windows (95/98/ME/XP/Vista/7/8/8.1/10), Linux, MAC, iOS, Android. Print Quality Quality: High-resolution scans ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type 1: Naturally Aspirated 2.5L SOHC EJ253 Boxer 4-Cylinder Displacement 1: 2498 cc (2.5 Liters) Bore X Stroke 1: 99.5 mm x 79.0 mm Compression Ratio 1: 9.7:1 Horsepower 1: 173 hp @ 5600 rpm Torque 1: 166 lb-ft @ 4000 rpm Fuel Delivery 1: Multi-point Fuel Injection (MPI) Ignition System 1: Distributorless Electronic Ignition System (DEIS) Engine Type 2: Turbocharged 2.5L DOHC EJ255 Boxer 4-Cylinder Displacement 2: 2498 cc (2.5 Liters) Bore X Stroke 2: 99.5 mm x 79.0 mm Compression Ratio 2: 8.4:1 Horsepower 2: 224 hp @ 5600 rpm (XT), 230 hp @ 5600 rpm (XT Limited/Sports) Torque 2: 235 lb-ft @ 3600 rpm (XT), 235 lb-ft @ 3600 rpm (XT Limited/Sports) Turbocharger Specs: IHI...

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Tipo: Car

Proveedor:

SKU: 421009

Colecciones: ALL Subaru

Disponibilidad: En stock

Etiquetas: 2005 2006 2007 2008 Car Cars FORESTER Misc Subaru

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Year:

2005-2008

Codes

Chassis Code:

Engine Codes Covered:

EJ253 (2.5L SOHC NA), EJ255 (2.5L DOHC Turbo)

Transmission Codes Covered:

TZ1A3ZD3AA (5MT), TZ1B3ZD3AA (5MT), 43700SA060 (4AT), 43700SA080 (4AT)

👋 Introduction

Market Position

Positioning:

The Subaru Forester of this generation (SG) was positioned as a versatile compact SUV/crossover, known for its standard Symmetrical All-Wheel Drive, practical utility, and Subaru's reputation for durability and safety. It competed against vehicles like the Honda CR-V, Toyota RAV4, and Ford Escape.

Competitive Analysis

Strengths:

Standard AWD, good visibility, comfortable ride, robust build quality, available turbocharged engine (XT models) providing strong performance.

Weaknesses:

Interior materials could be basic compared to some rivals, fuel economy was average, base engine lacked punch.

Key Features

Standard Features:

Symmetrical All-Wheel Drive, Boxer engine, independent suspension, power windows/locks/mirrors, cruise control, air conditioning, anti-lock braking system (ABS).

Optional Features:

Sunroof, leather upholstery, premium audio system, heated front seats, automatic climate control, body-colored cladding (on some trims).

📋 Manual Details

Coverage Areas

Region:

USA and Canada

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and assembly of all engine components. Includes timing belt replacement, piston/ring service, cylinder head and valve train, crankshaft and bearing service, oil pump, water pump, and cooling system.

Engine Performance:

Fuel injection system (EFI), ignition system, emissions control systems (EVAP, EGR), turbocharger system (if applicable), engine control module (ECM) diagnostics and programming.

Transmission Manual:

Clutch system, gearbox internal inspection and repair, shift linkage, driveshafts, differentials.

Transmission Automatic:

Torque converter, valve body, planetary gear sets, hydraulic control system, transmission control module (TCM) diagnostics and programming, fluid and filter service.

Drivetrain:

All-Wheel Drive (AWD) system, viscous coupling, center differential, rear differential service, CV joints and boots, propeller shaft.

Suspension:

Front and rear suspension components, struts, shock absorbers, control arms, bushings, wheel bearings, alignment specifications.

Brakes:

Front and rear brake systems (disc brakes), hydraulic lines, calipers, rotors, brake pads, parking brake system, ABS system diagnostics and component testing.

Steering:

Power steering system (hydraulic pump, reservoir, lines, rack and pinion), steering column, tie rod ends.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior lights), horn, fuses, relays, wiring diagrams for all circuits.

Body And Chassis:

Body panel removal and installation, door mechanisms, glass replacement, interior trim, exterior trim, frame and chassis repair, corrosion protection.

HVAC:

Air conditioning system (refrigerant cycle, compressor, condenser, evaporator), heating system, climate control unit, blower motor, ductwork.

Safety Systems:

Airbag system (SRS), seatbelt mechanisms, pre-tensioners, SRS control unit diagnostics.

Diagnostics:

OBD-II (On-Board Diagnostics II) procedures, diagnostic trouble codes (DTCs), live data stream interpretation, specific diagnostic tools and procedures for each system.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil and filter changes, fluid checks and top-offs, filter replacements (air, fuel, cabin), spark plug replacement, coolant flushes.

Troubleshooting:

Diagnostic flowcharts for common drivability issues, electrical faults, HVAC problems, brake system anomalies, and more.

Repair Procedures:

Step-by-step instructions for component replacement and repair, including detailed torque specifications and special tool requirements.

Component Testing:

Testing procedures for sensors, actuators, electrical components, and mechanical assemblies using multimeters, oscilloscopes, and specialized diagnostic equipment.

Engine Rebuild:

Comprehensive instructions for complete engine overhauls, including cylinder head resurfacing, valve seat grinding, and piston ring gap adjustment.

Transmission Overhaul:

Detailed steps for the complete disassembly, inspection, and reassembly of both automatic and manual transmissions.

Body Repair:

Procedures for collision repair, panel alignment, welding, and rust repair, with emphasis on structural integrity.

Electrical Diagnostics:

Detailed wiring diagrams, component location charts, and step-by-step troubleshooting guides for electrical issues.

Technical Depth

Depth:

Factory-level diagnostic and repair procedures, including advanced diagnostics, component-level repair, and complete system overhauls. Suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

Format:

Searchability:

Fully searchable text content for quick access to information.

Compatibility:

Windows (95/98/ME/XP/Vista/7/8/8.1/10), Linux, MAC, iOS, Android.

Print Quality

Quality:

High-resolution scans ensuring clarity of text and diagrams.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type 1:

Naturally Aspirated 2.5L SOHC EJ253 Boxer 4-Cylinder

Displacement 1:

2498 cc (2.5 Liters)

Bore X Stroke 1:

99.5 mm x 79.0 mm

Compression Ratio 1:

9.7:1

Horsepower 1:

173 hp @ 5600 rpm

Torque 1:

166 lb-ft @ 4000 rpm

Fuel Delivery 1:

Multi-point Fuel Injection (MPI)

Ignition System 1:

Distributorless Electronic Ignition System (DEIS)

Engine Type 2:

Turbocharged 2.5L DOHC EJ255 Boxer 4-Cylinder

Displacement 2:

2498 cc (2.5 Liters)

Bore X Stroke 2:

99.5 mm x 79.0 mm

Compression Ratio 2:

8.4:1

Horsepower 2:

224 hp @ 5600 rpm (XT), 230 hp @ 5600 rpm (XT Limited/Sports)

Torque 2:

235 lb-ft @ 3600 rpm (XT), 235 lb-ft @ 3600 rpm (XT Limited/Sports)

Turbocharger Specs:

IHI VF40 or VF48 (depending on trim/year)

Fuel Delivery 2:

Electronic Fuel Injection (EFI) with Turbocharger

Performance

0-60 Mph Na:

Approx. 8.5-9.5 seconds

0-60 Mph Xt:

Approx. 6.5-7.5 seconds

Fuel System

Recommended Fuel Na:

87 Octane (Regular Unleaded)

Recommended Fuel Xt:

91 Octane (Premium Unleaded)

Fuel Tank Capacity:

15.9 US gallons (60 Liters)

🔧 Transmission

Standard

Transmission Type Na:

5-Speed Manual Transmission (5MT)

Transmission Type Xt:

4-Speed Automatic Transmission (4AT)

Optional

Transmission Type Na Optional:

4-Speed Automatic Transmission (4AT)

Transmission Type Xt Optional:

5-Speed Manual Transmission (5MT) - less common than 4AT in XT models

Features

AWD System:

Symmetrical All-Wheel Drive with viscous coupling center differential.

Manual Transmission Fluid Spec:

Subaru Extra-S API GL-5 75W-90 or equivalent.

Automatic Transmission Fluid Spec:

Subaru ATF-HP (High Performance) or equivalent.

📐 Dimensions

Exterior

Length:

177.7 inches (4515 mm)

Width:

69.9 inches (1775 mm)

Height:

63.1 inches (1605 mm)

Wheelbase:

103.1 inches (2619 mm)

Ground Clearance:

7.9 inches (200 mm)

Wheelbase Turbo Models:

103.1 inches (2619 mm)

Cargo

Cargo Volume Behind Rear Seats:

31.5 cu ft (892 Liters)

Cargo Volume With Rear Seats Folded:

67.1 cu ft (1899 Liters)

Weights

Curb Weight Na:

Approx. 3200-3350 lbs (1450-1520 kg)

Curb Weight Xt:

Approx. 3400-3550 lbs (1540-1610 kg)

Towing Capacity:

2400 lbs (1089 kg)

Payload Capacity:

Approx. 800-900 lbs (363-408 kg)

Wheel Bolt Pattern:

5 x 100 mm

Wheel Size Standard:

16-inch alloy wheels

Wheel Size Optional Xt:

17-inch alloy wheels

Tire Size Standard:

215/60R16

Tire Size Optional Xt:

215/55R17

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Good (2005-2008 models)

NHTSA Front Impact Passenger:

Good (2005-2008 models)

NHTSA Side Impact Front Driver:

Good (2005-2008 models)

NHTSA Side Impact Front Passenger:

Good (2005-2008 models)

NHTSA Side Impact Rear Driver:

Good (2005-2008 models)

NHTSA Side Impact Rear Passenger:

Good (2005-2008 models)

IIHS Front Offset Crash Test:

Good (2005-2008 models)

IIHS Side Impact Crash Test:

Good (2005-2008 models)

Active Features

Standard Anti-lock Braking System (ABS)

E Brake:

Rear drum parking brake (mechanical)

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Optional front side-impact airbags

Airbags Curtain:

Optional front and rear curtain airbags

Seatbelts:

3-point height-adjustable front seatbelts with pretensioners and load limiters, 3-point rear seatbelts

Child Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player, optional premium audio system with subwoofer, optional satellite radio readiness.

Display:

Basic digital display for clock, temperature, and audio information. Optional navigation system available on higher trims.

Connectivity:

Auxiliary input jack for portable audio devices (on some models/trims), optional Bluetooth hands-free connectivity (dealer-installed accessory or later year update).

Driver Assistance

Cruise Control:

Standard electronic cruise control.

Traction Control:

Optional Subaru Vehicle Dynamics Control (VDC) system, which includes traction control and stability control (typically on higher trims or later model years within this range).

ABS System:

Standard 4-wheel Anti-lock Braking System (ABS).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 6 months (severe driving), or 7,500 miles or 12 months (normal driving). Refer to manual for specific recommendations based on driving conditions.

Engine Air Filter:

Inspect every 15,000 miles, replace every 30,000 miles or as needed.

Cabin Air Filter:

Replace every 15,000 miles or 12 months.

Fuel Filter:

Replace at 105,000 miles (or as specified in manual, typically integrated with fuel pump).

Spark Plugs Na:

Replace at 105,000 miles (Iridium type)

Spark Plugs Xt:

Replace at 60,000 miles (Platinum type, check manual for specific recommendations)

Timing Belt:

Replace at 105,000 miles. Critical service item.

Coolant Flush:

Drain and refill every 30,000 miles or 3 years.

Transmission Fluid Auto:

Inspect every 15,000 miles, change fluid and filter every 30,000 miles (severe driving) or 60,000 miles (normal driving).

Transmission Fluid Manual:

Inspect periodically, change fluid every 60,000 miles.

Fluid Specifications

Engine Oil Type:

SAE 5W-30. API SM or SN certified. Check manual for viscosity based on temperature extremes.

Engine Oil Capacity Na:

4.8 US quarts (4.6 Liters) with filter change.

Engine Oil Capacity Xt:

4.8 US quarts (4.6 Liters) with filter change.

Coolant Type:

Subaru Super Coolant (Blue) or equivalent P-HOAT (Phosphate Hybrid Organic Acid Technology) coolant. Mix 50/50 with distilled water.

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 EJ engines, head gasket leaks can still occur, particularly on higher-mileage naturally aspirated models. Turbocharged models are generally more robust in this regard.

Catalytic Converter:

Premature failure can occur due to internal engine issues or overheating. Check for rattling noises or reduced engine power.

Cv Axles:

Wear and tear on CV boots can lead to joint failure. Listen for clicking noises during turns.

Rear Wheel Bearings:

Can become noisy with age. Symptoms include humming or grinding noises that change with speed or cornering.

Turbocharger Issues Xt:

Specific to XT models, the turbocharger can develop issues if not properly maintained (e.g., oil changes). Common signs include loss of power or excessive smoke.

Oil Consumption:

Some EJ engines may exhibit higher oil consumption, particularly if pushed hard. Regular checks are essential.

📚 Vehicle History

Brand Heritage

Subaru Heritage:

Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history in aviation and automotive manufacturing. The company is renowned for its horizontally opposed Boxer engines and its commitment to All-Wheel Drive technology, which originated from rally racing heritage.

Model Evolution

Forester Generation 2 Sg:

The SG generation Forester, introduced for the 2003 model year in Japan and late 2003 for North America, represented a significant styling update from the first generation. It featured a more rounded and SUV-like appearance, improved interior quality, and enhanced safety features. The 2005 model year saw a mid-cycle refresh, including revised styling (grille, headlights, bumpers) and updated powertrains, particularly for the turbocharged XT models.

Production

Production Period:

2002-2008 (for the SG generation)

Manufacturing Locations:

Gunma Plant, Japan

Sales Figures:

The Forester consistently sold well in North America, solidifying Subaru's presence in the crossover segment.

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

The Subaru Forester earned 'Good' ratings in IIHS front and side impact crash tests during this period, indicating strong safety performance.

Consumer Reports:

Often rated as having good or above-average predicted reliability by publications like Consumer Reports.

Kerry Blue Award:

Forester models have been recognized for their all-weather capability and practicality.