SUBARU FORESTER Factory Service Repair Manual 2003-2004
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🏷️ Basic Information Identification Make: Subaru Model: Forester Model Generation: SG (Second Generation) Model Year: 2003-2004 Codes Chassis Code: SG5, SG9 👋 Introduction Market Position Target Audience: DIY enthusiasts, professional mechanics, and Subaru owners seeking comprehensive repair and maintenance information for their 2003-2004 Forester. Competitive Analysis Value Proposition: Provides factory-level information equivalent to dealership service manuals at a fraction of the cost, with instant download accessibility. Key Features Delivery Method: Instant Digital Download, eliminating shipping costs and wait times. Content Origin: Replicates the same manual provided to authorized Subaru service and repair shops. Illustration Count: Hundreds of illustrations, diagrams, and pictures for clear procedural guidance. Ease Of Use Instruction Style: Easy-to-follow, step-by-step instructions suitable for all skill levels. 📋 Manual Details Coverage Areas Covered Models: All Subaru Forester models for 2003 and 2004, including all engine variants and trim levels. Page Count Total Pages: Over 2000 Manual Type Type: Factory Service Repair Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul and rebuilding, timing belt replacement, engine performance tuning, firing orders, serpentine belt routings with diagrams. Brakes: Complete brake servicing procedures, front end and alignment procedures and specifications. Electrical And Diagnostics: Wiring diagrams, trouble codes, computer diagnostic trouble tree charts, computer diagnostic codes, vacuum diagrams. Chassis And Suspension: Suspension systems, U-joint and CV-joint service procedures. Powertrain: Transmission removal and installation, transmission in-car servicing. Comfort And Convenience: Sunroof service. HVAC: Air conditioning service and capacities. Procedures Included Maintenance: Factory maintenance schedules and charts, driving concerns. Repair And Rebuild: Comprehensive repair procedures for all covered systems, engine rebuilding, component replacement. Diagnostics: Troubleshooting and diagnostics, detailed diagnostic trouble tree charts, analysis of diagnostic trouble codes. Technical Depth Depth: Professional-level technical information covering all aspects from basic maintenance to complete engine and transmission rebuilds. Detailed diagnostic procedures and troubleshooting charts. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text within PDF Print Quality Printable Pages: All pages are printable, allowing users to print only necessary sections. Zoom Capability: High-resolution PDF allowing for detailed viewing and zooming into diagrams and part illustrations. Binding Type Binding: Digital Download (No physical binding) Paper Type Paper Type: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Options: EJ253 (2.5L SOHC), EJ255 (2.5L DOHC Turbocharged - XT models), EJ205 (2.0L DOHC Turbocharged - GT/STI variants in certain markets, though primarily US market focus on 2.5L). Performance Horsepower Range: Approx. 165-175 HP (NA), 210-230 HP (Turbocharged - XT models). Torque Range: Approx. 184-190 lb-ft (NA), 235-250 lb-ft (Turbocharged - XT models). Fuel System Injection Type: Electronic Fuel Injection (EFI) Cooling System Coolant Capacity: Approximately 6.8 US quarts (6.4 liters) for 2.5L models. Refer to manual for exact capacity based on engine and radiator type. Timing Belt Belt Material: Reinforced rubber composite. 🔧 Transmission Standard Type: 5-speed Manual Transmission, 4-speed Automatic Transmission (with Selectable AWD functionality). Optional Optional Types: N/A (These were the primary transmission offerings for the model years). Features AWD System: Symmetrical All-Wheel Drive (standard on all models). Automatic transmission models feature Active Torque Split AWD. Fluid Specs Manual Fluid: Subaru Extra HP GL5 75W-90 Gear Oil (or equivalent specification). Capacity approx. 2.4 US quarts (2.3 liters). Automatic Fluid: Subaru ATF-HP (High Performance Automatic Transmission Fluid). Capacity approx. 3.5 US quarts (3.3 liters) for torque converter drain and fill. Total capacity is higher. 📐 Dimensions Exterior Wheelbase: Approximately 101.4 inches (2575 mm) Length: Approximately 175.0 inches (4445 mm) Width: Approximately 69.7 inches (1770 mm) Height: Approximately 63.1 inches (1603 mm) Weights Curb Weight Range: Approximately 3100-3500 lbs (1406-1588 kg), depending on engine and transmission. Towing Capacity: Typically rated for 2000 lbs (907 kg) when properly equipped. 🛡️ Safety Features Ratings NHTSA Front Crash Rating: 5-star (for driver and passenger, in 2003 tests). IIHS Front Offset Crash Rating: Good (in 2003 tests). Active Features Braking System: Anti-lock Braking System (ABS) standard on all models. Traction Control: Traction Control System (TCS) available on some models, especially automatic transmission variants. Passive Features Airbags: Front airbags (driver and passenger), optional side-impact airbags. Seatbelts: Three-point seatbelts with pretensioners. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM/CD stereo systems with varying speaker configurations. Manual covers basic diagnostics and removal/installation. Driver Assistance Stability Control: Vehicle Dynamics Control (VDC) was an option on some higher trim levels, enhancing stability in slippery conditions. Connectivity Cruise Control: Standard cruise control system, details on operation and troubleshooting included. Lighting Headlight Types: Halogen headlights. Manual covers bulb replacement and aiming procedures. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,750 miles (6,000 km) for severe driving conditions or 7,500 miles (12,000 km) for normal conditions, using synthetic oil. Refer to manual for specific details. Timing Belt Replacement Interval: Recommended every 60,000 to 105,000 miles (96,000 to 168,000 km) or 7 years, whichever comes first, depending on engine and usage....
Suspension systems, U-joint and CV-joint service procedures.
Powertrain:
Transmission removal and installation, transmission in-car servicing.
Comfort And Convenience:
Sunroof service.
HVAC:
Air conditioning service and capacities.
Procedures Included
Maintenance:
Factory maintenance schedules and charts, driving concerns.
Repair And Rebuild:
Comprehensive repair procedures for all covered systems, engine rebuilding, component replacement.
Diagnostics:
Troubleshooting and diagnostics, detailed diagnostic trouble tree charts, analysis of diagnostic trouble codes.
Technical Depth
Depth:
Professional-level technical information covering all aspects from basic maintenance to complete engine and transmission rebuilds. Detailed diagnostic procedures and troubleshooting charts.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text within PDF
Print Quality
Printable Pages:
All pages are printable, allowing users to print only necessary sections.
Zoom Capability:
High-resolution PDF allowing for detailed viewing and zooming into diagrams and part illustrations.
Binding Type
Binding:
Digital Download (No physical binding)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Options:
EJ253 (2.5L SOHC), EJ255 (2.5L DOHC Turbocharged - XT models), EJ205 (2.0L DOHC Turbocharged - GT/STI variants in certain markets, though primarily US market focus on 2.5L).
Performance
Horsepower Range:
Approx. 165-175 HP (NA), 210-230 HP (Turbocharged - XT models).
N/A (These were the primary transmission offerings for the model years).
Features
AWD System:
Symmetrical All-Wheel Drive (standard on all models). Automatic transmission models feature Active Torque Split AWD.
Fluid Specs
Manual Fluid:
Subaru Extra HP GL5 75W-90 Gear Oil (or equivalent specification). Capacity approx. 2.4 US quarts (2.3 liters).
Automatic Fluid:
Subaru ATF-HP (High Performance Automatic Transmission Fluid). Capacity approx. 3.5 US quarts (3.3 liters) for torque converter drain and fill. Total capacity is higher.
📐 Dimensions
Exterior
Wheelbase:
Approximately 101.4 inches (2575 mm)
Length:
Approximately 175.0 inches (4445 mm)
Width:
Approximately 69.7 inches (1770 mm)
Height:
Approximately 63.1 inches (1603 mm)
Weights
Curb Weight Range:
Approximately 3100-3500 lbs (1406-1588 kg), depending on engine and transmission.
Towing Capacity:
Typically rated for 2000 lbs (907 kg) when properly equipped.
🛡️ Safety Features
Ratings
NHTSA Front Crash Rating:
5-star (for driver and passenger, in 2003 tests).
IIHS Front Offset Crash Rating:
Good (in 2003 tests).
Active Features
Braking System:
Anti-lock Braking System (ABS) standard on all models.
Traction Control:
Traction Control System (TCS) available on some models, especially automatic transmission variants.
Passive Features
Airbags:
Front airbags (driver and passenger), optional side-impact airbags.
Seatbelts:
Three-point seatbelts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM/CD stereo systems with varying speaker configurations. Manual covers basic diagnostics and removal/installation.
Driver Assistance
Stability Control:
Vehicle Dynamics Control (VDC) was an option on some higher trim levels, enhancing stability in slippery conditions.
Connectivity
Cruise Control:
Standard cruise control system, details on operation and troubleshooting included.
Lighting
Headlight Types:
Halogen headlights. Manual covers bulb replacement and aiming procedures.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,750 miles (6,000 km) for severe driving conditions or 7,500 miles (12,000 km) for normal conditions, using synthetic oil. Refer to manual for specific details.
Timing Belt Replacement Interval:
Recommended every 60,000 to 105,000 miles (96,000 to 168,000 km) or 7 years, whichever comes first, depending on engine and usage. Critical replacement item.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 API SG or higher (synthetic recommended for optimal performance and protection).
Coolant Type:
Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant with corrosion inhibitors. A 50/50 mixture with distilled water is standard.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid Type:
Subaru ATF-HP or a Dexron III compatible fluid.
Known Issues
Head Gaskets:
While not as prevalent as in some earlier Subaru models, head gasket leaks can still occur, particularly on higher mileage EJ25 engines. The manual will detail inspection and replacement procedures.
Catalytic Converter:
Premature failure of the catalytic converter can occur due to various engine issues, including oil burning. Manual covers related diagnostics.
Turbocharger Issues:
On turbocharged models (XT), proper oil maintenance is crucial to prevent turbocharger wear and failure. Manual provides specific lubrication and inspection details.
📚 Vehicle History
Brand Heritage
Subaru Specialty:
Renowned for its Symmetrical All-Wheel Drive system and horizontally opposed ('boxer') engines, providing a low center of gravity and balanced handling.
Model Evolution
Generation Introduction:
The second generation Forester (SG) was introduced for the 2003 model year, featuring a significant styling update and chassis enhancements over the first generation.
Design Changes:
The SG generation moved away from the more utilitarian wagon-like appearance of the first generation towards a more SUV-like stance with a revised front fascia, headlights, and grille.
Production
Manufacturing Location:
Primary manufacturing location was Subaru's Gunma Seisakusho Plant in Japan.
🏆 Awards & Recognition
Recognitions
Car And Driver Best SUV:
Subaru Forester was frequently recognized by automotive publications like Car and Driver for its all-weather capability and practicality.
Ratings
Kelley Blue Book Value:
The Forester has historically been praised for its strong resale value and longevity, aspects that contribute to its desirability and are implicitly supported by its build quality.
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