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SUBARU FORESTER SG 2004-2008 Full Repair Service Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation: SG Model Years Covered: 2004, 2005, 2006, 2007, 2008 Chassis Code: SG Codes Engine Code Primary: EJ25 (Non-turbo and Turbo variants) 👋 Introduction Market Position Segment: Compact Crossover SUV Niche: Known for Symmetrical All-Wheel Drive (standard on most models), practicality, and utility. Appeals to outdoor enthusiasts. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Nissan Xterra, Ford Escape Key Features Drivetrain: Standard Symmetrical All-Wheel Drive (AWD) Engine Options: Naturally aspirated and turbocharged boxer engines Body Style: Station wagon-like SUV with high ground clearance Practicality: Spacious interior for its class, good cargo capacity, durable construction 📋 Manual Details Coverage Areas Main Topics: Comprehensive repair, service, maintenance, diagnostics, troubleshooting, wiring diagrams, parts identification Trim Levels Covered: X, XS, XT (indicative of standard, sport, and turbo variants) Page Count Estimated Page Count: Likely 1000+ pages (typical for full workshop manuals of this scope) Manual Type Type: Full Repair Service Manual / Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical (including EJ25 variants), Fuel System, Emission Control, Intake System, Exhaust System, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Transmission (Automatic and Manual), Transfer Case, Differentials, Driveshaft System Chassis: Suspension (Front and Rear), Wheel and Tire, Brake System, Parking Brake, Steering System Body And Interior: Body and Accessories, Interior Trim, Exterior Trim, Airbag System, Seat Belt System HVAC And Electronics: Heating, Ventilation, Air Conditioning (HVAC), Control System, Cruise Control System, Electrical System, Wiring Diagrams Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, fluid checks), tune-ups, inspections Diagnostics: Troubleshooting guides, symptom-based diagnostics, OBD-II fault code interpretation Repair And Rebuild: Engine overhaul, transmission rebuild, brake component replacement, suspension component replacement, electrical component repair, body panel repair Installation: Component installation (e.g., aftermarket accessories with wiring considerations), factory specification checks Technical Depth Depth: Extensive, covering from basic adjustments to complete component overhauls and diagnostics. Includes detailed schematics and specifications. 📊 Manual Specifications File Format File Type: PDF File Size: 233MB Searchable Text: Likely searchable due to PDF format (depends on scanning quality of original source) Print Quality Resolution: Variable, dependent on original source scanned material. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Family: Subaru EJ Series Boxer Engine Code Specific: EJ253 (Naturally Aspirated), EJ255 (Turbocharged for XT models) Configuration: Flat-four (Boxer) Displacement: 2.5 Liters (2457 cc) Performance Horsepower Na: Approx. 170-175 hp @ 5600-6000 rpm (EJ253) Torque Na: Approx. 166-170 lb-ft @ 3700-4000 rpm (EJ253) Horsepower Turbo: Approx. 210-230 hp @ 5600-6000 rpm (EJ255 - XT models) Torque Turbo: Approx. 235-250 lb-ft @ 3600-4000 rpm (EJ255 - XT models) Fuel System Induction: Sequential Multi-Port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane minimum, 91 octane recommended for XT models) Turbocharger: Available on XT models (e.g., IHI VF40/VF45) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (TY756/TY757) Optional Transmission Type Optional: 4-speed Automatic Transmission (4EAT) Features Drivetrain Integration: Integrated with Symmetrical AWD system via center differential (manual) or planetary gearset (automatic). Gear Ratios: Specific gear ratios for manual and automatic transmissions are detailed within the manual. Fluid Type: Manual: Subaru Extra-S (or equivalent GL-5 75W-90), Automatic: Subaru ATF-HP (or equivalent Dexron III/Mercon) 📐 Dimensions Exterior Length: Approx. 177.0 inches (4495 mm) Width: Approx. 69.7 inches (1770 mm) Height: Approx. 63.6 inches (1615 mm) Wheelbase: Approx. 103.1 inches (2618 mm) Ground Clearance: Approx. 8.1 inches (205 mm) Weights Curb Weight: Approx. 3250-3600 lbs (1475-1630 kg), varies by trim and transmission Towing Capacity: Approx. 2400 lbs (1088 kg) with appropriate trailer brakes 🛡️ Safety Features Ratings NHTSA Front Crash: 5-Star (for driver and passenger in most configurations) IIHS Side Impact: Good (for most configurations) IIHS Rear Impact Whiplash: Good (for most configurations) Active Features ABS: Standard Anti-lock Braking System E-Brake: Electronic Brake Force Distribution (EBD) Traction Control: Available (especially on XT models) Stability Control: Available (Vehicle Dynamics Control - VDC) on higher trims/later years Passive Features Airbags: Front airbags, available side curtain airbags Seatbelts: 3-point seatbelts with pretensioners Child Anchors: LATCH (Lower Anchors and Tethers for Children) system 💡 Technology Features Infotainment Head Unit: Factory-fitted single-DIN or double-DIN radios, CD players, optional navigation systems. Speakers: Typically 4-6 speakers, with premium audio systems available on higher trims. Driver Assistance Cruise Control: Standard cruise control system, electronically controlled. ABS: Anti-lock Braking System (see safety section) Connectivity Aux Input: Available on some models for audio devices. Usb Port: Not typically standard on this generation, may be an aftermarket addition or available on later model year iterations. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 6 months (severe duty), 7,500 miles or 6 months (normal duty) Air Filter Replacement: Every 15,000 miles or 12 months (severe duty), 30,000 miles or 24 months (normal duty) Spark Plug Replacement:...
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SUBARU FORESTER SG 2004-2008 Full Repair Service Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Generation:
SG
Model Years Covered:
2004, 2005, 2006, 2007, 2008
Chassis Code:
SG
Codes
Engine Code Primary:
EJ25 (Non-turbo and Turbo variants)
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Niche:
Known for Symmetrical All-Wheel Drive (standard on most models), practicality, and utility. Appeals to outdoor enthusiasts.
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Nissan Xterra, Ford Escape
Key Features
Drivetrain:
Standard Symmetrical All-Wheel Drive (AWD)
Engine Options:
Naturally aspirated and turbocharged boxer engines
Body Style:
Station wagon-like SUV with high ground clearance
Practicality:
Spacious interior for its class, good cargo capacity, durable construction
📋 Manual Details
Coverage Areas
Main Topics:
Comprehensive repair, service, maintenance, diagnostics, troubleshooting, wiring diagrams, parts identification
Trim Levels Covered:
X, XS, XT (indicative of standard, sport, and turbo variants)
Page Count
Estimated Page Count:
Likely 1000+ pages (typical for full workshop manuals of this scope)
Manual Type
Type:
Full Repair Service Manual / Workshop Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Mechanical (including EJ25 variants), Fuel System, Emission Control, Intake System, Exhaust System, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Transmission (Automatic and Manual), Transfer Case, Differentials, Driveshaft System
Chassis:
Suspension (Front and Rear), Wheel and Tire, Brake System, Parking Brake, Steering System
Body And Interior:
Body and Accessories, Interior Trim, Exterior Trim, Airbag System, Seat Belt System
HVAC And Electronics:
Heating, Ventilation, Air Conditioning (HVAC), Control System, Cruise Control System, Electrical System, Wiring Diagrams
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, fluid checks), tune-ups, inspections
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, OBD-II fault code interpretation
Repair And Rebuild:
Engine overhaul, transmission rebuild, brake component replacement, suspension component replacement, electrical component repair, body panel repair
Installation:
Component installation (e.g., aftermarket accessories with wiring considerations), factory specification checks
Technical Depth
Depth:
Extensive, covering from basic adjustments to complete component overhauls and diagnostics. Includes detailed schematics and specifications.
📊 Manual Specifications
File Format
File Type:
PDF
File Size:
233MB
Searchable Text:
Likely searchable due to PDF format (depends on scanning quality of original source)
Print Quality
Resolution:
Variable, dependent on original source scanned material.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Subaru EJ Series Boxer
Engine Code Specific:
EJ253 (Naturally Aspirated), EJ255 (Turbocharged for XT models)
Configuration:
Flat-four (Boxer)
Displacement:
2.5 Liters (2457 cc)
Performance
Horsepower Na:
Approx. 170-175 hp @ 5600-6000 rpm (EJ253)
Torque Na:
Approx. 166-170 lb-ft @ 3700-4000 rpm (EJ253)
Horsepower Turbo:
Approx. 210-230 hp @ 5600-6000 rpm (EJ255 - XT models)
Torque Turbo:
Approx. 235-250 lb-ft @ 3600-4000 rpm (EJ255 - XT models)
Fuel System
Induction:
Sequential Multi-Port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane minimum, 91 octane recommended for XT models)
Turbocharger:
Available on XT models (e.g., IHI VF40/VF45)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission (TY756/TY757)
Optional
Transmission Type Optional:
4-speed Automatic Transmission (4EAT)
Features
Drivetrain Integration:
Integrated with Symmetrical AWD system via center differential (manual) or planetary gearset (automatic).
Gear Ratios:
Specific gear ratios for manual and automatic transmissions are detailed within the manual.
Fluid Type:
Manual: Subaru Extra-S (or equivalent GL-5 75W-90), Automatic: Subaru ATF-HP (or equivalent Dexron III/Mercon)
📐 Dimensions
Exterior
Length:
Approx. 177.0 inches (4495 mm)
Width:
Approx. 69.7 inches (1770 mm)
Height:
Approx. 63.6 inches (1615 mm)
Wheelbase:
Approx. 103.1 inches (2618 mm)
Ground Clearance:
Approx. 8.1 inches (205 mm)
Weights
Curb Weight:
Approx. 3250-3600 lbs (1475-1630 kg), varies by trim and transmission
Towing Capacity:
Approx. 2400 lbs (1088 kg) with appropriate trailer brakes
🛡️ Safety Features
Ratings
NHTSA Front Crash:
5-Star (for driver and passenger in most configurations)
IIHS Side Impact:
Good (for most configurations)
IIHS Rear Impact Whiplash:
Good (for most configurations)
Active Features
ABS:
Standard Anti-lock Braking System
E-Brake:
Electronic Brake Force Distribution (EBD)
Traction Control:
Available (especially on XT models)
Stability Control:
Available (Vehicle Dynamics Control - VDC) on higher trims/later years
Passive Features
Airbags:
Front airbags, available side curtain airbags
Seatbelts:
3-point seatbelts with pretensioners
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Head Unit:
Factory-fitted single-DIN or double-DIN radios, CD players, optional navigation systems.
Speakers:
Typically 4-6 speakers, with premium audio systems available on higher trims.
Driver Assistance
Cruise Control:
Standard cruise control system, electronically controlled.
ABS:
Anti-lock Braking System (see safety section)
Connectivity
Aux Input:
Available on some models for audio devices.
Usb Port:
Not typically standard on this generation, may be an aftermarket addition or available on later model year iterations.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe duty), 7,500 miles or 6 months (normal duty)
Air Filter Replacement:
Every 15,000 miles or 12 months (severe duty), 30,000 miles or 24 months (normal duty)
Spark Plug Replacement:
Iridium plugs: ~60,000 miles; Platinum plugs: ~30,000 miles (check specific engine variant)
Coolant Flush:
Every 30,000 miles or 24 months
Transmission Fluid Change Auto:
Every 30,000 miles or 24 months (severe duty), 60,000 miles or 48 months (normal duty)
Transmission Fluid Change Manual:
Every 30,000 miles or 24 months (severe duty), 60,000 miles or 48 months (normal duty)
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API SN or newer, synthetic blend or full synthetic recommended)
Engine Oil Capacity:
Approx. 4.8 US quarts (4.5 Liters) with filter change
Coolant Type:
Subaru Super Coolant (Blue, Ethylene Glycol based) or equivalent
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Head Gaskets:
Historically prone to head gasket failure in EJ engines, especially early models. Later models and revised designs improved reliability.
Oil Consumption:
Some EJ25 engines can exhibit higher than normal oil consumption, particularly if not properly maintained.
Turbo Issues:
Turbocharger wear or failure on XT models can occur with poor maintenance or age.
Sus Component Wear:
Rear trailing arm bushings and front control arm bushings can wear over time, affecting alignment and ride quality.
📚 Vehicle History
Brand Heritage
Manufacturer:
Subaru Corporation (formerly Fuji Heavy Industries)
Core Technologies:
Symmetrical All-Wheel Drive, Boxer engines
Model Evolution
First Generation:
1997-2002 (SF chassis)
Second Generation:
2003-2008 (SG chassis) - this generation
Third Generation:
2009-2013 (SH chassis)
Production
Manufacturing Plant:
Gunma Manufacturing Plant, Japan
Production Span Sg:
2003-2008 model years
🏆 Awards & Recognition
Recognitions
Car And Driver:
Subaru Forester often appeared on Car and Driver's 10Best lists in its early years, and the SG generation continued this positive reception for its segment.
Ratings
Kbb Value:
Typically rated well for resale value due to its durability and AWD capability.
Certifications
Safety Certifications:
Consistently achieved good safety ratings from IIHS and NHTSA for its generation.
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