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Subaru Forester 2003 2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation: Second Generation (SG) Model Years Covered: 2003, 2004 Codes Chassis Code: SG5, SG9 👋 Introduction Market Position Segment: Compact Crossover SUV Key Selling Points: Standard Symmetrical AWD, practicality, off-road capability for its class, robust build. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Mazda Tribute. Key Features Defining Features: The second-generation Forester continued Subaru's legacy of offering standard All-Wheel Drive, a horizontally-opposed 'boxer' engine for a lower center of gravity, and a practical, family-oriented design. 📋 Manual Details Coverage Areas Primary Coverage: Complete service and repair instructions for the 2003-2004 Subaru Forester. Engine Coverage: 2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255 - XT models) Transmission Coverage: 4-speed Automatic, 5-speed Manual Drivetrain Coverage: Symmetrical All-Wheel Drive (AWD) system, differentials, driveshafts. Body And Chassis Coverage: Body panels, frame, suspension, steering, brakes, exhaust. Electrical Coverage: Wiring diagrams, lighting, instrumentation, audio, comfort systems, ECU diagnostics. Page Count Estimated Page Count: 1500-2000+ (typical for comprehensive workshop manuals) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine electrical, fuel & emissions, cooling, lubrication, ignition, exhaust systems. Drivetrain And Suspension: Clutch, transmission (manual & automatic), transfer case, driveshafts, differentials, axles, front & rear suspension components, wheel bearings. Brakes And Steering: Brake system hydraulics, ABS, parking brake, steering gear, power steering system. Electrical And Electronics: Battery, charging system, starting system, lighting, instruments, wipers, horn, power windows/locks, SRS (airbag) system, immobilizer, ECU/ECM diagnostics. Body And Interior: Body exterior (panels, doors, glass), interior trim, seats, HVAC (Heating, Ventilation, and Air Conditioning) system. Procedures Included Maintenance: Routine maintenance tasks, fluid changes, filter replacements, inspection points. Repair: Detailed step-by-step repair procedures for all major components and systems. Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), diagnostic procedures for electrical and mechanical faults. Disassembly And Assembly: Complete instructions for component removal, disassembly, inspection, repair, and reassembly. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and wiring schematics. 📊 Manual Specifications File Format File Type: Searchable PDF Printability: Printable Print Quality Image Resolution: High-resolution, clear diagrams and images. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code Naturally Aspirated: EJ253 Engine Displacement Naturally Aspirated: 2.5 Liters (2457 cc) Engine Configuration Naturally Aspirated: Horizontally-opposed (Boxer), 4-cylinder, SOHC (Single Overhead Cam) Engine Power Naturally Aspirated: 165 hp @ 5600 rpm Engine Torque Naturally Aspirated: 166 lb-ft @ 3600 rpm Turbocharged Engine Engine Code Turbocharged: EJ255 Engine Displacement Turbocharged: 2.5 Liters (2457 cc) Engine Configuration Turbocharged: Horizontally-opposed (Boxer), 4-cylinder, DOHC (Double Overhead Cam), Turbocharged Engine Power Turbocharged: 210 hp @ 5600 rpm (XT models) Engine Torque Turbocharged: 235 lb-ft @ 3600 rpm (XT models) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Recommended Octane Naturally Aspirated: 87 AKI Recommended Octane Turbocharged: 91 AKI (Premium) 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission Features Drivetrain System: Symmetrical All-Wheel Drive (AWD) - standard on all models. AWD System Details: Viscous coupling center differential (manual) or electronically controlled multi-plate transfer clutch (automatic) distributing torque front to rear. 📐 Dimensions Exterior Wheelbase: 103.1 inches (2619 mm) Length: 173.4 inches (4404 mm) Width: 69.7 inches (1770 mm) Height: 63.0 inches (1600 mm) Ground Clearance: 8.1 inches (206 mm) Weights Curb Weight Manual: Approx. 3285 lbs (1490 kg) Curb Weight Automatic: Approx. 3350 lbs (1520 kg) Gross Vehicle Weight Rating: Approx. 4600 lbs (2087 kg) Cargo Cargo Volume Behind Rear Seat: 32.1 cu ft (0.909 m³) Cargo Volume With Rear Seat Folded: 63.0 cu ft (1.784 m³) 🛡️ Safety Features Ratings NHTSA Frontal Driver Rating: 4 Stars (2003 Model Year) NHTSA Frontal Passenger Rating: 4 Stars (2003 Model Year) NHTSA Side Front Driver Rating: 5 Stars (2003 Model Year) NHTSA Side Front Passenger Rating: 5 Stars (2003 Model Year) NHTSA Side Rear Driver Rating: 4 Stars (2003 Model Year) NHTSA Side Rear Passenger Rating: 4 Stars (2003 Model Year) IIHS Frontal Offset Rating: Good (2003 Model Year) Active Features Braking System: Front ventilated discs, Rear solid discs. Anti-lock Braking System (ABS) standard. Traction Control: Optional (usually on higher trims or AWD models). Passive Features Airbags: Front dual-stage airbags. Optional front side-impact airbags. Seatbelts: 3-point seatbelts with pretensioners and force limiters in all seating positions. Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system. 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player, often with optional premium audio systems and satellite radio readiness. Display Technology: Basic digital or analog instrument cluster, climate control displays. No touchscreens or complex infotainment systems typical of modern vehicles. Driver Assistance ABS: Standard Anti-lock Braking System (ABS). Cruise Control: Standard on most trims. Connectivity Auxiliary Input:...
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Subaru Forester 2003 2004 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Generation:
Second Generation (SG)
Model Years Covered:
2003, 2004
Codes
Chassis Code:
SG5, SG9
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Key Selling Points:
Standard Symmetrical AWD, practicality, off-road capability for its class, robust build.
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Mazda Tribute.
Key Features
Defining Features:
The second-generation Forester continued Subaru's legacy of offering standard All-Wheel Drive, a horizontally-opposed 'boxer' engine for a lower center of gravity, and a practical, family-oriented design.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete service and repair instructions for the 2003-2004 Subaru Forester.
Engine Coverage:
2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255 - XT models)
Transmission Coverage:
4-speed Automatic, 5-speed Manual
Drivetrain Coverage:
Symmetrical All-Wheel Drive (AWD) system, differentials, driveshafts.
Body And Chassis Coverage:
Body panels, frame, suspension, steering, brakes, exhaust.
Electrical Coverage:
Wiring diagrams, lighting, instrumentation, audio, comfort systems, ECU diagnostics.
Page Count
Estimated Page Count:
1500-2000+ (typical for comprehensive workshop manuals)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine electrical, fuel & emissions, cooling, lubrication, ignition, exhaust systems.
Drivetrain And Suspension:
Clutch, transmission (manual & automatic), transfer case, driveshafts, differentials, axles, front & rear suspension components, wheel bearings.
Brakes And Steering:
Brake system hydraulics, ABS, parking brake, steering gear, power steering system.
Electrical And Electronics:
Battery, charging system, starting system, lighting, instruments, wipers, horn, power windows/locks, SRS (airbag) system, immobilizer, ECU/ECM diagnostics.
Body And Interior:
Body exterior (panels, doors, glass), interior trim, seats, HVAC (Heating, Ventilation, and Air Conditioning) system.
Procedures Included
Maintenance:
Routine maintenance tasks, fluid changes, filter replacements, inspection points.
Repair:
Detailed step-by-step repair procedures for all major components and systems.
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), diagnostic procedures for electrical and mechanical faults.
Disassembly And Assembly:
Complete instructions for component removal, disassembly, inspection, repair, and reassembly.
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and wiring schematics.
📊 Manual Specifications
File Format
File Type:
Searchable PDF
Printability:
Printable
Print Quality
Image Resolution:
High-resolution, clear diagrams and images.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Naturally Aspirated:
EJ253
Engine Displacement Naturally Aspirated:
2.5 Liters (2457 cc)
Engine Configuration Naturally Aspirated:
Horizontally-opposed (Boxer), 4-cylinder, SOHC (Single Overhead Cam)
Engine Power Naturally Aspirated:
165 hp @ 5600 rpm
Engine Torque Naturally Aspirated:
166 lb-ft @ 3600 rpm
Turbocharged Engine
Engine Code Turbocharged:
EJ255
Engine Displacement Turbocharged:
2.5 Liters (2457 cc)
Engine Configuration Turbocharged:
Horizontally-opposed (Boxer), 4-cylinder, DOHC (Double Overhead Cam), Turbocharged
Engine Power Turbocharged:
210 hp @ 5600 rpm (XT models)
Engine Torque Turbocharged:
235 lb-ft @ 3600 rpm (XT models)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Recommended Octane Naturally Aspirated:
87 AKI
Recommended Octane Turbocharged:
91 AKI (Premium)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Drivetrain System:
Symmetrical All-Wheel Drive (AWD) - standard on all models.
AWD System Details:
Viscous coupling center differential (manual) or electronically controlled multi-plate transfer clutch (automatic) distributing torque front to rear.
📐 Dimensions
Exterior
Wheelbase:
103.1 inches (2619 mm)
Length:
173.4 inches (4404 mm)
Width:
69.7 inches (1770 mm)
Height:
63.0 inches (1600 mm)
Ground Clearance:
8.1 inches (206 mm)
Weights
Curb Weight Manual:
Approx. 3285 lbs (1490 kg)
Curb Weight Automatic:
Approx. 3350 lbs (1520 kg)
Gross Vehicle Weight Rating:
Approx. 4600 lbs (2087 kg)
Cargo
Cargo Volume Behind Rear Seat:
32.1 cu ft (0.909 m³)
Cargo Volume With Rear Seat Folded:
63.0 cu ft (1.784 m³)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver Rating:
4 Stars (2003 Model Year)
NHTSA Frontal Passenger Rating:
4 Stars (2003 Model Year)
NHTSA Side Front Driver Rating:
5 Stars (2003 Model Year)
NHTSA Side Front Passenger Rating:
5 Stars (2003 Model Year)
NHTSA Side Rear Driver Rating:
4 Stars (2003 Model Year)
NHTSA Side Rear Passenger Rating:
4 Stars (2003 Model Year)
IIHS Frontal Offset Rating:
Good (2003 Model Year)
Active Features
Braking System:
Front ventilated discs, Rear solid discs. Anti-lock Braking System (ABS) standard.
Traction Control:
Optional (usually on higher trims or AWD models).
Passive Features
Airbags:
Front dual-stage airbags. Optional front side-impact airbags.
Seatbelts:
3-point seatbelts with pretensioners and force limiters in all seating positions.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, often with optional premium audio systems and satellite radio readiness.
Display Technology:
Basic digital or analog instrument cluster, climate control displays. No touchscreens or complex infotainment systems typical of modern vehicles.
Driver Assistance
ABS:
Standard Anti-lock Braking System (ABS).
Cruise Control:
Standard on most trims.
Connectivity
Auxiliary Input:
Rare, if present, typically an aftermarket addition or limited to specific trim levels.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3.75 months, whichever comes first (severe driving conditions), 7,500 miles (12,000 km) or 7.5 months (normal driving conditions).
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 15 months.
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or 15 months.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for standard models; Platinum/Iridium plugs may have longer intervals, consult manual.
Coolant Flush:
Every 30,000 miles (48,000 km) or 30 months.
Transmission Fluid Change Automatic:
Every 30,000 miles (48,000 km) or 30 months (severe service).
Transmission Fluid Change Manual:
Every 60,000 miles (96,000 km) or 60 months.
Fluid Specifications
Engine Oil Type:
SAE 5W-30, API Service SL or SM rated, ILSAC GF-3 or GF-4 certified.
Engine Oil Capacity:
Approx. 4.8 US quarts (4.5 Liters) with filter change (EJ253).
Coolant Type:
Subaru Super Coolant (Blue) or equivalent (Ethylene Glycol based, 50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4.
Transmission Fluid Automatic:
Subaru ATF-HP (High Performance) or equivalent.
Transmission Fluid Manual:
SAE 75W-90 GL-5 gear oil.
Differential Fluid Front Rear:
SAE 75W-90 GL-5 gear oil.
Known Issues
Head Gaskets:
While less prevalent than in earlier EJ engines, head gasket leaks can still occur, especially in higher-mileage vehicles or those subjected to high heat or stress.
Catalytic Converter:
Can degrade over time, leading to reduced engine performance and potential check engine lights.
Radiator And Hoses:
Plastic radiator tanks can become brittle and crack; rubber hoses can degrade and leak.
Clutch Wear:
Typical wear item in manual transmission vehicles, requiring replacement based on driving habits.
Automatic Transmission Issues:
Some models may experience occasional rough shifting or hesitation; regular fluid maintenance is crucial.
📚 Vehicle History
Brand Heritage
Subaru Dna:
Subaru is renowned for its Symmetrical All-Wheel Drive and horizontally-opposed 'boxer' engines, which contribute to enhanced traction, stability, and a lower center of gravity.
Model Evolution
Generation Introduction:
The second generation Forester (SG) was introduced for the 2003 model year, replacing the first generation (SF). It featured a significant redesign with a stiffer chassis and updated styling.
Mid-Cycle Refresh:
A minor facelift occurred for the 2006 model year, but this manual specifically covers the pre-facelift 2003-2004 models.
Production
Manufacturing Location:
Japan (Gunma Plant)
🏆 Awards & Recognition
Recognitions
Car And Driver Towing Award:
Forester often cited for its capability and AWD system in comparisons.
Ratings
Consumer Reports Reliability:
Generally considered average to good, with some model years showing better reliability than others. Specific issues noted, as detailed in maintenance section.
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