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Subaru Forester Service and Repair Manual 2004

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2004 Generation Generation: Second Generation (SG) Codes Chassis Code: SG5, SG9 👋 Introduction Market Position Positioning: Targeted at DIY enthusiasts and professional mechanics seeking an accurate, dealership-level repair resource for the 2004 Subaru Forester. Competitive Analysis Comparison: Presents itself as a high-quality, authentic factory service manual, contrasting with potentially inaccurate third-party publications. Emphasizes comprehensiveness and dealership-level detail. Key Features Features: Detailed illustrations, step-by-step instructions, printable pages, comprehensive system coverage, diagnostic flowcharts, and wiring diagrams. 📋 Manual Details Coverage Areas Trim Levels Covered: All Styles Covered Page Count Total Pages: 3700+ Manual Type Type: Factory Service & Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Engine Mechanical, Engine Control System, Engine Coolant, Lubrication System, SFI System, Ignition System Drivetrain: Manual Transaxle System, Transmission Valve Body, Drive Shaft, Differential Case Assy, Rear Axle Hub, Rear Axle Beam Suspension Steering: Suspension System, Rear Suspension System, Steering System, Power Steering, Steering Column Brakes: Brake System, Brake Master Cylinder, Brake Booster, Brake Actuator, ABS System, Parking Brake Electrical: Charging System, Starting System, Lighting System, Combination Meter, Instrument Panel, Wiring Diagrams, Wire Harness Repair Body Interior: Body Repair, Roof Headlining, Hood, Doors, Seats, Interior Trim, Sun Roof System, Power Window Control System, Power Door Lock Control System Safety Features: Supplemental Restraint System (SRS), Curtain Shield Air Bag Assy, Side Air Bag Sensor Assy, Seat Position Air Bag Sensor, Seat Belt, Seat Belt Warning System Procedures Included Maintenance: Oil Change, Filter Replacement, Fluid Checks and Replacements, Tire Rotation, Brake Pad Inspection Diagnostics Troubleshooting: Detailed Troubleshooting guides for all systems, DTC code interpretation, Electrical System Diagnosis Repair Rebuild: Engine disassembly and reassembly, Transmission overhaul, Brake system repair, Suspension component replacement, Body panel repair Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Printable without restriction Binding Type Binding Type: Digital Download (Printable Pages) Paper Type Paper Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Engine Options: 2.5L EJ253 SOHC (Naturally Aspirated), 2.5L EJ255 DOHC (Turbocharged - XT models) Performance Horsepower: Approx. 165 hp (EJ253), Approx. 210 hp (EJ255 Turbo) Torque: Approx. 170 lb-ft (EJ253), Approx. 235 lb-ft (EJ255 Turbo) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Sequential Port Injection (SPI) Engine Mechanical Bore X Stroke: 99.5 mm x 79.0 mm (EJ253 & EJ255) Compression Ratio: 9.7:1 (EJ253), 8.4:1 (EJ255) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Optional Transmission Type: 4-Speed Automatic with Lock-up Torque Converter Features Drivetrain: Symmetrical All-Wheel Drive (AWD) standard on all models. 📐 Dimensions Exterior Length: 4,485 mm (176.6 in) Width: 1,735 mm (68.3 in) Height: 1,590 mm (62.6 in) Wheelbase: 2,630 mm (103.5 in) Weights Curb Weight: Approximately 1,450 kg - 1,550 kg (3,200 lbs - 3,417 lbs) depending on configuration. 🛡️ Safety Features Ratings NHTSA Front Impact: 5 Stars NHTSA Side Impact: 4 Stars Active Features Active Safety: Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA), Traction Control System (TCS), Vehicle Stability Control (VSC) Passive Features Passive Safety: Driver and Front Passenger Airbags, Side Curtain Airbags (Optional/Standard depending on trim), Front Seatbelt Pretensioners, Crumple Zones 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player. Optional premium audio systems with subwoofer may be available on higher trims. Driver Assistance Cruise Control: Standard cruise control. Connectivity Auxiliary Input: Typically not standard; aftermarket solutions often required for auxiliary or USB input. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 3 months (severe conditions), 7,500 miles or 6 months (normal conditions), consult manual for specific details. Timing Belt Replacement: 105,000 miles or 105 months (for models equipped with timing belt, typically naturally aspirated engines). Turbocharged models may have different recommendations or chain-driven components. Fluid Specifications Engine Oil: SAE 5W-30 (API SG or higher). Check manual for specific viscosity based on climate. Coolant: Subaru Super Coolant (Blue) or equivalent silicate-free, long-life antifreeze. 50/50 mixture with distilled water. Transmission Fluid Manual: API GL-5 SAE 75W-90 Gear Oil Transmission Fluid Automatic: Subaru ATF-HP or equivalent DEXRON III/MERCON compatible fluid. Brake Fluid: DOT 3 or DOT 4 Brake Fluid Known Issues Head Gaskets: While less common on the second generation than the first, head gasket leaks can still occur, particularly on higher mileage or poorly maintained naturally aspirated EJ25 engines. Turbocharged engines are less susceptible. Catalytic Converter: Premature failure of the catalytic converter can occur due to engine oil consumption or misfires. Symptoms include reduced engine power and Check Engine Light. Susceptibility: Subaru vehicles are known for their AWD systems. Regular maintenance of the differentials and transmission fluids is crucial for longevity. 📚 Vehicle History Brand Heritage Heritage: Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history of producing durable and capable...
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Subaru Forester Service and Repair Manual 2004
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Year:
2004
Generation
Generation:
Second Generation (SG)
Codes
Chassis Code:
SG5, SG9
👋 Introduction
Market Position
Positioning:
Targeted at DIY enthusiasts and professional mechanics seeking an accurate, dealership-level repair resource for the 2004 Subaru Forester.
Competitive Analysis
Comparison:
Presents itself as a high-quality, authentic factory service manual, contrasting with potentially inaccurate third-party publications. Emphasizes comprehensiveness and dealership-level detail.
Key Features
Features:
Detailed illustrations, step-by-step instructions, printable pages, comprehensive system coverage, diagnostic flowcharts, and wiring diagrams.
📋 Manual Details
Coverage Areas
Trim Levels Covered:
All Styles Covered
Page Count
Total Pages:
3700+
Manual Type
Type:
Factory Service & Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine Mechanical, Engine Control System, Engine Coolant, Lubrication System, SFI System, Ignition System
Drivetrain:
Manual Transaxle System, Transmission Valve Body, Drive Shaft, Differential Case Assy, Rear Axle Hub, Rear Axle Beam
Suspension Steering:
Suspension System, Rear Suspension System, Steering System, Power Steering, Steering Column
Brakes:
Brake System, Brake Master Cylinder, Brake Booster, Brake Actuator, ABS System, Parking Brake
Electrical:
Charging System, Starting System, Lighting System, Combination Meter, Instrument Panel, Wiring Diagrams, Wire Harness Repair
Body Interior:
Body Repair, Roof Headlining, Hood, Doors, Seats, Interior Trim, Sun Roof System, Power Window Control System, Power Door Lock Control System
Safety Features:
Supplemental Restraint System (SRS), Curtain Shield Air Bag Assy, Side Air Bag Sensor Assy, Seat Position Air Bag Sensor, Seat Belt, Seat Belt Warning System
Procedures Included
Maintenance:
Oil Change, Filter Replacement, Fluid Checks and Replacements, Tire Rotation, Brake Pad Inspection
Diagnostics Troubleshooting:
Detailed Troubleshooting guides for all systems, DTC code interpretation, Electrical System Diagnosis
Repair Rebuild:
Engine disassembly and reassembly, Transmission overhaul, Brake system repair, Suspension component replacement, Body panel repair
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Printable without restriction
Binding Type
Binding Type:
Digital Download (Printable Pages)
Paper Type
Paper Type:
Not Applicable (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Options:
2.5L EJ253 SOHC (Naturally Aspirated), 2.5L EJ255 DOHC (Turbocharged - XT models)
Performance
Horsepower:
Approx. 165 hp (EJ253), Approx. 210 hp (EJ255 Turbo)
Torque:
Approx. 170 lb-ft (EJ253), Approx. 235 lb-ft (EJ255 Turbo)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Sequential Port Injection (SPI)
Engine Mechanical
Bore X Stroke:
99.5 mm x 79.0 mm (EJ253 & EJ255)
Compression Ratio:
9.7:1 (EJ253), 8.4:1 (EJ255)
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Optional
Transmission Type:
4-Speed Automatic with Lock-up Torque Converter
Features
Drivetrain:
Symmetrical All-Wheel Drive (AWD) standard on all models.
📐 Dimensions
Exterior
Length:
4,485 mm (176.6 in)
Width:
1,735 mm (68.3 in)
Height:
1,590 mm (62.6 in)
Wheelbase:
2,630 mm (103.5 in)
Weights
Curb Weight:
Approximately 1,450 kg - 1,550 kg (3,200 lbs - 3,417 lbs) depending on configuration.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5 Stars
NHTSA Side Impact:
4 Stars
Active Features
Active Safety:
Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA), Traction Control System (TCS), Vehicle Stability Control (VSC)
Passive Features
Passive Safety:
Driver and Front Passenger Airbags, Side Curtain Airbags (Optional/Standard depending on trim), Front Seatbelt Pretensioners, Crumple Zones
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player. Optional premium audio systems with subwoofer may be available on higher trims.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Auxiliary Input:
Typically not standard; aftermarket solutions often required for auxiliary or USB input.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3 months (severe conditions), 7,500 miles or 6 months (normal conditions), consult manual for specific details.
Timing Belt Replacement:
105,000 miles or 105 months (for models equipped with timing belt, typically naturally aspirated engines). Turbocharged models may have different recommendations or chain-driven components.
Fluid Specifications
Engine Oil:
SAE 5W-30 (API SG or higher). Check manual for specific viscosity based on climate.
Coolant:
Subaru Super Coolant (Blue) or equivalent silicate-free, long-life antifreeze. 50/50 mixture with distilled water.
Transmission Fluid Manual:
API GL-5 SAE 75W-90 Gear Oil
Transmission Fluid Automatic:
Subaru ATF-HP or equivalent DEXRON III/MERCON compatible fluid.
Brake Fluid:
DOT 3 or DOT 4 Brake Fluid
Known Issues
Head Gaskets:
While less common on the second generation than the first, head gasket leaks can still occur, particularly on higher mileage or poorly maintained naturally aspirated EJ25 engines. Turbocharged engines are less susceptible.
Catalytic Converter:
Premature failure of the catalytic converter can occur due to engine oil consumption or misfires. Symptoms include reduced engine power and Check Engine Light.
Susceptibility:
Subaru vehicles are known for their AWD systems. Regular maintenance of the differentials and transmission fluids is crucial for longevity.
📚 Vehicle History
Brand Heritage
Heritage:
Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history of producing durable and capable vehicles, often with a focus on all-wheel-drive technology.
Model Evolution
Evolution:
The 2004 Forester represents the second generation (SG) of the model, launched in 2002. It featured a more refined design, improved interior, and enhanced safety features compared to the first generation.
Production
Production Years:
2002-2008 (Second Generation SG chassis)
Manufacturing Location:
Ota City, Gunma Prefecture, Japan
🏆 Awards & Recognition
Recognitions
Safety Awards:
The 2004 Subaru Forester generally received good safety ratings from organizations like the IIHS and NHTSA, reflecting its robust construction and available safety features.
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