Subaru Forester 2004 Digital Factory Repair Manual
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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 Market Position: The 2004 Subaru Forester is positioned as a compact crossover SUV known for its standard All-Wheel Drive, practicality, and go-anywhere capability, appealing to outdoor enthusiasts and those in inclement weather regions. Competitive Analysis Competitive Analysis: Competed against vehicles like the Honda CR-V, Toyota RAV4, Ford Escape, and Nissan Xterra. The Forester's key differentiators were its Subaru Boxer engine and standard Symmetrical All-Wheel Drive system, providing superior traction and a lower center of gravity compared to many competitors. Key Features Key Features: Standard Symmetrical All-Wheel Drive, available turbocharged engine (XT models), versatile cargo space, good visibility, and refined ride comfort for its class. 📋 Manual Details Coverage Areas Coverage Areas: Engine, Transmission, Chassis, Body, Electrical System, Maintenance, Troubleshooting, Diagnostics, Repair Procedures Page Count Page Count: Estimated 2000+ pages (typical for comprehensive factory service manuals, exact count not specified but implied by extensive coverage) Manual Type Manual Type: Factory Repair/Service Manual Language Language: English Format Format: PDF Content Source Content Source: Factory Dealer Workshop Manual 📖 Manual Coverage Systems Covered Systems Covered: Engine (H4DOTC Turbocharged, H4SO Naturally Aspirated), Drivetrain (All-Wheel Drive System, Manual & Automatic Transmissions), Suspension, Steering, Brakes (ABS, EBD), HVAC, Fuel System, Exhaust System, Cooling System, Lubrication System, Electrical System (Wiring Diagrams, ECUs, Sensors), Body and Interior, Safety Systems Procedures Included Procedures Included: Routine Maintenance, Scheduled Servicing, Engine Overhaul, Transmission Repair/Rebuild, Brake System Service, Suspension and Steering Alignment, Electrical Diagnostics and Repair, Body Panel Replacement, HVAC System Servicing, Diagnostic Trouble Codes (DTCs) and Troubleshooting, Torque Specifications, Fluid Capacities and Specifications, Component Removal and Installation Technical Depth Technical Depth: Comprehensive. Covers basic to advanced repairs, diagnostics, and rebuilding procedures, mirroring dealer workshop specifications. Includes detailed step-by-step instructions and exploded diagrams. Diagnostic Tools Diagnostic Tools: The manual details diagnostic procedures, which can be performed using Subaru's proprietary diagnostic equipment (e.g., Subaru Select Monitor) or compatible OBD-II scanners for engine-related codes. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Digital PDF with Zoom In/Out capability for clarity of diagrams and text. Binding Type Binding Type: Not Applicable (Digital Format) Paper Type Paper Type: Not Applicable (Digital Format) Software Requirements Software Requirements: Adobe PDF Reader, WinZip (for extraction) Compatibility Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Primary Engine: 2.5L Naturally Aspirated EJ253 Boxer-4 (H4SO) Turbocharged Engine Turbocharged Engine: 2.5L Turbocharged EJ255 Boxer-4 (H4DOTC) - Found in Forester XT models Performance Naturally Aspirated Horsepower: 165 hp @ 5,600 rpm (approx.) Turbocharged Horsepower: 210 hp @ 5,600 rpm (approx. for XT) Naturally Aspirated Torque: 166 lb-ft @ 4,000 rpm (approx.) Turbocharged Torque: 235 lb-ft @ 3,600 rpm (approx. for XT) Fuel System Fuel System: Electronic Fuel Injection (EFI) Engine Layout Engine Layout: Horizontally-opposed (Boxer) Engine Codes Engine Codes: EJ253 (2.5L SOHC NA), EJ255 (2.5L DOHC Turbocharged) 🔧 Transmission Standard Standard Transmission: 5-Speed Manual Transmission Optional Optional Transmission: 4-Speed Automatic Transmission (with Selectable Driveway Monitor) Features All Wheel Drive: Standard Symmetrical All-Wheel Drive (AWD) on all models Fluid Type Manual Transmission Fluid: Subaru Genuine Gear Oil (API GL-5, SAE 75W-90) or equivalent Automatic Transmission Fluid: Subaru Genuine ATF HP or equivalent 📐 Dimensions Exterior Length: 176.9 inches (4493 mm) Width: 69.7 inches (1770 mm) Height: 63.2 inches (1605 mm) Wheelbase: 103.1 inches (2619 mm) Ground Clearance: 7.5 inches (191 mm) Weights Curb Weight Manual: Approximately 3240 lbs (1470 kg) Curb Weight Automatic: Approximately 3275 lbs (1485 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5 Stars NHTSA Front Impact Passenger: 5 Stars NHTSA Side Impact Front Seat: 4 Stars NHTSA Side Impact Rear Seat: 4 Stars IIHS Frontal Offset: Good IIHS Side Impact: Good Active Features Active Features: All-Wheel Drive, Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) Passive Features Passive Features: Dual Front Airbags, Front Side-Impact Airbags (optional on some trims), Pretensioner seatbelts 💡 Technology Features Infotainment Infotainment System: Basic AM/FM/CD stereo system. Higher trims may have optional premium audio systems or cassette players. Driver Assistance Driver Assistance: Limited driver assistance features by modern standards. Standard features include ABS and EBD. Cruise control is standard. Connectivity Connectivity: No integrated Bluetooth or USB connectivity. May feature an auxiliary input jack on some aftermarket or higher trim head units. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 3 months, whichever comes first (severe driving) or 7,500 miles or 6 months (normal driving), using synthetic oil recommended for longer intervals. Engine Air Filter Replacement: Every 15,000 miles or 12 months (replace more often in dusty conditions) Cabin Air Filter Replacement: Every 15,000 miles or 12 months Spark Plug Replacement: iridium-tipped spark plugs typically last up to 60,000 miles Timing Belt Replacement: 105,000 miles or 105 months (crucial for EJ engines...
The 2004 Subaru Forester is positioned as a compact crossover SUV known for its standard All-Wheel Drive, practicality, and go-anywhere capability, appealing to outdoor enthusiasts and those in inclement weather regions.
Competitive Analysis
Competitive Analysis:
Competed against vehicles like the Honda CR-V, Toyota RAV4, Ford Escape, and Nissan Xterra. The Forester's key differentiators were its Subaru Boxer engine and standard Symmetrical All-Wheel Drive system, providing superior traction and a lower center of gravity compared to many competitors.
Key Features
Key Features:
Standard Symmetrical All-Wheel Drive, available turbocharged engine (XT models), versatile cargo space, good visibility, and refined ride comfort for its class.
Estimated 2000+ pages (typical for comprehensive factory service manuals, exact count not specified but implied by extensive coverage)
Manual Type
Manual Type:
Factory Repair/Service Manual
Language
Language:
English
Format
Format:
PDF
Content Source
Content Source:
Factory Dealer Workshop Manual
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine (H4DOTC Turbocharged, H4SO Naturally Aspirated), Drivetrain (All-Wheel Drive System, Manual & Automatic Transmissions), Suspension, Steering, Brakes (ABS, EBD), HVAC, Fuel System, Exhaust System, Cooling System, Lubrication System, Electrical System (Wiring Diagrams, ECUs, Sensors), Body and Interior, Safety Systems
Procedures Included
Procedures Included:
Routine Maintenance, Scheduled Servicing, Engine Overhaul, Transmission Repair/Rebuild, Brake System Service, Suspension and Steering Alignment, Electrical Diagnostics and Repair, Body Panel Replacement, HVAC System Servicing, Diagnostic Trouble Codes (DTCs) and Troubleshooting, Torque Specifications, Fluid Capacities and Specifications, Component Removal and Installation
Technical Depth
Technical Depth:
Comprehensive. Covers basic to advanced repairs, diagnostics, and rebuilding procedures, mirroring dealer workshop specifications. Includes detailed step-by-step instructions and exploded diagrams.
Diagnostic Tools
Diagnostic Tools:
The manual details diagnostic procedures, which can be performed using Subaru's proprietary diagnostic equipment (e.g., Subaru Select Monitor) or compatible OBD-II scanners for engine-related codes.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
Digital PDF with Zoom In/Out capability for clarity of diagrams and text.
Binding Type
Binding Type:
Not Applicable (Digital Format)
Paper Type
Paper Type:
Not Applicable (Digital Format)
Software Requirements
Software Requirements:
Adobe PDF Reader, WinZip (for extraction)
Compatibility
Compatibility:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Primary Engine:
2.5L Naturally Aspirated EJ253 Boxer-4 (H4SO)
Turbocharged Engine
Turbocharged Engine:
2.5L Turbocharged EJ255 Boxer-4 (H4DOTC) - Found in Forester XT models
Standard Symmetrical All-Wheel Drive (AWD) on all models
Fluid Type
Manual Transmission Fluid:
Subaru Genuine Gear Oil (API GL-5, SAE 75W-90) or equivalent
Automatic Transmission Fluid:
Subaru Genuine ATF HP or equivalent
📐 Dimensions
Exterior
Length:
176.9 inches (4493 mm)
Width:
69.7 inches (1770 mm)
Height:
63.2 inches (1605 mm)
Wheelbase:
103.1 inches (2619 mm)
Ground Clearance:
7.5 inches (191 mm)
Weights
Curb Weight Manual:
Approximately 3240 lbs (1470 kg)
Curb Weight Automatic:
Approximately 3275 lbs (1485 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
NHTSA Side Impact Front Seat:
4 Stars
NHTSA Side Impact Rear Seat:
4 Stars
IIHS Frontal Offset:
Good
IIHS Side Impact:
Good
Active Features
Active Features:
All-Wheel Drive, Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD)
Passive Features
Passive Features:
Dual Front Airbags, Front Side-Impact Airbags (optional on some trims), Pretensioner seatbelts
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM/CD stereo system. Higher trims may have optional premium audio systems or cassette players.
Driver Assistance
Driver Assistance:
Limited driver assistance features by modern standards. Standard features include ABS and EBD. Cruise control is standard.
Connectivity
Connectivity:
No integrated Bluetooth or USB connectivity. May feature an auxiliary input jack on some aftermarket or higher trim head units.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3 months, whichever comes first (severe driving) or 7,500 miles or 6 months (normal driving), using synthetic oil recommended for longer intervals.
Engine Air Filter Replacement:
Every 15,000 miles or 12 months (replace more often in dusty conditions)
Cabin Air Filter Replacement:
Every 15,000 miles or 12 months
Spark Plug Replacement:
iridium-tipped spark plugs typically last up to 60,000 miles
Timing Belt Replacement:
105,000 miles or 105 months (crucial for EJ engines to prevent catastrophic failure if belt breaks).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic recommended (check owner's manual for specific API service category)
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free long-life coolant
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid:
Subaru Genuine Power Steering Fluid or Dexron II/III ATF
Known Issues
Known Issues:
Head Gasket Failure (particularly on earlier EJ25 engines, though less common on later 2.5L SOHC in this generation than DOHC), Oil Leaks (e.g., valve cover gaskets, oil pan), Catalytic Converter Failure (can occur with age/mileage), Minor electrical gremlins, Turbocharger issues on XT models (if not properly maintained), Suspension wear (bushings, ball joints) due to AWD system and typical use.
Torque Settings
Torque Settings:
Detailed torque specifications for all critical fasteners are included, such as cylinder head bolts, wheel lug nuts, suspension components, and engine accessories. Example: Wheel lug nuts typically torqued to 73.8 lb-ft (100 Nm).
📚 Vehicle History
Brand Heritage
Brand Heritage:
Subaru, a division of Subaru Corporation, has a long history of producing reliable vehicles with a focus on unique engineering, particularly its horizontally-opposed Boxer engines and All-Wheel Drive systems, dating back to its origins in aerospace.
Model Evolution
Model Evolution:
The 2004 Forester represents the second generation (SG), which debuted for the 2003 model year. It featured updated styling, a stiffer chassis, improved interior amenities, and an optional turbocharged engine for the XT model, enhancing its performance capabilities.
Production
Production Location:
Japan (Main production facility)
🏆 Awards & Recognition
Recognitions
Recognitions:
The Subaru Forester consistently received praise from automotive critics for its standard AWD, utility, and overall value. It was often cited as a top pick in the compact SUV segment by publications like Consumer Reports and Edmunds.
Ratings
IIHS Ratings:
Consistently received 'Good' ratings in IIHS crash tests for frontal offset and side impact for its model year.
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