2004 Subaru Forester Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2004 Codes Chassis Code: SG 👋 Introduction Market Position Segment: Compact Crossover SUV Key Differentiators: Standard Symmetrical All-Wheel Drive, Boxer engine, wagon-like utility. Competitive Analysis Direct Competitors 2004: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra. Key Features Powertrain Layout: Front-engine, All-Wheel Drive Body Styles Offered: 5-door SUV/Crossover 📋 Manual Details Coverage Areas Primary Focus: Repair and Service Procedures Supported Regions: Global (primarily North American specifications) Page Count Estimated Pages: Approximately 2000+ pages (typical for factory service manuals) Manual Type Type: Factory Service Manual (FSM) Equivalent Dealer Manual: Yes Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Complete diagnosis, repair, overhaul for EJ25 SOHC and DOHC naturally aspirated and turbocharged engines. Transmission: Manual (5-speed) and Automatic (4-speed) transmission diagnosis, repair, and overhaul. Drivetrain: All-Wheel Drive (AWD) system, differentials (front and rear), driveshafts, CV joints. Suspension: Front and rear suspension components, struts, shocks, bushings, alignment specifications. Brakes: Front and rear brake systems (disc brakes), ABS, brake fluid specifications, bleeding procedures. Steering: Power steering system, steering rack, tie rods, alignment. Electrical: Complete wiring diagrams, fuse box locations, component testing, charging system, starting system, lighting, accessories. Climate Control: HVAC system diagnosis, refrigerant, compressor, heater core, A/C components. Fuel System: Fuel pump, injectors, fuel pressure, EVAP system. Cooling System: Radiator, water pump, thermostat, coolant specifications, flushing procedures. Exhaust System: Catalytic converter, mufflers, exhaust pipes, O2 sensors. Body And Frame: Body panel removal/installation, glass, interior trim, chassis data. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, air filter replacement. Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides. Repair Overhaul: Component-level repair and complete overhaul procedures for major systems. Diagnostic Testing: Procedures for testing electrical components, sensors, actuators, and mechanical systems. Torque Specifications: Detailed torque values for all critical fasteners. Special Tools: Identification of required special tools for specific procedures. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, and advanced electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (depending on original source quality). Print Quality Printability: Printable pages. Binding Type Binding For Digital: N/A (digital format) Paper Type Paper Type For Print: N/A (digital format) ⚙️ Engine Specifications Primary Engine Engine Code Na: EJ251 (2.5L SOHC Naturally Aspirated) Engine Code Turbo: EJ255 (2.5L DOHC Turbocharged - XT models) Performance Horsepower Na: 165 hp @ 5600 rpm Torque Na: 166 lb-ft @ 4000 rpm Horsepower Turbo: 210 hp @ 5600 rpm (XT models) Torque Turbo: 235 lb-ft @ 3600 rpm (XT models) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded gasoline (87 octane minimum, 91 octane recommended for turbo models) Engine Type Cylinders: 4-Cylinder Boxer 🔧 Transmission Standard Type Na: 5-Speed Manual Optional Type Auto: 4-Speed Automatic (with overdrive) Features AWD System: Symmetrical All-Wheel Drive (Active Torque Split AWD for automatic transmission, viscous center diff for manual). 📐 Dimensions Exterior Wheelbase: Approx. 103.1 inches Length: Approx. 179.9 inches Width: Approx. 70.1 inches Height: Approx. 65.1 inches Weights Curb Weight: Approx. 3200 - 3500 lbs (varies by trim and transmission) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 4/5 Stars (provided by NHTSA data for similar models, specific 2004 rating may vary) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Optional (may be standard on certain trims or introduced later in model year) Passive Features Airbags: Front dual-stage airbags for driver and front passenger, available front side-impact airbags. Seatbelts: Three-point seatbelts with pretensioners and load limiters. 💡 Technology Features Infotainment Head Unit: Factory AM/FM/CD player, optional premium audio systems. Display: Basic LCD display for radio information and climate controls. Driver Assistance Cruise Control: Standard or optional depending on trim level. Connectivity Auxiliary Input: Not standard, aftermarket integration typically required. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 3 months (severe conditions) / 7,500 miles or 6 months (normal conditions). Air Filter Replacement: Every 15,000-30,000 miles depending on driving conditions. Spark Plug Replacement: Platinum-tipped plugs typically rated for 60,000-100,000 miles. Check manual for specific intervals. Coolant Flush: Initial flush at 30,000 miles, then every 30,000 miles thereafter (or every 2 years). Fluid Specifications Engine Oil Type: SAE 5W-30 (API SG or SH, or ILSAC GF-2) Engine Oil Capacity: Approx. 4.8 quarts (with filter) Transmission Fluid Type Auto: Subaru ATF-HP (or equivalent Dexron-III/Mercon) Transmission Fluid Type Manual: GL-5 75W-90 Gear Oil Coolant Type: Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant (50/50 mix with distilled water) Known Issues Head Gaskets: While less common than in earlier generations, coolant leaks and potential head gasket issues can still occur. Manual covers diagnosis and repair. Turbo Oil Lines: Turbocharged XT models require regular inspection and potential replacement of oil feed lines to prevent turbo failure. Manual details inspection. Awt...