Subaru Forester 2003 2004 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2004 Codes Chassis Code: SG series Generation Generation Code: Second Generation (SG) Generation Years: 2002-2008 👋 Introduction Market Position Segment: Compact Crossover SUV, known for its AWD capability and practicality. Usp: Subaru's Symmetrical All-Wheel Drive system, robust build, and wagon-like utility. Competitive Analysis Key Competitors 2003 2004: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra. Key Features Vehicle AWD Standard: Standard Symmetrical All-Wheel Drive across all trims, a significant differentiator. Engine Orientation: Horizontally-opposed ('boxer') engine, contributing to a lower center of gravity. Key Features Manual Completeness: Comprehensive A-Z coverage of all mechanical and electrical repairs, making it a vital resource for any owner or technician. Visuals: Extensive use of detailed pictures and diagrams, significantly aiding in understanding complex procedures. 📋 Manual Details Coverage Areas Models Covered: All Forester models for 2003 and 2004, including various trim levels. Page Count Estimated Page Count: Likely extensive, typically 1000+ pages for a comprehensive workshop manual. Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Printable (digital format assumed, e.g., PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication, cooling system. Engine Performance: Engine tuning, fuel injection, ignition system, emissions control. Transmission Manual: Manual transmission removal, disassembly, assembly, repair, clutch system. Transmission Automatic: Automatic transmission removal, disassembly, assembly, repair, torque converter. Drivetrain: All-Wheel Drive (AWD) system, front and rear differentials, drive shafts, CV joints, hubs. Suspension: Front and rear suspension components, struts, springs, control arms, anti-roll bars, alignment. Steering: Power steering system, steering gear, column, tie rods, power steering pump and lines. Brakes: Brake system components (discs, pads, calipers, hoses), ABS system, parking brake. Electrical System: Battery, charging system, starting system, lighting, fuses, relays, wiring diagrams. Body Interior: Interior trim, seats, dashboard, door panels, headliner, body panels, glass, weatherstripping. Body Exterior: Bumpers, fenders, hood, trunk, doors, body shell, rust prevention, paint repair (basic guidelines). HVAC: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant, diagnosis. Safety Systems: Airbag system, seat belts, SRS diagnostics. Procedures Included Maintenance: Regular maintenance tasks, fluid changes, filter replacements, tune-ups. Troubleshooting: Diagnostic procedures for common and uncommon faults, fault codes. Repair Rebuild: Detailed step-by-step instructions for component removal, disassembly, repair, and reassembly. Diagnostics: Electrical system diagnostics, engine diagnostics, transmission diagnostics. Adjustment Calibration: Wheel alignment, brake adjustment, clutch adjustment. Technical Depth Depth: Comprehensive, covering everything from basic fluid checks to full engine and transmission rebuilds. Detail Level: Extremely detailed, with specific torque values, clearances, and procedures. Diagnostic Tools: Information on necessary special tools and diagnostic equipment. 📊 Manual Specifications File Format Digital Format: Likely PDF, optimized for readability and searchability. Print Quality Image Quality: High-quality images and diagrams, crucial for repair accuracy. Text Clarity: Clear, concise text for easy understanding. Binding Type Physical Format: If printed, typically coil-bound or comb-bound for lay-flat use. Paper Type Physical Format: If printed, often on durable, coated paper to withstand workshop environments. ⚙️ Engine Specifications Primary Engine Engine Code Usdm: EJ253 Engine Type: 2.5L SOHC EJ253 Flat-4 (Boxer) Engine Performance Horsepower 2003 2004: Approximately 165 hp @ 5600 rpm (USDM models) Torque 2003 2004: Approximately 170 lb-ft @ 3600 rpm (USDM models) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential port injection Fuel Type: Unleaded gasoline Engine Mechanical Bore X Stroke: 99.5 mm x 79.0 mm Compression Ratio: 9.7:1 Valve Train: SOHC (Single Overhead Camshaft) with 16 valves Timing Belt Interval: Recommended replacement every 105,000 miles or 7 years, whichever comes first (critical maintenance item). 🔧 Transmission Standard Transmission Type Base: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission (4EAT) Features AWD System: Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled clutch pack (automatic). Fluid Specifications Automatic Automatic Transmission Fluid: Subaru ATF-HP (High Performance) or equivalent DEXRON-III/MERCON compatible fluid. Fluid Specifications Manual Manual Transmission Fluid: API GL-5, SAE 75W-90 gear oil. 📐 Dimensions Exterior Length: Approx. 177.0 inches (4495 mm) Width: Approx. 69.7 inches (1770 mm) Height: Approx. 63.0 inches (1600 mm) Wheelbase: Approx. 103.0 inches (2615 mm) Ground Clearance: Approx. 7.9 inches (200 mm) Weights Curb Weight Approx: 3,200 - 3,400 lbs (1450 - 1540 kg), depending on transmission and trim. 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-Star (for 2003 models) NHTSA Front Impact Passenger: 5-Star (for 2003 models) NHTSA Side Impact Front Driver: 5-Star (for 2003 models) NHTSA Side Impact Front Passenger: 5-Star (for 2003 models) IIHS Frontal Offset: Good (for 2003 models) Active Features ABS: Standard Anti-lock Braking System (ABS) AWD: Symmetrical All-Wheel Drive (Standard) Passive Features Airbags: Driver and front passenger airbags, available side-impact airbags. Seatbelts: Three-point seatbelts with pretensioners for front occupants. 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player, optional premium audio systems with more speakers. Display: Basic dashboard display for audio, climate,...
Comprehensive, covering everything from basic fluid checks to full engine and transmission rebuilds.
Detail Level:
Extremely detailed, with specific torque values, clearances, and procedures.
Diagnostic Tools:
Information on necessary special tools and diagnostic equipment.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, optimized for readability and searchability.
Print Quality
Image Quality:
High-quality images and diagrams, crucial for repair accuracy.
Text Clarity:
Clear, concise text for easy understanding.
Binding Type
Physical Format:
If printed, typically coil-bound or comb-bound for lay-flat use.
Paper Type
Physical Format:
If printed, often on durable, coated paper to withstand workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Code Usdm:
EJ253
Engine Type:
2.5L SOHC EJ253 Flat-4 (Boxer) Engine
Performance
Horsepower 2003 2004:
Approximately 165 hp @ 5600 rpm (USDM models)
Torque 2003 2004:
Approximately 170 lb-ft @ 3600 rpm (USDM models)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with sequential port injection
Fuel Type:
Unleaded gasoline
Engine Mechanical
Bore X Stroke:
99.5 mm x 79.0 mm
Compression Ratio:
9.7:1
Valve Train:
SOHC (Single Overhead Camshaft) with 16 valves
Timing Belt Interval:
Recommended replacement every 105,000 miles or 7 years, whichever comes first (critical maintenance item).
🔧 Transmission
Standard
Transmission Type Base:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission (4EAT)
Features
AWD System:
Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled clutch pack (automatic).
Fluid Specifications Automatic
Automatic Transmission Fluid:
Subaru ATF-HP (High Performance) or equivalent DEXRON-III/MERCON compatible fluid.
Fluid Specifications Manual
Manual Transmission Fluid:
API GL-5, SAE 75W-90 gear oil.
📐 Dimensions
Exterior
Length:
Approx. 177.0 inches (4495 mm)
Width:
Approx. 69.7 inches (1770 mm)
Height:
Approx. 63.0 inches (1600 mm)
Wheelbase:
Approx. 103.0 inches (2615 mm)
Ground Clearance:
Approx. 7.9 inches (200 mm)
Weights
Curb Weight Approx:
3,200 - 3,400 lbs (1450 - 1540 kg), depending on transmission and trim.
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star (for 2003 models)
NHTSA Front Impact Passenger:
5-Star (for 2003 models)
NHTSA Side Impact Front Driver:
5-Star (for 2003 models)
NHTSA Side Impact Front Passenger:
5-Star (for 2003 models)
IIHS Frontal Offset:
Good (for 2003 models)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
AWD:
Symmetrical All-Wheel Drive (Standard)
Passive Features
Airbags:
Driver and front passenger airbags, available side-impact airbags.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, optional premium audio systems with more speakers.
Display:
Basic dashboard display for audio, climate, and warning lights. No integrated navigation or touchscreens typically.
Driver Assistance
Cruise Control:
Standard cruise control on most trims.
ABS:
Standard ABS system.
Connectivity
Auxiliary Input:
Generally not available on factory head units; aftermarket solutions might be required.
🔧 Maintenance
Service Intervals Oil
Engine Oil Change:
Every 3,750 miles or 3.75 months for severe driving conditions; 7,500 miles or 7.5 months for normal driving conditions (refer to owner's manual for exact definition of conditions).
Service Intervals Filters
Oil Filter Replacement:
Replace with every oil change.
Engine Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Cabin Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Service Intervals Timing
Timing Belt Replacement:
105,000 miles or 7 years (critical item to prevent catastrophic engine damage).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 synthetic or synthetic blend oil meeting API SJ or higher classification.
Coolant Type:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based antifreeze with Subaru's specific additive package.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Head Gasket Leaks:
While less prevalent on the SOHC EJ253 compared to some earlier DOHC EJ25 engines, it's still a potential concern that requires careful inspection and documentation of symptoms like coolant loss or external leaks.
Suspension Wear:
Struts and bushings can wear over time, leading to a less composed ride and potential for clunks or rattles.
Catalytic Converter Failure:
Can occur due to engine misfires or rich fuel conditions, leading to reduced performance and check engine lights.
📚 Vehicle History
Brand Heritage
Subaru Heritage:
Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history of engineering distinctive vehicles, particularly known for its horizontally-opposed engines and all-wheel-drive systems.
Model Evolution
Forester Genesis:
The Forester debuted in 1997 as a 'sport utility wagon,' blending the ride height and capability of an SUV with the driving characteristics of a car.
Sg Generation Introduction:
The second generation (SG) was introduced for the 2003 model year, featuring a significant styling update, a more refined interior, and improved safety features over its predecessor.
Production
Manufacturing Location:
Primarily manufactured in Japan (Gunma Prefecture) and also in Taiwan and Malaysia for specific markets.
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
The 2003 Forester was recognized as an IIHS Top Safety Pick.
Kbb Best Resale Value:
Subaru vehicles, including the Forester, often receive accolades for strong resale value.
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