2004 Subaru Forester Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2004 Generation: Second Generation (SG) Body Style: Compact Crossover SUV Codes Chassis Code: SG5 Engine Codes: EJ253 (H4SO), EJ255 (H4DOTC - Turbocharged) 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV (also known as Soft-roader) SUV Capabilities: Known for its standard Symmetrical All-Wheel Drive system, offering enhanced traction and stability in various conditions. Competitive Analysis Key Competitors 2004: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Mazda Tribute Key Features Defining Attributes: Standard AWD, Boxer engine configuration, practical cargo space, comfortable ride, available turbocharged variant. Manual Value Proposition Cost Effectiveness: Inexpensive way to keep your vehicle working properly, saving on dealership service costs. Diy Empowerment: Empowers both novice and experienced individuals to perform maintenance and repairs themselves. 📋 Manual Details Coverage Areas Primary Coverage: North America Secondary Coverage: Global market variations may exist, but manual is English Page Count Estimated Page Count: Comprehensive (specific page count not provided, but factory service manuals are typically extensive) Manual Type Manual Classification: Factory Service Repair Workshop Manual Language Language: English Format File Format: PDF Compatibility: All Versions of Windows & Mac Delivery Method: Instant Download Printability: All pages are printable Digital Requirements: Adobe PDF Reader & WinZip 📖 Manual Coverage Systems Covered Powertrain: Engine (H4DOTC - Turbocharged, H4SO - Naturally Aspirated), Transmission (Manual & Automatic) Chassis And Suspension: Front Suspension, Rear Suspension, Steering System, Drivetrain (All-Wheel Drive Components) Braking System: Front Brakes, Rear Brakes, ABS System Electrical System: Wiring Diagrams, Lighting, Ignition System, Charging System, Starting System, ECU and Sensors Body And Interior: Body Panels, Doors, Windows, Seats, Trim, HVAC System Procedures Included Routine Maintenance: Oil Changes, Filter Replacements, Fluid Checks, Spark Plug Service, Belt Inspection/Replacement Major Repairs: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Service Diagnostics: Troubleshooting Guides, Symptom-Based Diagnostics, OBD-II Code Explanations and Procedures Component Replacement: Step-by-step instructions for replacing virtually all mechanical and electrical components Technical Adjustments: Wheel Alignment Specifications, Idle Speed Adjustments, Clutch Adjustments (if applicable) Technical Depth Depth Of Information: Complete disassembly of the machine, covering all aspects from basic maintenance to complex repairs and diagnostics. Diagrams And Illustrations: Easy-to-read text sections with top quality diagrams and highly detailed exploded pictures and diagrams. Target Audience: Do-it-yourselfer as well as the experienced mechanic. 📊 Manual Specifications File Format Digital File Type: PDF (Portable Document Format) Print Quality Text Readability: Easy-to-read text sections Diagram Quality: Top quality diagrams and highly detailed exploded pictures Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download - Printable) ⚙️ Engine Specifications Primary Engine Naturally Aspirated Engine Code: EJ253 Configuration: 2.5L Naturally Aspirated SOHC/DOHC Boxer-4 (H4SO) Displacement: 2457 cc (2.5 Liters) Bore X Stroke: 99.5 mm x 79.0 mm Horsepower Est: 165 hp @ 5600 rpm Torque Est: 166 lb-ft @ 4000 rpm Fuel System: Multi-point Fuel Injection (MPI) Primary Engine Turbocharged Engine Code: EJ255 Configuration: 2.5L Turbocharged DOHC Boxer-4 (H4DOTC) Displacement: 2457 cc (2.5 Liters) Horsepower Est: 210 hp @ 5600 rpm (Forester XT) Torque Est: 235 lb-ft @ 3500 rpm (Forester XT) Fuel System: Multi-point Fuel Injection (MPI) with Turbocharger Engine Characteristics Engine Placement: Front, longitudinally mounted Engine Type: Horizontally opposed (Boxer) engines, known for lower center of gravity and reduced vibration. Timing System: Timing Belt (requires periodic replacement, consult manual for intervals) 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transmission Optional Transmission Type: 4-Speed Automatic Transmission (with Sportshift on some models) Drivetrain System: Symmetrical All-Wheel Drive (AWD) standard on all models. AWD Features: Driver-selectable modes (e.g., viscous coupling center differential in manual, electronically controlled in automatic). Detailed operation and maintenance covered. Fluid Specifications Manual Transmission Fluid: Refer to manual for specific API GL-5 gear oil requirements (e.g., 75W-90) Automatic Transmission Fluid: Subaru ATF-HP (refer to manual for exact specification and capacity) 📐 Dimensions Exterior Dimensions Length: Approx. 177.0 inches (4495 mm) Width: Approx. 69.7 inches (1770 mm) Height: Approx. 63.0 inches (1600 mm) (ground clearance varies) Wheelbase: Approx. 103.1 inches (2619 mm) Ground Clearance: Approx. 7.7 inches (196 mm) Cargo Dimensions Cargo Volume Behind Rear Seats: Approx. 31.4 cubic feet (889 Liters) Cargo Volume With Rear Seats Folded: Approx. 63.0 cubic feet (1784 Liters) Weights Curb Weight Est: Approx. 3,200 - 3,400 lbs (1450 - 1542 kg) depending on trim and transmission Towing Capacity Est: Up to 2,000 lbs (907 kg) (check local regulations and manual for specifics) 🛡️ Safety Features Ratings NHTSA Front Crash Test Rating: 5-Star (for both driver and passenger in frontal crash) NHTSA Side Impact Test Rating: 5-Star (for front and rear passengers in side impact) IIHS Frontal Offset Rating: Good (for many 2004 models, check specific test dates) Active Features Braking: 4-wheel disc brakes (front ventilated), ABS (Anti-lock Braking System) Traction Control: Standard Symmetrical AWD provides enhanced traction. Traction Control System (TCS) and/or Electronic Stability Control (ESC) may be available on certain...
Complete disassembly of the machine, covering all aspects from basic maintenance to complex repairs and diagnostics.
Diagrams And Illustrations:
Easy-to-read text sections with top quality diagrams and highly detailed exploded pictures and diagrams.
Target Audience:
Do-it-yourselfer as well as the experienced mechanic.
📊 Manual Specifications
File Format
Digital File Type:
PDF (Portable Document Format)
Print Quality
Text Readability:
Easy-to-read text sections
Diagram Quality:
Top quality diagrams and highly detailed exploded pictures
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download - Printable)
⚙️ Engine Specifications
Primary Engine Naturally Aspirated
Engine Code:
EJ253
Configuration:
2.5L Naturally Aspirated SOHC/DOHC Boxer-4 (H4SO)
Displacement:
2457 cc (2.5 Liters)
Bore X Stroke:
99.5 mm x 79.0 mm
Horsepower Est:
165 hp @ 5600 rpm
Torque Est:
166 lb-ft @ 4000 rpm
Fuel System:
Multi-point Fuel Injection (MPI)
Primary Engine Turbocharged
Engine Code:
EJ255
Configuration:
2.5L Turbocharged DOHC Boxer-4 (H4DOTC)
Displacement:
2457 cc (2.5 Liters)
Horsepower Est:
210 hp @ 5600 rpm (Forester XT)
Torque Est:
235 lb-ft @ 3500 rpm (Forester XT)
Fuel System:
Multi-point Fuel Injection (MPI) with Turbocharger
Engine Characteristics
Engine Placement:
Front, longitudinally mounted
Engine Type:
Horizontally opposed (Boxer) engines, known for lower center of gravity and reduced vibration.
Timing System:
Timing Belt (requires periodic replacement, consult manual for intervals)
🔧 Transmission
Standard Transmission
Type:
5-Speed Manual Transmission
Optional Transmission
Type:
4-Speed Automatic Transmission (with Sportshift on some models)
Drivetrain
System:
Symmetrical All-Wheel Drive (AWD) standard on all models.
AWD Features:
Driver-selectable modes (e.g., viscous coupling center differential in manual, electronically controlled in automatic). Detailed operation and maintenance covered.
Fluid Specifications
Manual Transmission Fluid:
Refer to manual for specific API GL-5 gear oil requirements (e.g., 75W-90)
Automatic Transmission Fluid:
Subaru ATF-HP (refer to manual for exact specification and capacity)
Standard Symmetrical AWD provides enhanced traction. Traction Control System (TCS) and/or Electronic Stability Control (ESC) may be available on certain trims.
Passive Features
Airbags:
Front airbags, optional side-impact airbags.
Seatbelts:
3-point front and rear seatbelts, pre-tensioners for front seats.
Body Structure:
Reinforced chassis and crumple zones designed for safety.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player. Higher trims may feature premium audio systems, Nakamichi systems (rare), or a single-disc CD player. Manual covers head unit removal and basic wiring.
Navigation:
Optional factory navigation system available on some higher trims.
Driver Assistance
Cruise Control:
Standard on most trims.
All Wheel Drive:
The core technology of the Forester, providing superior all-weather and traction capabilities.
Connectivity
Power Windows Locks Mirrors:
Standard on most trims, with auto-up/down for driver's window.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 3,750 miles or 3 months (severe conditions) / 7,500 miles or 6 months (normal conditions) - Refer to owner's manual or this service manual for definitive schedule.
Engine Air Filter:
Inspect every 15,000 miles, replace as needed.
Cabin Air Filter:
Replace annually or as needed based on environment.
Spark Plugs:
Typically every 60,000-100,000 miles depending on type (Iridium recommended). Consult manual for specific interval.
Timing Belt:
Crucial replacement interval, typically around 90,000 - 105,000 miles or 7-8 years. Failure can cause catastrophic engine damage. This manual will detail the procedure and correct tensioning.
Coolant Flush:
Every 30,000 miles or 2 years (Super Coolant).
Transmission Fluid Change Auto:
Every 30,000 miles or 2 years for severe use, 60,000 miles or 4 years for normal use. Consult manual for detailed recommendations.
Differential Fluid Change:
Front and Rear Differentials: Every 30,000 miles or 2 years.
Fluid Specifications
Engine Oil Type Na:
5W-30 Synthetic or Synthetic Blend (API SN or higher recommended)
Engine Oil Type Turbo:
5W-30 or 10W-30 Synthetic (API SN or higher recommended, especially for turbo engine)
Engine Oil Capacity:
Approx. 4.4 US quarts (4.2 Liters) with filter for 2.5L NA, slightly more for Turbo. Consult manual for exact capacity.
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation).
Known Issues
Head Gaskets:
While less prevalent than in some older Subaru models, it's a known potential issue, especially on higher-mileage NA engines. Manual will detail inspection and replacement.
Turbocharger Maintenance Xt:
Turbocharged XT models require diligent maintenance, including regular oil changes with quality synthetic oil, to ensure turbo longevity. Manual covers turbo system diagnostics and repair.
Awt System Maintenance:
Regularly scheduled maintenance of AWD components (differential fluids, transfer case fluids) is crucial for longevity.
📚 Vehicle History
Brand Heritage
Subaru Specialization:
Subaru is renowned for its Symmetrical All-Wheel Drive system and horizontally opposed Boxer engines, emphasizing safety, reliability, and all-weather capability.
Model Evolution
Forester Concept:
First generation launched in 1997. The 2004 model is part of the second generation (SG), introduced for the 2003 model year, featuring a more SUV-like appearance, larger dimensions, and improved comfort.
Second Generation Updates:
The SG generation saw significant updates including a revised chassis, independent rear suspension for all models, and the introduction of the turbocharged XT variant for enhanced performance.
Production
Manufacturing Location:
Gunma Manufacturing Plant, Japan.
Production Years For Sg Generation:
2003 - 2008
🏆 Awards & Recognition
Recognitions
Car And Driver Best SUV To Buy:
Forester often cited in 'best value' or 'best compact SUV' lists by automotive publications like Car and Driver and MotorTrend during its generation.
IIHS Top Safety Pick:
Often received 'Top Safety Pick' awards from the IIHS for its excellent crash test performance.
Consumer Reports Ratings:
Generally received good to excellent ratings for reliability and performance from Consumer Reports.
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