2003-2004 Subaru Forester Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation: Second Generation (SG) Codes Model Code: SG Chassis Code Examples: SG5, SG9 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience: Enthusiasts, DIY mechanics, independent repair shops seeking authentic factory service information. Competitive Analysis Key Competitors 2003-2004: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra Key Features Vehicle Differentiation: Standard Symmetrical All-Wheel Drive, boxer engine layout, practical cargo space, go-anywhere capability for its class. Manual Value Proposition: Provides the same detailed information as used by Subaru dealerships and certified technicians, empowering owners to perform complex repairs and maintenance accurately. 📋 Manual Details Coverage Areas Years Covered: 2003, 2004 Regions Covered: Global (primarily North American and European specifications) Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Repair Manual (Workshop Manual) Language Language: English Format Format: Digital (likely PDF, printable) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine management, fuel system, exhaust system, cooling system, lubrication system, ignition system, turbocharging system (for XT models) Drivetrain: Manual transmission, automatic transmission, all-wheel drive system (Symmetrical AWD), differentials, driveshafts, wheel hubs Chassis: Suspension (front and rear), steering system, brake system (ABS, EBD), wheels and tires Electrical: Body electrical systems, lighting, instruments, audio system, power accessories (windows, locks, mirrors), climate control, engine control module (ECM), transmission control module (TCM), airbag system (SRS) Body And Interior: Exterior body panels, interior trim, seats, safety restraints, glass, doors, hood, tailgate Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement Repair: Component disassembly and reassembly, major component overhaul, sensor replacement, wiring harness repair, body panel repair, suspension component replacement, brake caliper and rotor service Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), diagnostic connector pinouts, testing procedures for sensors and actuators Specifications And Tolerances: Torque specifications, clearances, alignment data, fluid capacities, electrical resistance values, pressure specifications Technical Depth Depth: Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds. Includes detailed wiring diagrams and diagnostic flowcharts. 📊 Manual Specifications File Format Digital Format Details: Likely a PDF document, optimized for searching and printing. May include hyperlinked sections for easy navigation. Print Quality Illustration Quality: High-quality, clear, and detailed illustrations and diagrams. Binding Type Digital Binding: N/A (digital format) Paper Type Digital Paper Simulation: N/A (digital format) ⚙️ Engine Specifications Primary Engine Engine Code Na: EJ253 Engine Type Na: 2.5L SOHC Naturally Aspirated Flat-4 (Boxer) Horsepower Na Approx: 165 hp @ 5600 rpm Torque Na Approx: 166 lb-ft @ 4000 rpm Turbocharged Engine Engine Code Turbo: EJ255 Engine Type Turbo: 2.5L DOHC Turbocharged Flat-4 (Boxer) Horsepower Turbo Approx: 210 hp @ 5600 rpm Torque Turbo Approx: 235 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (MPI) Fuel Type: Unleaded gasoline (87 octane recommended, 91 octane recommended for XT model) Engine Management ECM Type: Denso or Hitachi ECU (specific part numbers vary) 🔧 Transmission Standard Transmission Type Na: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission (with Sportshift on some models) Features AWD System: Symmetrical All-Wheel Drive (mechanical or electronically controlled center differential depending on transmission) Fluid Specifications Manual Transmission Fluid: API GL-5, SAE 75W-90 Gear Oil Automatic Transmission Fluid: Subaru ATF HP (or equivalent Dexron III/Mercon) 📐 Dimensions Exterior Wheelbase: 103.1 inches (2619 mm) Length: 177.4 inches (4506 mm) Width: 69.7 inches (1770 mm) Height: 65.2 inches (1656 mm) Ground Clearance: 8.0 inches (203 mm) Weights Curb Weight Approx: 3200 - 3500 lbs (1450 - 1588 kg), varies by trim and drivetrain Cargo Cargo Volume Behind Rear Seats: 32.1 cubic feet (0.91 cubic meters) Cargo Volume With Rear Seats Folded: 64.7 cubic feet (1.83 cubic meters) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-star (2003 model) NHTSA Front Impact Passenger: 5-star (2003 model) NHTSA Side Impact Front Driver: 5-star (2003 model) NHTSA Side Impact Front Passenger: 5-star (2003 model) NHTSA Side Impact Rear Driver: 5-star (2003 model) NHTSA Side Impact Rear Passenger: 5-star (2003 model) Active Features Standard Active Safety: Symmetrical All-Wheel Drive, Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD) Passive Features Standard Passive Safety: Front airbags, front side-impact airbags, height-adjustable front seatbelts, LATCH child seat anchors Optional Passive Safety: Curtain airbags (availability varies by trim and market) 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional premium audio with amplifier and subwoofer (depending on trim level). Display: Basic digital display for clock, temperature, and audio information. No central touchscreen infotainment system. Driver Assistance Assistance Features: Primarily relies on mechanical systems like AWD and ABS. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane-keeping assist. Connectivity Connectivity Options: Limited to basic auxiliary inputs for portable audio devices on some later models or aftermarket installations. No Bluetooth or USB integration from the factory. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles (6,000...
Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra
Key Features
Vehicle Differentiation:
Standard Symmetrical All-Wheel Drive, boxer engine layout, practical cargo space, go-anywhere capability for its class.
Manual Value Proposition:
Provides the same detailed information as used by Subaru dealerships and certified technicians, empowering owners to perform complex repairs and maintenance accurately.
📋 Manual Details
Coverage Areas
Years Covered:
2003, 2004
Regions Covered:
Global (primarily North American and European specifications)
Suspension (front and rear), steering system, brake system (ABS, EBD), wheels and tires
Electrical:
Body electrical systems, lighting, instruments, audio system, power accessories (windows, locks, mirrors), climate control, engine control module (ECM), transmission control module (TCM), airbag system (SRS)
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement
Repair:
Component disassembly and reassembly, major component overhaul, sensor replacement, wiring harness repair, body panel repair, suspension component replacement, brake caliper and rotor service
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), diagnostic connector pinouts, testing procedures for sensors and actuators
Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds. Includes detailed wiring diagrams and diagnostic flowcharts.
📊 Manual Specifications
File Format
Digital Format Details:
Likely a PDF document, optimized for searching and printing. May include hyperlinked sections for easy navigation.
Print Quality
Illustration Quality:
High-quality, clear, and detailed illustrations and diagrams.
4-Speed Automatic Transmission (with Sportshift on some models)
Features
AWD System:
Symmetrical All-Wheel Drive (mechanical or electronically controlled center differential depending on transmission)
Fluid Specifications
Manual Transmission Fluid:
API GL-5, SAE 75W-90 Gear Oil
Automatic Transmission Fluid:
Subaru ATF HP (or equivalent Dexron III/Mercon)
📐 Dimensions
Exterior
Wheelbase:
103.1 inches (2619 mm)
Length:
177.4 inches (4506 mm)
Width:
69.7 inches (1770 mm)
Height:
65.2 inches (1656 mm)
Ground Clearance:
8.0 inches (203 mm)
Weights
Curb Weight Approx:
3200 - 3500 lbs (1450 - 1588 kg), varies by trim and drivetrain
Cargo
Cargo Volume Behind Rear Seats:
32.1 cubic feet (0.91 cubic meters)
Cargo Volume With Rear Seats Folded:
64.7 cubic feet (1.83 cubic meters)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-star (2003 model)
NHTSA Front Impact Passenger:
5-star (2003 model)
NHTSA Side Impact Front Driver:
5-star (2003 model)
NHTSA Side Impact Front Passenger:
5-star (2003 model)
NHTSA Side Impact Rear Driver:
5-star (2003 model)
NHTSA Side Impact Rear Passenger:
5-star (2003 model)
Active Features
Standard Active Safety:
Symmetrical All-Wheel Drive, Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD)
Passive Features
Standard Passive Safety:
Front airbags, front side-impact airbags, height-adjustable front seatbelts, LATCH child seat anchors
Optional Passive Safety:
Curtain airbags (availability varies by trim and market)
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio with amplifier and subwoofer (depending on trim level).
Display:
Basic digital display for clock, temperature, and audio information. No central touchscreen infotainment system.
Driver Assistance
Assistance Features:
Primarily relies on mechanical systems like AWD and ABS. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane-keeping assist.
Connectivity
Connectivity Options:
Limited to basic auxiliary inputs for portable audio devices on some later models or aftermarket installations. No Bluetooth or USB integration from the factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months (severe conditions), 7,500 miles (12,000 km) or 6 months (normal conditions). Check owner's manual for specifics.
Engine Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement Na:
Every 60,000 miles (96,000 km) with iridium-tipped plugs.
Automatic Transmission Service:
Every 30,000 miles (48,000 km) or 24 months, replace filter at 60,000 miles (96,000 km).
Fluid Specifications
Engine Oil Specification:
API SG/SH/SJ/SL, ILSAC GF-2/GF-3, SAE 5W-30 (check specific engine for viscosity recommendations).
Coolant Specification:
Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant with Subaru additives, mixed 50/50 with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Known Issues
Head Gasket Leaks:
While less prevalent than on earlier generations, head gasket seepage or leaks can occur, particularly on higher-mileage naturally aspirated engines.
Oil Consumption:
Some EJ25 engines, especially the naturally aspirated variants, can exhibit higher than average oil consumption. Regular checks are crucial.
Catalytic Converter Concerns:
Premature failure of the catalytic converter can occur due to engine misfires or oil burning, leading to performance issues and check engine lights.
Rear Wheel Bearing Noise:
Rear wheel bearings are a known wear item and can develop noise over time, particularly after encountering potholes or harsh conditions.
📚 Vehicle History
Brand Heritage
Subaru Legacy Connection:
The Forester originated as a more utilitarian, taller version of the Subaru Legacy station wagon, emphasizing AWD capability and practicality.
Model Evolution
First Generation Introduction:
Introduced in 1997 (Japan), 1998 (North America) as the 'Sport Utility Wagon'.
Second Generation Launch:
The SG generation debuted in late 2002 for the 2003 model year, featuring a significant redesign with a more car-like appearance and improved interior.
Facelift Impact:
The 2005 model year saw a facelift for the SG generation, but this manual specifically covers the pre-facelift 2003-2004 models.
Production
Manufacturing Locations:
Japan (Ota Plant)
🏆 Awards & Recognition
Recognitions
Car And Driver Odi:
Car and Driver's '10Best Trucks' list in 2003.
Iku Award:
Recognized for its combination of SUV utility and car-like handling.
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