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Subaru Forester 2005-2008 Service & Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Codes Chassis Codes: SG5, SG9 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Target Audience: Families, outdoor enthusiasts, those seeking AWD capability and practicality Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Mazda CX-5, Nissan Xterra Key Features Drivetrain: Standard Symmetrical All-Wheel Drive Practicality: Spacious interior, excellent cargo volume, elevated ride height Performance: Reliable boxer engines, comfortable ride, capable handling 📋 Manual Details Coverage Areas Years Covered: 2005, 2006, 2007, 2008 Page Count Estimated Pages: 2000+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine: 2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255, EJ257 - XT models) Transmission: 5-Speed Manual (TY756), 4-Speed Automatic (4EAT/430) - All Wheel Drive Systems (Symmetrical AWD) Brakes: Front Ventilated Discs, Rear Solid Discs (ABS, EBD) Suspension: Front MacPherson Struts, Rear Multi-link Independent Electrical: Wiring Diagrams, Fuses, Relays, Lighting, Body Control Modules, ECU, Immobilizer HVAC: Air Conditioning, Heating, Ventilation System Operation and Repair Body: Body Panels, Doors, Windows, Seals, Interior Trim, Body Repair Procedures Included Maintenance: Oil Changes, Filter Replacements, Spark Plug Service, Belt Inspections/Replacements, Coolant Flush, Brake Fluid Flush Diagnostics: OBD-II Fault Code Interpretation, Sensor Testing, Component Diagnosis Repair: Engine Rebuild, Transmission Overhaul, Brake Component Replacement, Suspension Bushing Replacement, Steering System Repair Troubleshooting: Step-by-step guides for common and complex issues Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including torque specifications and diagnostic procedures. 📊 Manual Specifications File Format Searchable Text: Yes Printable: Yes Print Quality Image Resolution: High-resolution diagrams and illustrations Binding Type Digital Format: PDF Paper Type Physical Format Implication: Simulates factory paper manual quality for clarity ⚙️ Engine Specifications Primary Engine Engine Code Base: EJ253 Displacement Base: 2.5 Liters (2498cc) Configuration Base: Naturally Aspirated, Horizontally Opposed (Boxer) 4-Cylinder Horsepower Base: 173 hp @ 6000 RPM Torque Base: 166 lb-ft @ 4400 RPM Turbocharged Engine Engine Code Xt: EJ255 (Phase 1/2), EJ257 Displacement Xt: 2.5 Liters (2498cc) Configuration Xt: Turbocharged, Horizontally Opposed (Boxer) 4-Cylinder Horsepower Xt: 210-230 hp (varies by specific XT model/year) Torque Xt: 235-250 lb-ft (varies by specific XT model/year) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline Required Octane Base: 87 AKI (Premium Recommended for optimal performance) Required Octane Xt: 91 AKI or higher Engine Management ECM: Subaru Select Monitor (SSM) for diagnostics 🔧 Transmission Standard Type: 5-Speed Manual (TY756) Optional Type: 4-Speed Automatic (4EAT / 430) Features AWD System: Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled clutch pack (automatic) Fluid Spec Manual Type: GL-5 Gear Oil (75W-90 recommended) Fluid Spec Automatic Type: Subaru Genuine ATF HP or equivalent 📐 Dimensions Exterior Length: 179.3 inches (4555 mm) Width: 70.1 inches (1780 mm) Height: 65.7 inches (1670 mm) Wheelbase: 103.0 inches (2615 mm) Ground Clearance: 8.1 inches (206 mm) Cargo Cargo Volume Seats Up: 38.7 cubic feet (1096 L) Cargo Volume Seats Down: 67.1 cubic feet (1900 L) Weights Curb Weight Base: 3300-3450 lbs (1497-1565 kg) Curb Weight Xt: 3500-3650 lbs (1588-1656 kg) Towing Capacity: 2400 lbs (1089 kg) 🛡️ Safety Features Ratings NHTSA Frontal Driver: 5-Star NHTSA Frontal Passenger: 5-Star NHTSA Side Driver: 5-Star NHTSA Side Passenger: 5-Star NHTSA Side Rear Seat: 5-Star IIHS Frontal Offset: Good IIHS Side Impact: Good Active Features ABS: Standard Anti-lock Braking System Ebd: Standard Electronic Brake-force Distribution Traction Control: Available Passive Features Airbags: Front Dual-Stage SRS Airbags, Front Side-Impact SRS Airbags, Side Curtain Airbags (available on some trims) Seatbelts: 3-point height-adjustable front seatbelts with pretensioners and load limiters, rear 3-point seatbelts 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional satellite radio, speaker configurations (e.g., 6-speaker system) Navigation: Optional factory-installed GPS navigation system Driver Assistance Cruise Control: Standard on most trims Connectivity Auxiliary Input: Optional auxiliary audio input jack Convenience Keyless Entry: Standard or optional Power Accessories: Power windows, power locks, power mirrors 🔧 Maintenance Service Intervals Oil Change: Every 3,750 miles (6,000 km) or 3 months (severe conditions), 7,500 miles (12,000 km) or 6 months (normal conditions) Engine Air Filter: Every 15,000 miles (24,000 km) or 12 months Cabin Air Filter: Every 15,000 miles (24,000 km) or 12 months Spark Plugs Naturally Aspirated: Every 60,000 miles (96,000 km) - Iridium type Spark Plugs Turbocharged: Every 30,000 miles (48,000 km) - Platinum type Timing Belt: Replace every 105,000 miles (168,000 km) or 7 years. (Note: This manual covers engines with timing belts.) Coolant Flush: Initial flush at 30,000 miles (48,000 km) or 24 months, then every 30,000 miles (48,000 km) or 24 months thereafter. Fluid Specifications Engine Oil Capacity: 4.8 US quarts (4.5 L) with filter (EJ253, EJ255), 5.0 US quarts (4.7 L) with filter (EJ257) Engine Oil Viscosity: 5W-30 (API SG or higher) Coolant Type: Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant Brake Fluid Type: DOT 3...
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Subaru Forester 2005-2008 Service & Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Codes
Chassis Codes:
SG5, SG9
👋 Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV
Target Audience:
Families, outdoor enthusiasts, those seeking AWD capability and practicality
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Mazda CX-5, Nissan Xterra
Key Features
Drivetrain:
Standard Symmetrical All-Wheel Drive
Practicality:
Spacious interior, excellent cargo volume, elevated ride height
Performance:
Reliable boxer engines, comfortable ride, capable handling
📋 Manual Details
Coverage Areas
Years Covered:
2005, 2006, 2007, 2008
Page Count
Estimated Pages:
2000+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine:
2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255, EJ257 - XT models)
Transmission:
5-Speed Manual (TY756), 4-Speed Automatic (4EAT/430) - All Wheel Drive Systems (Symmetrical AWD)
Brakes:
Front Ventilated Discs, Rear Solid Discs (ABS, EBD)
Suspension:
Front MacPherson Struts, Rear Multi-link Independent
Electrical:
Wiring Diagrams, Fuses, Relays, Lighting, Body Control Modules, ECU, Immobilizer
HVAC:
Air Conditioning, Heating, Ventilation System Operation and Repair
Body:
Body Panels, Doors, Windows, Seals, Interior Trim, Body Repair
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Spark Plug Service, Belt Inspections/Replacements, Coolant Flush, Brake Fluid Flush
Diagnostics:
OBD-II Fault Code Interpretation, Sensor Testing, Component Diagnosis
Repair:
Engine Rebuild, Transmission Overhaul, Brake Component Replacement, Suspension Bushing Replacement, Steering System Repair
Troubleshooting:
Step-by-step guides for common and complex issues
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including torque specifications and diagnostic procedures.
📊 Manual Specifications
File Format
Searchable Text:
Yes
Printable:
Yes
Print Quality
Image Resolution:
High-resolution diagrams and illustrations
Binding Type
Digital Format:
PDF
Paper Type
Physical Format Implication:
Simulates factory paper manual quality for clarity
⚙️ Engine Specifications
Primary Engine
Engine Code Base:
EJ253
Displacement Base:
2.5 Liters (2498cc)
Configuration Base:
Naturally Aspirated, Horizontally Opposed (Boxer) 4-Cylinder
Horsepower Base:
173 hp @ 6000 RPM
Torque Base:
166 lb-ft @ 4400 RPM
Turbocharged Engine
Engine Code Xt:
EJ255 (Phase 1/2), EJ257
Displacement Xt:
2.5 Liters (2498cc)
Configuration Xt:
Turbocharged, Horizontally Opposed (Boxer) 4-Cylinder
Horsepower Xt:
210-230 hp (varies by specific XT model/year)
Torque Xt:
235-250 lb-ft (varies by specific XT model/year)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Required Octane Base:
87 AKI (Premium Recommended for optimal performance)
Required Octane Xt:
91 AKI or higher
Engine Management
ECM:
Subaru Select Monitor (SSM) for diagnostics
🔧 Transmission
Standard
Type:
5-Speed Manual (TY756)
Optional
Type:
4-Speed Automatic (4EAT / 430)
Features
AWD System:
Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled clutch pack (automatic)
Fluid Spec Manual
Type:
GL-5 Gear Oil (75W-90 recommended)
Fluid Spec Automatic
Type:
Subaru Genuine ATF HP or equivalent
📐 Dimensions
Exterior
Length:
179.3 inches (4555 mm)
Width:
70.1 inches (1780 mm)
Height:
65.7 inches (1670 mm)
Wheelbase:
103.0 inches (2615 mm)
Ground Clearance:
8.1 inches (206 mm)
Cargo
Cargo Volume Seats Up:
38.7 cubic feet (1096 L)
Cargo Volume Seats Down:
67.1 cubic feet (1900 L)
Weights
Curb Weight Base:
3300-3450 lbs (1497-1565 kg)
Curb Weight Xt:
3500-3650 lbs (1588-1656 kg)
Towing Capacity:
2400 lbs (1089 kg)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
5-Star
NHTSA Frontal Passenger:
5-Star
NHTSA Side Driver:
5-Star
NHTSA Side Passenger:
5-Star
NHTSA Side Rear Seat:
5-Star
IIHS Frontal Offset:
Good
IIHS Side Impact:
Good
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brake-force Distribution
Traction Control:
Available
Passive Features
Airbags:
Front Dual-Stage SRS Airbags, Front Side-Impact SRS Airbags, Side Curtain Airbags (available on some trims)
Seatbelts:
3-point height-adjustable front seatbelts with pretensioners and load limiters, rear 3-point seatbelts
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional satellite radio, speaker configurations (e.g., 6-speaker system)
Navigation:
Optional factory-installed GPS navigation system
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Auxiliary Input:
Optional auxiliary audio input jack
Convenience
Keyless Entry:
Standard or optional
Power Accessories:
Power windows, power locks, power mirrors
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles (6,000 km) or 3 months (severe conditions), 7,500 miles (12,000 km) or 6 months (normal conditions)
Engine Air Filter:
Every 15,000 miles (24,000 km) or 12 months
Cabin Air Filter:
Every 15,000 miles (24,000 km) or 12 months
Spark Plugs Naturally Aspirated:
Every 60,000 miles (96,000 km) - Iridium type
Spark Plugs Turbocharged:
Every 30,000 miles (48,000 km) - Platinum type
Timing Belt:
Replace every 105,000 miles (168,000 km) or 7 years. (Note: This manual covers engines with timing belts.)
Coolant Flush:
Initial flush at 30,000 miles (48,000 km) or 24 months, then every 30,000 miles (48,000 km) or 24 months thereafter.
Fluid Specifications
Engine Oil Capacity:
4.8 US quarts (4.5 L) with filter (EJ253, EJ255), 5.0 US quarts (4.7 L) with filter (EJ257)
Engine Oil Viscosity:
5W-30 (API SG or higher)
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Head Gaskets:
While less prevalent than earlier generations, some models can still experience head gasket leaks. The manual will detail diagnostic procedures and replacement.
Turbocharger Lag Xt:
Turbo lag is characteristic of the EJ255/EJ257 engines. Manual covers turbo system inspection and maintenance.
Catalytic Converter:
Premature failure can occur if engine runs rich or misfires. Manual details diagnostic and replacement.
Oil Consumption:
Some EJ engines can consume oil, especially under high load. Manual guides on checking oil level and engine health.
📚 Vehicle History
Brand Heritage
Subaru Legacy:
Shared platform and engine technology with Subaru Legacy models of the era.
Model Evolution
Generation:
Second Generation (SG Chassis)
Design Philosophy:
Evolved from the first generation, with updated styling, improved interior, and enhanced safety features.
Production
Manufacturing Location:
Gunma Plant, Japan
Production Years:
2003-2008 (SG Chassis)
🏆 Awards & Recognition
Recognitions
Car And Driver Alist:
Subaru Forester often featured on Car and Driver's '10Best' lists for its class and capability.
IIHS Top Safety Pick:
Consistently received high safety ratings from IIHS and NHTSA for its generation.
Certifications
Epa Fuel Economy Base:
Approx. 20 MPG City / 26 MPG Highway (Manual transmission)
Epa Fuel Economy Xt:
Approx. 19 MPG City / 23 MPG Highway (Automatic transmission)
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