Subaru Forester 2003 2004 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2003-2004 Codes Chassis Codes: SG5, SG9 👋 Introduction Market Position Segment: Compact Crossover SUV Usp: Symmetrical All-Wheel Drive, Boxer Engine, Practicality Competitive Analysis Competitors 2003: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra Key Features Standard AWD: Yes Engine Layout: Horizontally Opposed (Boxer) Ground Clearance: Industry Leading (approx. 8 inches) Cargo Capacity: Versatile and Spacious 📋 Manual Details Coverage Areas General Repair: Comprehensive Overhaul: Detailed Page Count Estimated Pages: Approx. 2500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Drivetrain, Exhaust Chassis: Suspension, Steering, Brakes, Wheels & Tires Electrical: Wiring Diagrams, Lighting, Instruments, Audio, ECU Body And Interior: Body Panels, Doors, Seats, HVAC, Safety Restraints Procedures Included Maintenance: Scheduled Maintenance, Fluid Changes, Inspections Diagnostics: Troubleshooting Guides, DTC Interpretation Repair: Component Removal, Installation, Reassembly Overhaul: Engine Rebuild, Transmission Rebuild Technical Depth Depth: Expert Level (for trained technicians) 📊 Manual Specifications File Format Searchability: Searchable Text Printability: Printable Pages Resolution: High Resolution (clear text and diagrams) Binding Type Type: N/A (Digital PDF) Paper Type Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Usdm: EJ253 (2.5L SOHC) Engine Displacement Liters: 2.5 Engine Type: Naturally Aspirated, Horizontally Opposed (Boxer) Cylinders Configuration: 4-Cylinder Boxer Horsepower Bhp Approx: 165 Torque Lb Ft Approx: 166 Bore X Stroke Mm: 99.5 x 80.0 Compression Ratio: 9.7:1 Valvetrain: SOHC (Single Overhead Camshaft), 16 Valves Performance Fuel Type: Unleaded Gasoline Fuel System System: Electronic Fuel Injection (EFI) Fuel Octane Rating Minimum: 87 AKI (Octane) Engine Code Other Markets Engine Code Ej251: EJ251 (2.5L DOHC - less common in 2003-2004 USDM, but covered) Engine Code Ej255 Turbo: EJ255 (2.5L DOHC Turbo - SG9 WRX STI variants, often covered) 🔧 Transmission Standard Type Manual: 5-Speed Manual Type Automatic: 4-Speed Automatic (Activematic) Optional Turbo Transmission: 5-Speed Manual (WRX STI variants) Features Drivetrain Engagement: Symmetrical All-Wheel Drive (Variable Torque Distribution for Auto, Direct Coupling for Manual) Fluid Specifications Automatic Transmission Fluid Type: Subaru ATF-HP or equivalent Manual Transmission Fluid Type: Subaru Gear Oil API GL-5 75W-90 Fluid Capacities Automatic Transmission Capacity Liters: Approx. 6.4 (total fill) Manual Transmission Capacity Liters: Approx. 2.3 📐 Dimensions Exterior Length Mm Approx: 4475 Width Mm Approx: 1735 Height Mm Approx: 1675 Wheelbase Mm Approx: 2630 Track Width Front Mm Approx: 1490 Track Width Rear Mm Approx: 1490 Ground Clearance Mm Approx: 200 Approach Angle Degrees Approx: 33 Departure Angle Degrees Approx: 28 Weights Curb Weight Kg Approx: 1450-1550 Gross Vehicle Weight Rating Kg Approx: 1950-2050 Towing Capacity Kg Unbraked Approx: 750 Towing Capacity Kg Braked Approx: 1500 Cargo Cargo Volume Liters Behind Rear Seats Approx: 870 Cargo Volume Liters With Rear Seats Folded Approx: 1850 🛡️ Safety Features Ratings NHTSA Rollover Rating 2003: 4/5 Stars (Higher Center of Gravity) IIHS Front Crash Rating: Good IIHS Side Crash Rating: Acceptable Active Features ABS: Standard Electronic Brake Force Distribution Ebd: Standard Traction Control System TCS: Optional/Standard on some trims Passive Features Airbags Front: Standard Dual Frontal Airbags Side Impact: Optional Front Side Seatbelts: 3-Point ELR Front and Rear, Pretensioners Child Seat Anchors: LATCH System 💡 Technology Features Infotainment Audio System: Base 4-speaker or optional 6-speaker AM/FM/CD stereo. Navigation: Optional dealer-installed or aftermarket navigation systems were available. Not standard. Climate Control: Manual or optional automatic climate control. Driver Assistance Cruise Control: Standard All Wheel Drive System: Symmetrical AWD is a core technological feature. Connectivity Auxiliary Input: Not standard on most models; aftermarket solutions common. Bluetooth: Not available from factory. 🔧 Maintenance Service Intervals Oil Change Frequency: Every 3,750 miles or 3 months (severe conditions) or 7,500 miles or 6 months (normal conditions) Engine Air Filter Replacement: Every 15,000 miles or 12 months Cabin Air Filter Replacement: Every 7,500 miles or 6 months Spark Plug Replacement: Every 60,000 miles (NGK Iridium) Timing Belt Replacement: Not Applicable (Utilizes a timing chain) Fluid Specifications Engine Oil Type Viscosity: SAE 5W-30 (API SG or higher, ILSAC GF-2 or higher) Engine Oil Capacity Liters With Filter: 4.5 Coolant Type: Subaru Super Coolant (Blue) or equivalent silicate-free long-life coolant Brake Fluid Type: DOT 3 or DOT 4 Power Steering Fluid Type: Subaru Genuine ATF or Dexron III equivalent Known Issues Head Gasket Leaks: Common issue on EJ25 engines, though less prevalent in later models like the 2003-2004 compared to earlier generations. The manual will detail inspection and replacement procedures. Oil Consumption: Some EJ25 engines can exhibit increased oil consumption. Manual provides information on diagnosis and potential solutions. Catalytic Converter Failure: Can occur due to engine misfires or oil burning. Manual covers exhaust system diagnostics. Suspension Components: Wear on bushings, ball joints, and tie rod ends can occur with age and mileage. Manual details inspection and replacement. 📚 Vehicle History Brand Heritage Subaru Legacy: Developed from Subaru's experience with the Subaru Legacy station...
Body Panels, Doors, Seats, HVAC, Safety Restraints
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Inspections
Diagnostics:
Troubleshooting Guides, DTC Interpretation
Repair:
Component Removal, Installation, Reassembly
Overhaul:
Engine Rebuild, Transmission Rebuild
Technical Depth
Depth:
Expert Level (for trained technicians)
📊 Manual Specifications
File Format
Searchability:
Searchable Text
Printability:
Printable Pages
Resolution:
High Resolution (clear text and diagrams)
Binding Type
Type:
N/A (Digital PDF)
Paper Type
Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Usdm:
EJ253 (2.5L SOHC)
Engine Displacement Liters:
2.5
Engine Type:
Naturally Aspirated, Horizontally Opposed (Boxer)
Cylinders Configuration:
4-Cylinder Boxer
Horsepower Bhp Approx:
165
Torque Lb Ft Approx:
166
Bore X Stroke Mm:
99.5 x 80.0
Compression Ratio:
9.7:1
Valvetrain:
SOHC (Single Overhead Camshaft), 16 Valves
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
System:
Electronic Fuel Injection (EFI)
Fuel Octane Rating Minimum:
87 AKI (Octane)
Engine Code Other Markets
Engine Code Ej251:
EJ251 (2.5L DOHC - less common in 2003-2004 USDM, but covered)
Engine Code Ej255 Turbo:
EJ255 (2.5L DOHC Turbo - SG9 WRX STI variants, often covered)
🔧 Transmission
Standard
Type Manual:
5-Speed Manual
Type Automatic:
4-Speed Automatic (Activematic)
Optional
Turbo Transmission:
5-Speed Manual (WRX STI variants)
Features
Drivetrain Engagement:
Symmetrical All-Wheel Drive (Variable Torque Distribution for Auto, Direct Coupling for Manual)
Fluid Specifications
Automatic Transmission Fluid Type:
Subaru ATF-HP or equivalent
Manual Transmission Fluid Type:
Subaru Gear Oil API GL-5 75W-90
Fluid Capacities
Automatic Transmission Capacity Liters:
Approx. 6.4 (total fill)
Manual Transmission Capacity Liters:
Approx. 2.3
📐 Dimensions
Exterior
Length Mm Approx:
4475
Width Mm Approx:
1735
Height Mm Approx:
1675
Wheelbase Mm Approx:
2630
Track Width Front Mm Approx:
1490
Track Width Rear Mm Approx:
1490
Ground Clearance Mm Approx:
200
Approach Angle Degrees Approx:
33
Departure Angle Degrees Approx:
28
Weights
Curb Weight Kg Approx:
1450-1550
Gross Vehicle Weight Rating Kg Approx:
1950-2050
Towing Capacity Kg Unbraked Approx:
750
Towing Capacity Kg Braked Approx:
1500
Cargo
Cargo Volume Liters Behind Rear Seats Approx:
870
Cargo Volume Liters With Rear Seats Folded Approx:
1850
🛡️ Safety Features
Ratings
NHTSA Rollover Rating 2003:
4/5 Stars (Higher Center of Gravity)
IIHS Front Crash Rating:
Good
IIHS Side Crash Rating:
Acceptable
Active Features
ABS:
Standard
Electronic Brake Force Distribution Ebd:
Standard
Traction Control System TCS:
Optional/Standard on some trims
Passive Features
Airbags Front:
Standard Dual Frontal
Airbags Side Impact:
Optional Front Side
Seatbelts:
3-Point ELR Front and Rear, Pretensioners
Child Seat Anchors:
LATCH System
💡 Technology Features
Infotainment
Audio System:
Base 4-speaker or optional 6-speaker AM/FM/CD stereo.
Navigation:
Optional dealer-installed or aftermarket navigation systems were available. Not standard.
Climate Control:
Manual or optional automatic climate control.
Driver Assistance
Cruise Control:
Standard
All Wheel Drive System:
Symmetrical AWD is a core technological feature.
Connectivity
Auxiliary Input:
Not standard on most models; aftermarket solutions common.
Bluetooth:
Not available from factory.
🔧 Maintenance
Service Intervals
Oil Change Frequency:
Every 3,750 miles or 3 months (severe conditions) or 7,500 miles or 6 months (normal conditions)
Engine Air Filter Replacement:
Every 15,000 miles or 12 months
Cabin Air Filter Replacement:
Every 7,500 miles or 6 months
Spark Plug Replacement:
Every 60,000 miles (NGK Iridium)
Timing Belt Replacement:
Not Applicable (Utilizes a timing chain)
Fluid Specifications
Engine Oil Type Viscosity:
SAE 5W-30 (API SG or higher, ILSAC GF-2 or higher)
Engine Oil Capacity Liters With Filter:
4.5
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free long-life coolant
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Subaru Genuine ATF or Dexron III equivalent
Known Issues
Head Gasket Leaks:
Common issue on EJ25 engines, though less prevalent in later models like the 2003-2004 compared to earlier generations. The manual will detail inspection and replacement procedures.
Oil Consumption:
Some EJ25 engines can exhibit increased oil consumption. Manual provides information on diagnosis and potential solutions.
Catalytic Converter Failure:
Can occur due to engine misfires or oil burning. Manual covers exhaust system diagnostics.
Suspension Components:
Wear on bushings, ball joints, and tie rod ends can occur with age and mileage. Manual details inspection and replacement.
📚 Vehicle History
Brand Heritage
Subaru Legacy:
Developed from Subaru's experience with the Subaru Legacy station wagon.
AWD Philosophy:
Subaru's long-standing commitment to all-wheel-drive technology.
Model Evolution
First Generation:
Introduced in 1997 (BG chassis).
Second Generation:
Introduced for the 2003 model year (SG chassis), this generation brought significant styling and mechanical updates.
Facelift 2006:
Mid-cycle refresh introduced for the 2006 model year, including updated styling and features.
Production
Manufacturing Location:
Gunma Plant, Japan
Production Years Sg Chassis:
2003-2008
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Forester was a frequent contender and occasional winner in 'Best Small SUV' categories by various automotive publications.
IIHS Top Safety Pick:
Awarded 'Good' ratings in front and side impact tests by IIHS.
Ratings
Autotrader Reviews:
Consistently praised for its AWD system, cargo versatility, and driving dynamics for its class.
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