Subaru Forester Complete Workshop Service Repair Manual 2003 2004
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🏷️ Basic Information Identification Make: Subaru Model: Forester Model Generation: Second Generation (SG) Model Years Covered: 2003, 2004 Codes Chassis Codes: SG5, SG9 👋 Introduction Market Position Segment: Compact SUV / Crossover Usp: Symmetrical All-Wheel Drive (standard on most trims), practicality, SUV utility with car-like handling. Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra. Key Features AWD System: Standard Symmetrical All-Wheel Drive system provides superior traction and stability in various driving conditions. Engine Layout: Horizontally-opposed Boxer engine, contributing to a lower center of gravity. Body Style: Wagon-like SUV profile offering ample cargo space and comfortable seating. 📋 Manual Details Coverage Areas Market Coverage: North America (USA, Canada, Mexico) Page Count Estimated Page Count: 1500-2500 (Varies by specific edition, comprehensive nature) Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, exhaust systems Transmission: Manual and Automatic transmission repair, clutch, driveshaft, differentials Chassis: Suspension (front and rear), steering, brakes (ABS, standard), wheels, tires Electrical: Wiring diagrams, lighting, starting and charging, instrument cluster, HVAC controls, power accessories, body electronics, ECU troubleshooting Body: Body panels, doors, windows, locks, interior trim, HVAC system, exterior components Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and replacements Repair: Component removal and installation, component overhaul, sub-assembly repair Diagnostics: Troubleshooting charts, diagnostic trouble codes (DTCs), system testing procedures Specifications: Torque specifications, clearances, fluid capacities, electrical data Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and body repair. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Print Quality Searchability: Text-searchable for quick information retrieval. Image Resolution: High-resolution for clear diagrams, illustrations, and photographs. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: EJ251 (Naturally Aspirated), EJ255 (Turbocharged) Displacement: 2.5 Liters (2498 cc) Configuration: 2.5L Flat-4 (Boxer) Valvetrain: DOHC (Dual Overhead Camshafts), 16 Valves Performance Horsepower Na: 165 hp @ 5600 rpm (EJ251) Torque Na: 166 lb-ft @ 4000 rpm (EJ251) Horsepower Turbo: 210 hp @ 5600 rpm (EJ255 - Forester XT) Torque Turbo: 235 lb-ft @ 3600 rpm (EJ255 - Forester XT) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline, 87 Octane (91 Octane recommended for XT models) Cooling System Coolant Type: Subaru Super Coolant (Blue) or equivalent silicate-free, ethylene glycol-based coolant. Lubrication Oil Type: SAE 0W-20 (preferred) or 5W-30 API Service Category SG or higher. Oil Capacity: 4.8 US quarts (4.5 liters) with filter change. 🔧 Transmission Standard Type: 5-Speed Manual Transmission (TY756 V-Series or similar) Optional Type: 4-Speed Automatic Transmission (4EAT - Electronic Automatic Transmission) Features AWD Integration: Active Torque Split All-Wheel Drive for automatic, viscous coupling center differential for manual. (Specific system varies by transmission type and trim). Fluid Specifications Automatic Transmission Fluid: Subaru ATF HP (High Performance) or Dexron III equivalent. Manual Transmission Fluid: SAE 75W-90 API GL-5 Gear Oil. 📐 Dimensions Exterior Length: Approx. 179.7 inches (4565 mm) Width: Approx. 69.7 inches (1770 mm) Height: Approx. 63.0 inches (1600 mm) (without roof rails) Wheelbase: Approx. 103.1 inches (2619 mm) Ground Clearance: Approx. 7.7 inches (196 mm) Interior Passenger Volume: Approx. 97.5 cubic feet (2760 liters) Cargo Cargo Volume Behind Rear Seats: Approx. 31.4 cubic feet (889 liters) Cargo Volume With Rear Seats Folded: Approx. 67.1 cubic feet (1900 liters) Weights Curb Weight: Approx. 3200 - 3500 lbs (1450 - 1590 kg) (Varies by trim and transmission) Gross Vehicle Weight Rating Gvwr: Approx. 4500 - 4700 lbs (2040 - 2130 kg) 🛡️ Safety Features Ratings NHTSA Front Impact: 5 Stars (Driver and Passenger) NHTSA Side Impact: 4 Stars (Front and Rear Passengers) IIHS Crash Test Results: Good (Head Restraints and Seats, Roof Strength) - Primarily refers to the later part of the SG generation's testing. Active Features ABS: Anti-lock Braking System (Standard on most trims) Traction Control: Available on some models, especially XT trims. Electronic Stability Control: Not commonly equipped on these model years. Passive Features Airbags: Driver and front passenger airbags, side curtain airbags (available on higher trims). Seatbelts: 3-point height-adjustable front seatbelts with pretensioners, rear 3-point seatbelts. Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM/CD player, with optional premium audio systems and CD changer on some trims. Display: Digital clock, exterior temperature display, and odometer/trip meter in instrument cluster. Larger integrated displays were not common for this era. Driver Assistance Cruise Control: Standard on most models. Keyless Entry: Available on higher trims. Connectivity Auxiliary Input: Not typically standard; aftermarket solutions often required. Convenience Features Power Windows And Locks: Standard on most models. Heated Seats: Available on higher trim levels. 🔧 Maintenance Service Intervals Oil And Filter Change:...
Active Torque Split All-Wheel Drive for automatic, viscous coupling center differential for manual. (Specific system varies by transmission type and trim).
Fluid Specifications
Automatic Transmission Fluid:
Subaru ATF HP (High Performance) or Dexron III equivalent.
Approx. 3200 - 3500 lbs (1450 - 1590 kg) (Varies by trim and transmission)
Gross Vehicle Weight Rating Gvwr:
Approx. 4500 - 4700 lbs (2040 - 2130 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5 Stars (Driver and Passenger)
NHTSA Side Impact:
4 Stars (Front and Rear Passengers)
IIHS Crash Test Results:
Good (Head Restraints and Seats, Roof Strength) - Primarily refers to the later part of the SG generation's testing.
Active Features
ABS:
Anti-lock Braking System (Standard on most trims)
Traction Control:
Available on some models, especially XT trims.
Electronic Stability Control:
Not commonly equipped on these model years.
Passive Features
Airbags:
Driver and front passenger airbags, side curtain airbags (available on higher trims).
Seatbelts:
3-point height-adjustable front seatbelts with pretensioners, rear 3-point seatbelts.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM/CD player, with optional premium audio systems and CD changer on some trims.
Display:
Digital clock, exterior temperature display, and odometer/trip meter in instrument cluster. Larger integrated displays were not common for this era.
Driver Assistance
Cruise Control:
Standard on most models.
Keyless Entry:
Available on higher trims.
Connectivity
Auxiliary Input:
Not typically standard; aftermarket solutions often required.
Convenience Features
Power Windows And Locks:
Standard on most models.
Heated Seats:
Available on higher trim levels.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe conditions), or 7,500 miles (12,000 km) or 12 months (normal conditions).
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for platinum-tipped plugs.
Timing Belt Replacement:
Not applicable; these models use timing chains.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 Brake Fluid.
Power Steering Fluid:
Subaru Genuine Power Steering Fluid or Dexron III ATF.
Known Issues
Head Gaskets:
While not as prevalent as in earlier EJ engines, some EJ251/EJ255 engines can develop coolant leaks from the head gaskets. The manual provides diagnostic and repair procedures for this.
Catalytic Converter Failure:
Can occur due to misfires or rich fuel conditions. The manual covers exhaust system diagnostics.
Automatic Transmission Issues:
Early 4EAT transmissions can sometimes exhibit wear. Regular fluid changes are critical. The manual details transmission maintenance and repair.
Oil Consumption:
Some EJ engines may exhibit increased oil consumption over time, particularly if not maintained with correct oil type and change intervals.
📚 Vehicle History
Brand Heritage
Brand Foundation:
Subaru Corporation, a division of Fuji Heavy Industries, established in 1953, known for its horizontally-opposed engines and All-Wheel Drive systems.
Model Evolution
First Generation:
First generation Forester (SF) introduced in 1997 (for the 1998 model year).
Second Generation:
Second generation (SG) launched for the 2003 model year, featuring a significant redesign with a larger body, improved interior, and updated powertrains. The XT model with the turbocharged engine was introduced during this generation.
Production
Manufacturing Location:
Japan (Gunma Prefecture) and other global Subaru assembly plants.
🏆 Awards & Recognition
Recognitions
Car And Driver Best SUVs:
Forester frequently appeared on Car and Driver's Ten Best SUVs lists in its early years, highlighting its balance of utility, handling, and AWD capability.
Kbb Best Resale Value:
Subaru vehicles, including the Forester, are generally recognized for strong resale value, reflecting their durability and AWD reputation.
Icam Awards:
The Forester has often been lauded for its safety features and AWD system by various automotive organizations.