SUBARU FORESTER Service Repair Workshop 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 Code: SG 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Key Selling Points: Standard Symmetrical All-Wheel Drive, Boxer engine, practicality, utility, safety reputation. Competitive Analysis Primary Competitors 2003 2004: Honda CR-V, Toyota RAV4, Nissan Xterra, Ford Escape, Mazda Tribute, Mitsubishi Outlander. Key Features Distinctive Features: Subaru's signature Boxer engine provides a lower center of gravity for improved handling. Symmetrical All-Wheel Drive enhances traction and stability in various conditions. Higher ground clearance compared to many car-based SUVs. 📋 Manual Details Coverage Areas Manual Type: Service Repair Workshop Manual Language: English Format: Digital (likely PDF, implied by 'on Tradebit') Completeness Statement: Complete Manual - No Missing Pages. Best Manual Available On Tradebit! 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, piston, crankshaft, connecting rods, lubrication system, cooling system, fuel injection system (MPI), ignition system, exhaust system, turbocharger (if applicable to specific models within the year range) Engine Electrical: ECU (Engine Control Unit) diagnosis, sensors (MAP, MAF, O2, Crankshaft Position, Camshaft Position, Coolant Temperature), actuators (injectors, ignition coils), starter system, charging system (alternator, battery) Transmission Manual: Clutch system, gearbox assembly, internal components, shift linkage, maintenance, repair, troubleshooting Transmission Automatic: Automatic transmission assembly, torque converter, valve body, hydraulic control system, electronic controls, maintenance, repair, troubleshooting Drivetrain: All-Wheel Drive (AWD) system, front differential, rear differential, driveshafts, CV joints, propeller shaft, final drive maintenance and repair Suspension: Front suspension (MacPherson struts, control arms), rear suspension (multi-link), springs, shock absorbers, bushings, alignment specifications, repair procedures Steering: Power steering system, steering rack, power steering pump, fluid specifications, repair and adjustment Brakes: Front and rear disc brakes, ABS (Anti-lock Braking System) components, hydraulic system, brake pads, rotors, calipers, master cylinder, bleeding procedures, troubleshooting Electrical Body: Lighting system (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, fuses, relays, wiring diagrams HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, blower motor, control panel Interior: Seating systems, dashboard, trim panels, airbag system (SRS) components and safety precautions Exterior: Body panels, doors, hood, liftgate, bumpers, glass, seals, rust prevention, repair and replacement Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, belt inspection and replacement Diagnostic Procedures: Troubleshooting guides for common symptoms, DTC (Diagnostic Trouble Code) interpretation and clearing, specific system diagnostics Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment for all major systems Overhaul Procedures: Detailed instructions for complete engine and transmission rebuilds Electrical Troubleshooting: Wiring diagrams, circuit testing, fault finding for electrical systems Suspension And Steering Repair: Alignment specifications, component replacement, power steering system service Brake System Service: Brake pad/rotor replacement, caliper service, ABS system bleeding, master cylinder replacement Technical Depth Depth Of Information: Comprehensive coverage from basic maintenance to advanced repair and diagnostics, suitable for professional technicians and experienced DIY enthusiasts Detail Level: Detailed torque specifications, clearances, tolerances, and assembly instructions Diagnostic Tools: Information pertaining to the use of Subaru-specific diagnostic tools and generic OBD-II scanners 📊 Manual Specifications File Format File Type: Digital (PDF assumed), searchable text content Print Quality: High-resolution, suitable for printing individual pages or entire sections Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) Page Count Estimated Page Count: Likely over 2000 pages, typical for a complete factory service manual covering all systems and variations. ⚙️ Engine Specifications Primary Engine Engine Code And Type: EJ251/EJ253 (2.5L Naturally Aspirated Boxer-4), EJ255 (2.5L Turbocharged Boxer-4 - XT models) Performance Naturally Aspirated Horsepower: Approx. 165 hp @ 5600 rpm Naturally Aspirated Torque: Approx. 170 lb-ft @ 4000 rpm Turbocharged Horsepower Xt Model: Approx. 210 hp @ 5600 rpm Turbocharged Torque Xt Model: Approx. 235 lb-ft @ 3600 rpm Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Recommended Fuel: 87 Octane (Regular Unleaded) for Naturally Aspirated, 91 Octane (Premium Unleaded) for Turbocharged models General Bore X Stroke: 99.5 mm x 79.0 mm (for EJ25 series) Compression Ratio: 9.7:1 (NA), 8.4:1 (Turbo) 🔧 Transmission Standard Standard Transmission: 5-Speed Manual Transmission Optional Optional Transmission: 4-Speed Automatic Transmission (with electronically controlled AWD) Features AWD System: Symmetrical All-Wheel Drive AWD Type Auto: Viscous coupling all-wheel drive (for manual transmission), electronically controlled AWD with multi-plate transfer clutch (for automatic transmission) 📐 Dimensions Exterior Length: Approx. 179.7 inches (4565 mm) Width: Approx. 69.7 inches (1770 mm) Height: Approx. 63.2 inches (1605 mm) Wheelbase: Approx. 103.0 inches (2615 mm) Ground Clearance: Approx. 8.0 inches (203 mm) Weights Curb Weight: Approx. 3100-3400 lbs (1400-1540 kg), varies by trim and transmission. Towing Capacity: Approx. 2400 lbs (1089 kg) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 5 Stars (2003 model) NHTSA Frontal Impact Passenger: 5 Stars (2003 model) IIHS Frontal Offset: Good (2003 model) Active Features Active Safety Systems: Anti-lock Braking System (ABS), Electronic Brake-force...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Model Generation:

Second Generation (SG)

Model Years Covered:

2003-2004

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact Crossover SUV

Key Selling Points:

Standard Symmetrical All-Wheel Drive, Boxer engine, practicality, utility, safety reputation.

Competitive Analysis

Primary Competitors 2003 2004:

Honda CR-V, Toyota RAV4, Nissan Xterra, Ford Escape, Mazda Tribute, Mitsubishi Outlander.

Key Features

Distinctive Features:

Subaru's signature Boxer engine provides a lower center of gravity for improved handling. Symmetrical All-Wheel Drive enhances traction and stability in various conditions. Higher ground clearance compared to many car-based SUVs.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Workshop Manual

Language:

English

Format:

Digital (likely PDF, implied by 'on Tradebit')

Completeness Statement:

Complete Manual - No Missing Pages. Best Manual Available On Tradebit!

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, piston, crankshaft, connecting rods, lubrication system, cooling system, fuel injection system (MPI), ignition system, exhaust system, turbocharger (if applicable to specific models within the year range)

Engine Electrical:

ECU (Engine Control Unit) diagnosis, sensors (MAP, MAF, O2, Crankshaft Position, Camshaft Position, Coolant Temperature), actuators (injectors, ignition coils), starter system, charging system (alternator, battery)

Transmission Manual:

Clutch system, gearbox assembly, internal components, shift linkage, maintenance, repair, troubleshooting

Transmission Automatic:

Automatic transmission assembly, torque converter, valve body, hydraulic control system, electronic controls, maintenance, repair, troubleshooting

Drivetrain:

All-Wheel Drive (AWD) system, front differential, rear differential, driveshafts, CV joints, propeller shaft, final drive maintenance and repair

Suspension:

Front suspension (MacPherson struts, control arms), rear suspension (multi-link), springs, shock absorbers, bushings, alignment specifications, repair procedures

Steering:

Power steering system, steering rack, power steering pump, fluid specifications, repair and adjustment

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System) components, hydraulic system, brake pads, rotors, calipers, master cylinder, bleeding procedures, troubleshooting

Electrical Body:

Lighting system (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, fuses, relays, wiring diagrams

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, blower motor, control panel

Interior:

Seating systems, dashboard, trim panels, airbag system (SRS) components and safety precautions

Exterior:

Body panels, doors, hood, liftgate, bumpers, glass, seals, rust prevention, repair and replacement

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, belt inspection and replacement

Diagnostic Procedures:

Troubleshooting guides for common symptoms, DTC (Diagnostic Trouble Code) interpretation and clearing, specific system diagnostics

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment for all major systems

Overhaul Procedures:

Detailed instructions for complete engine and transmission rebuilds

Electrical Troubleshooting:

Wiring diagrams, circuit testing, fault finding for electrical systems

Suspension And Steering Repair:

Alignment specifications, component replacement, power steering system service

Brake System Service:

Brake pad/rotor replacement, caliper service, ABS system bleeding, master cylinder replacement

Technical Depth

Depth Of Information:

Comprehensive coverage from basic maintenance to advanced repair and diagnostics, suitable for professional technicians and experienced DIY enthusiasts

Detail Level:

Detailed torque specifications, clearances, tolerances, and assembly instructions

Diagnostic Tools:

Information pertaining to the use of Subaru-specific diagnostic tools and generic OBD-II scanners

📊 Manual Specifications

File Format

File Type:

Digital (PDF assumed), searchable text content

Print Quality:

High-resolution, suitable for printing individual pages or entire sections

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

Page Count

Estimated Page Count:

Likely over 2000 pages, typical for a complete factory service manual covering all systems and variations.

⚙️ Engine Specifications

Primary Engine

Engine Code And Type:

EJ251/EJ253 (2.5L Naturally Aspirated Boxer-4), EJ255 (2.5L Turbocharged Boxer-4 - XT models)

Performance

Naturally Aspirated Horsepower:

Approx. 165 hp @ 5600 rpm

Naturally Aspirated Torque:

Approx. 170 lb-ft @ 4000 rpm

Turbocharged Horsepower Xt Model:

Approx. 210 hp @ 5600 rpm

Turbocharged Torque Xt Model:

Approx. 235 lb-ft @ 3600 rpm

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Recommended Fuel:

87 Octane (Regular Unleaded) for Naturally Aspirated, 91 Octane (Premium Unleaded) for Turbocharged models

General

Bore X Stroke:

99.5 mm x 79.0 mm (for EJ25 series)

Compression Ratio:

9.7:1 (NA), 8.4:1 (Turbo)

🔧 Transmission

Standard

Standard Transmission:

5-Speed Manual Transmission

Optional

Optional Transmission:

4-Speed Automatic Transmission (with electronically controlled AWD)

Features

AWD System:

Symmetrical All-Wheel Drive

AWD Type Auto:

Viscous coupling all-wheel drive (for manual transmission), electronically controlled AWD with multi-plate transfer clutch (for automatic transmission)

📐 Dimensions

Exterior

Length:

Approx. 179.7 inches (4565 mm)

Width:

Approx. 69.7 inches (1770 mm)

Height:

Approx. 63.2 inches (1605 mm)

Wheelbase:

Approx. 103.0 inches (2615 mm)

Ground Clearance:

Approx. 8.0 inches (203 mm)

Weights

Curb Weight:

Approx. 3100-3400 lbs (1400-1540 kg), varies by trim and transmission.

Towing Capacity:

Approx. 2400 lbs (1089 kg)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

5 Stars (2003 model)

NHTSA Frontal Impact Passenger:

5 Stars (2003 model)

IIHS Frontal Offset:

Good (2003 model)

Active Features

Active Safety Systems:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist (BA) on some trims.

Passive Features

Passive Safety Features:

Driver and front passenger airbags, front side-impact airbags (optional on some trims), side curtain airbags (optional/late availability), front seatbelt pretensioners, collapsible steering column.

💡 Technology Features

Infotainment

Infotainment System Features:

Basic AM/FM/CD audio system, optional CD changer, optional premium audio. Bluetooth connectivity and touchscreens were not standard in this era.

Driver Assistance

Driver Assistance Features:

Cruise control, optional traction control (on automatic models).

Connectivity

Connectivity Options:

Limited to basic power outlets. No integrated USB or Bluetooth streaming typically found.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3.75 months (severe driving), or 7,500 miles or 7.5 months (normal driving), consult manual for specifics.

Engine Air Filter:

Inspect every 15,000 miles, replace as needed (typically 30,000 miles).

Cabin Air Filter:

Inspect every 15,000 miles, replace as needed (typically 15,000-30,000 miles).

Spark Plugs:

Replace at 100,000 miles (Platinum/Iridium tipped)

Timing Belt:

Not applicable (EJ series engines use a timing chain for Naturally Aspirated, timing belt for Turbocharged engines - check specific model details, likely belt for some XT models). Update: EJ251/EJ253 use a timing belt. Timing belt replacement interval is typically 105,000 miles or 105 months. The manual will specify this.

Fluid Specifications

Engine Oil Type Na:

SAE 5W-30 API SN or higher (check manual for specific API rating for this era).

Engine Oil Capacity Na:

Approx. 4.5 US quarts (4.3 L) with filter change.

Transmission Fluid Type Manual:

Subaru Genuine Gear Oil API GL-5 SAE 75W-90.

Transmission Fluid Type Automatic:

Subaru ATF-HP (High Performance) Automatic Transmission Fluid.

Coolant Type:

Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant with Subaru anti-corrosion additive.

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Head Gasket Leaks:

A well-documented potential issue with EJ series engines, especially in earlier years. The manual will detail inspection and replacement procedures.

Oil Consumption:

Some EJ engines can be prone to increased oil consumption as they age. The manual will provide oil level checking procedures.

Catalytic Converter Issues:

Premature failure can occur due to oil burning or other engine issues. The manual will cover exhaust system diagnosis.

📚 Vehicle History

Brand Heritage

Subaru Brand Focus:

Subaru is renowned for its focus on Symmetrical All-Wheel Drive and Boxer engines, often associated with outdoor enthusiasts and drivers in adverse weather conditions.

Model Evolution

First Generation Forester:

Introduced in 1997, based on the Impreza platform, establishing the crossover utility vehicle niche.

Second Generation Launch:

The SG generation debuted in 2002 for the 2003 model year, offering a more refined design, improved interior, and updated powertrains.

Production

Manufacturing Location:

Gunma Plant, Japan

🏆 Awards & Recognition

Recognitions

Ii Hs Award History:

The Forester typically performed well in IIHS crash tests, often receiving 'Good' ratings for frontal offset impacts in its earlier generations.

Consumer Reports Ratings:

Consumer Reports generally rated the Forester as average to above-average for reliability in these model years, though head gasket concerns were sometimes noted.