2003 2004 2005 Subaru Forester Service Repair Manuals

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🏷️ Basic Information Identification Make: Subaru Model: Forester Codes Chassis Codes: SG5, SG9 Generation Generation: Second Generation (SG) 👋 Introduction Market Position Segment: Compact Crossover SUV Positioning: Known for its...

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UGS: 255863

Mots clés: 2003 2004 2005 Car Cars Forester Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Codes

Chassis Codes:

SG5, SG9

Generation

Generation:

Second Generation (SG)

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Positioning:

Known for its standard All-Wheel Drive, practicality, and comfortable ride, appealing to outdoor enthusiasts and families.

Competitive Analysis

Key Competitors:

Toyota RAV4, Honda CR-V, Ford Escape, Nissan Xterra (though Xterra is more body-on-frame SUV).

Key Features

Standard AWD:

Symmetrical All-Wheel Drive system is a defining characteristic.

Practicality:

Spacious interior, good cargo volume, wagon-like utility.

Comfort:

Comfortable ride quality compared to some competitors, especially on rougher roads.

📋 Manual Details

Coverage Areas

Model Years Covered:

2003, 2004, 2005

Engine Variants Covered:

2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255/EJ257 - XT models)

Page Count

Estimated Page Count:

~1500-2000 pages (cumulative for all applicable years/sections)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnostics, fuel injection, ignition, cooling, lubrication, emissions control, timing belt replacement, turbocharger systems.

Transmission:

Manual (5-speed) and Automatic (4-speed) transmission overhaul, diagnostics, fluid changes, torque converter service, clutch replacement (MT).

Drivetrain:

All-Wheel Drive (AWD) system, differentials (front and rear), propeller shaft, CV joints, wheel bearings, hub assemblies.

Chassis:

Suspension (front struts, rear multi-link), steering system (power steering pump, rack and pinion), braking system (ABS, rotors, pads, calipers, lines), wheel alignment specifications.

Body:

Body panel removal/installation, interior trim, glass replacement, door mechanisms, tailgate, sunroof, bumper systems, body repair procedures.

Electrical:

Complete wiring diagrams, fuse box locations, lighting, power windows, locks, mirrors, wipers, horn, audio system, instrument cluster, climate control, starter, alternator, battery.

HVAC:

Air conditioning system service, heater core replacement, blower motor, climate control unit diagnostics.

Safety Systems:

Airbag system diagnostics and replacement, seat belt mechanisms, ABS system components and troubleshooting.

Procedures Included

Routine Maintenance:

Oil change intervals, filter replacements (oil, air, cabin, fuel), spark plug replacement, coolant flushes, brake fluid changes, differential fluid changes.

Diagnostic Procedures:

Troubleshooting guides for common and uncommon issues, OBD-II diagnostic codes and explanations, system-specific diagnostic flowcharts.

Repair Procedures:

Step-by-step instructions for component removal, installation, and adjustment (e.g., engine rebuild, transmission repair, suspension overhaul, body panel replacement).

Troubleshooting Guides:

Detailed guides for diagnosing engine performance issues, electrical faults, transmission problems, and chassis-related concerns.

Torque Specifications:

Precise torque values for all critical fasteners (engine, transmission, suspension, brakes, body).

Special Tools:

Identification of specialized tools required for specific repairs and maintenance tasks.

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical system troubleshooting.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Printability:

Printable pages for in-garage use.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Na:

EJ253

Engine Type Na:

2.5L Naturally Aspirated SOHC EJ-Series Boxer-4

Displacement Na:

2498 cc (152.4 cu in)

Bore X Stroke Na:

99.5 mm x 80.0 mm

Compression Ratio Na:

9.7:1

Horsepower Na:

165 hp @ 5600 rpm (approx.)

Torque Na:

166 lb-ft @ 3600 rpm (approx.)

Fuel System Na:

Electronic Multi-Point Fuel Injection (MPI)

Turbo Engine

Engine Code Turbo:

EJ255 (2004-2005 XT) / EJ257 (some early XT/STI-based)

Engine Type Turbo:

2.5L DOHC Turbocharged EJ-Series Boxer-4

Horsepower Turbo:

210-230 hp @ 5600 rpm (approx. varies by year/spec)

Torque Turbo:

235-241 lb-ft @ 3600 rpm (approx. varies by year/spec)

Fuel System Turbo:

Electronic Sequential Multi-Point Fuel Injection (SEPI) with Turbocharger

General

Timing Belt:

Timing Belt Driven (Interference Engine)

Coolant Type:

Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant

Oil Type:

SAE 0W-20 or 5W-30 (check owner's manual for specific recommendations based on climate)

🔧 Transmission

Standard

Manual Transmission:

5-speed manual transmission (TY756)

Optional

Automatic Transmission:

4-speed automatic transmission (4EAT)

Features

AWD System:

Symmetrical All-Wheel Drive with either mechanical center differential (manual) or electronically controlled clutch pack (automatic).

Fluid Specifications

Manual Transmission Fluid:

Subaru Extra-S Gear Oil 75W-90 or equivalent API GL-5

Automatic Transmission Fluid:

Subaru ATF HP (High Performance) or equivalent

📐 Dimensions

Exterior

Length:

Approx. 179.5 inches (4560 mm)

Width:

Approx. 70.1 inches (1780 mm)

Height:

Approx. 63.0 inches (1600 mm)

Wheelbase:

Approx. 103.1 inches (2619 mm)

Ground Clearance:

Approx. 7.9 inches (200 mm)

Cargo

Cargo Volume Rear Seats Up:

Approx. 30.0 cubic feet (850 L)

Cargo Volume Rear Seats Down:

Approx. 63.0 cubic feet (1784 L)

Weights

Curb Weight:

Approx. 3200-3500 lbs (1450-1590 kg), varies by trim and drivetrain.

Towing Capacity:

2400 lbs (1088 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5 Stars

NHTSA Front Impact Passenger:

5 Stars

NHTSA Side Impact Front Seat:

4 Stars

NHTSA Side Impact Rear Seat:

4 Stars

IIHS Front Offset Crash Rating:

IIHS Side Impact Crash Rating:

Acceptable

Active Features

Standard Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD)

Traction Control:

Available Traction Control System (TCS)

Passive Features

Airbags:

Front dual-stage airbags, available front side-impact airbags and side curtain airbags (depending on trim and year).

Seatbelts:

3-point seatbelts with pretensioners and load limiters for all occupants.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player. Higher trims may have premium audio systems and subwoofer. Aux input availability varies.

Navigation:

Optional factory navigation system on some higher trim models.

Driver Assistance

Cruise Control:

Standard cruise control.

All Wheel Drive:

Advanced Symmetrical All-Wheel Drive system is the primary technological feature.

Connectivity

Auxiliary Input:

May be present on some models for audio connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 3.75 months (whichever comes first) for severe conditions, or 7,500 miles (12,000 km) or 7.5 months for normal conditions (consult specific year manual).

Timing Belt Replacement Interval:

Every 105,000 miles (168,000 km) or 105 months. Crucial due to interference engine design.

Coolant Replacement Interval:

Initial flush at 30,000 miles (48,000 km) or 30 months, then every 30,000 miles (48,000 km) or 30 months thereafter.

Spark Plug Replacement Interval:

Approximately 60,000 miles (96,000 km) for standard plugs; iridium plugs may last longer.

Fluid Specifications

Engine Oil Capacity:

Approx. 4.8 US quarts (4.5 L) with filter for 2.5L engines.

Engine Coolant Capacity:

Approx. 7.6 US quarts (7.2 L) for automatic transmission, 7.2 US quarts (6.8 L) for manual transmission.

Brake Fluid Type:

DOT 3 or DOT 4 compatible brake fluid.

Known Issues

Head Gaskets:

While the EJ253 (SOHC) is less prone than earlier DOHC EJ25s, head gasket failure can still occur, especially on higher-mileage turbocharged models (EJ255/EJ257).

Oil Consumption:

Some owners report increased oil consumption with age, especially on turbocharged models.

Rear Wheel Bearings:

Rear wheel bearings can sometimes wear out prematurely.

Catalytic Converter:

Can become clogged over time, affecting performance.

Cv Axle Boots:

Torn CV axle boots can lead to joint damage if not addressed promptly.

📚 Vehicle History

Brand Heritage

Manufacturer:

Subaru Corporation (formerly Fuji Heavy Industries)

Model Evolution

Introduction Year:

1997 (First Generation)

Second Gen Introduction:

Facelift:

Minor facelift for 2006 model year, but this manual covers the pre-facelift SG generation.

Production

Production Plant:

Gunma Manufacturing Plant, Japan

🏆 Awards & Recognition

Recognitions

Edmunds Best SUVs:

Forester has historically received accolades from sources like Edmunds for its practicality and AWD capability.

IIHS Top Safety Picks:

The Forester consistently performed well in IIHS crash testing for its generation.

Ratings

Consumer Reports Reliability:

Reliability ratings vary by year, with some years showing average to above-average reliability, though certain known issues (like head gaskets) can impact overall scores.