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2004 Subaru Forester Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2004 Codes Chassis Code: SG 👋 Introduction Market Position Segment: Compact Crossover SUV Key Differentiators: Standard Symmetrical All-Wheel Drive, Boxer engine,...
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Sku: 363894
2004 Subaru Forester Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Year:
2004
Codes
Chassis Code:
SG
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Key Differentiators:
Standard Symmetrical All-Wheel Drive, Boxer engine, wagon-like utility.
Competitive Analysis
Direct Competitors 2004:
Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra.
Key Features
Powertrain Layout:
Front-engine, All-Wheel Drive
Body Styles Offered:
5-door SUV/Crossover
📋 Manual Details
Coverage Areas
Primary Focus:
Repair and Service Procedures
Supported Regions:
Global (primarily North American specifications)
Page Count
Estimated Pages:
Approximately 2000+ pages (typical for factory service manuals)
Manual Type
Type:
Factory Service Manual (FSM)
Equivalent Dealer Manual:
Yes
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete diagnosis, repair, overhaul for EJ25 SOHC and DOHC naturally aspirated and turbocharged engines.
Transmission:
Manual (5-speed) and Automatic (4-speed) transmission diagnosis, repair, and overhaul.
Drivetrain:
All-Wheel Drive (AWD) system, differentials (front and rear), driveshafts, CV joints.
Suspension:
Front and rear suspension components, struts, shocks, bushings, alignment specifications.
Brakes:
Front and rear brake systems (disc brakes), ABS, brake fluid specifications, bleeding procedures.
Steering:
Power steering system, steering rack, tie rods, alignment.
Electrical:
Complete wiring diagrams, fuse box locations, component testing, charging system, starting system, lighting, accessories.
Climate Control:
HVAC system diagnosis, refrigerant, compressor, heater core, A/C components.
Fuel System:
Fuel pump, injectors, fuel pressure, EVAP system.
Cooling System:
Radiator, water pump, thermostat, coolant specifications, flushing procedures.
Exhaust System:
Catalytic converter, mufflers, exhaust pipes, O2 sensors.
Body And Frame:
Body panel removal/installation, glass, interior trim, chassis data.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, air filter replacement.
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides.
Repair Overhaul:
Component-level repair and complete overhaul procedures for major systems.
Diagnostic Testing:
Procedures for testing electrical components, sensors, actuators, and mechanical systems.
Torque Specifications:
Detailed torque values for all critical fasteners.
Special Tools:
Identification of required special tools for specific procedures.
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, and advanced electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (depending on original source quality).
Print Quality
Printability:
Printable pages.
Binding Type
Binding For Digital:
N/A (digital format)
Paper Type
Paper Type For Print:
N/A (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code Na:
EJ251 (2.5L SOHC Naturally Aspirated)
Engine Code Turbo:
EJ255 (2.5L DOHC Turbocharged - XT models)
Performance
Horsepower Na:
165 hp @ 5600 rpm
Torque Na:
166 lb-ft @ 4000 rpm
Horsepower Turbo:
210 hp @ 5600 rpm (XT models)
Torque Turbo:
235 lb-ft @ 3600 rpm (XT models)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane minimum, 91 octane recommended for turbo models)
Engine Type
Cylinders:
4-Cylinder Boxer
🔧 Transmission
Standard
Type Na:
5-Speed Manual
Optional
Type Auto:
4-Speed Automatic (with overdrive)
Features
AWD System:
Symmetrical All-Wheel Drive (Active Torque Split AWD for automatic transmission, viscous center diff for manual).
📐 Dimensions
Exterior
Wheelbase:
Approx. 103.1 inches
Length:
Approx. 179.9 inches
Width:
Approx. 70.1 inches
Height:
Approx. 65.1 inches
Weights
Curb Weight:
Approx. 3200 - 3500 lbs (varies by trim and transmission)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
4/5 Stars (provided by NHTSA data for similar models, specific 2004 rating may vary)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional (may be standard on certain trims or introduced later in model year)
Passive Features
Airbags:
Front dual-stage airbags for driver and front passenger, available front side-impact airbags.
Seatbelts:
Three-point seatbelts with pretensioners and load limiters.
💡 Technology Features
Infotainment
Head Unit:
Factory AM/FM/CD player, optional premium audio systems.
Display:
Basic LCD display for radio information and climate controls.
Driver Assistance
Cruise Control:
Standard or optional depending on trim level.
Connectivity
Auxiliary Input:
Not standard, aftermarket integration typically required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3 months (severe conditions) / 7,500 miles or 6 months (normal conditions).
Air Filter Replacement:
Every 15,000-30,000 miles depending on driving conditions.
Spark Plug Replacement:
Platinum-tipped plugs typically rated for 60,000-100,000 miles. Check manual for specific intervals.
Coolant Flush:
Initial flush at 30,000 miles, then every 30,000 miles thereafter (or every 2 years).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API SG or SH, or ILSAC GF-2)
Engine Oil Capacity:
Approx. 4.8 quarts (with filter)
Transmission Fluid Type Auto:
Subaru ATF-HP (or equivalent Dexron-III/Mercon)
Transmission Fluid Type Manual:
GL-5 75W-90 Gear Oil
Coolant Type:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant (50/50 mix with distilled water)
Known Issues
Head Gaskets:
While less common than in earlier generations, coolant leaks and potential head gasket issues can still occur. Manual covers diagnosis and repair.
Turbo Oil Lines:
Turbocharged XT models require regular inspection and potential replacement of oil feed lines to prevent turbo failure. Manual details inspection.
Awt Clutch Wear:
Automatic transmission AWD system clutches can experience wear over time. Manual provides diagnostic procedures.
📚 Vehicle History
Brand Heritage
Subaru Legacy Relation:
Shares platform elements and powertrain with the Subaru Legacy.
Model Evolution
Generation:
Second Generation (SG) Forester (2003-2008)
Design Changes From Previous:
Revised styling, more car-like interior, improved safety features, more powerful engine options.
Production
Manufacturing Location:
Japan (Gunma Plant)
🏆 Awards & Recognition
Recognitions
Motor Trend SUV Of The Year:
The Subaru Forester was a finalist for MotorTrend's Sport/Utility of the Year in 2004.
Ratings
IIHS Top Safety Pick:
Subaru vehicles of this era generally performed well in IIHS crash tests, but specific designation for 2004 Forester should be verified.
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