SUBARU FORESTER Service Repair Manual 2005-2008

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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation: Second Generation (SG) Years Covered By Manual: 2005-2008 Codes Chassis Code: SG5, SG9 👋 Introduction Market Position Vehicle Segment: Compact Crossover...

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Type: Car

Vendor:

Sku: 297833

Tags: 2005 2006 2007 2008 Car Cars FORESTER Misc Subaru

Product variants

Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Generation:

Second Generation (SG)

Years Covered By Manual:

2005-2008

Codes

Chassis Code:

SG5, SG9

👋 Introduction

Market Position

Vehicle Segment:

Compact Crossover SUV

Target Audience:

Families, outdoor enthusiasts, individuals seeking a versatile AWD vehicle with a reputation for durability.

Competitive Analysis

Key Competitors:

Toyota RAV4, Honda CR-V, Nissan X-Trail (Rogue), Mazda CX-5, Ford Escape.

Key Features

Symmetrical AWD:

Standard Symmetrical All-Wheel Drive system, a hallmark of Subaru vehicles, providing superior traction and stability in various conditions.

Horizontally Opposed Engine:

Boxer (horizontally opposed) engine design for a lower center of gravity, improving handling and stability.

Practicality:

Spacious interior, good cargo capacity, excellent visibility, and a reputation for practicality and utility.

📋 Manual Details

Coverage Areas

Covered Regions:

Global (North America, Europe, Asia, Australia)

Page Count

Estimated Page Count:

~2000+ pages (comprehensive estimate based on typical Subaru factory service manuals of this era)

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical (EJ253, EJ255, EJ257, EJ205), engine management (ECU, sensors, actuators), fuel system, lubrication, cooling, exhaust, emissions control

Transmission:

Manual transmission (5-speed), Automatic transmission (4-speed) diagnosis and repair, driveline, transfer case, differentials

Brakes:

Front and rear brake systems (disc brakes), ABS (Anti-lock Braking System), parking brake

Suspension Steering:

Front and rear suspension components (struts, springs, control arms), steering system (rack and pinion), power steering

Electrical:

Complete electrical diagrams, lighting system, charging system, starting system, body electricals, HVAC controls, power accessories, diagnostic trouble codes (DTCs)

Body Chassis:

Body panels, interior trim, exterior trim, chassis components, frame structure, doors, windows, sunroof

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis, repair, and component replacement

Procedures Included

Routine Maintenance:

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

Engine Repair:

Engine overhaul, head gasket replacement, piston and ring replacement, valve adjustment, timing belt/chain service

Transmission Repair:

Clutch replacement, transmission overhaul (manual and automatic), seal replacement, fluid service

Brake Service:

Brake pad and rotor replacement, caliper overhaul, brake line replacement, ABS component testing and replacement

Suspension Steering Repair:

Strut and shock absorber replacement, ball joint replacement, tie rod end replacement, power steering pump and rack replacement

Electrical Diagnostics:

Troubleshooting electrical faults, component testing, wiring harness repair, battery and alternator testing

Body Repair:

Panel replacement, door and window regulator repair, bumper repair, interior trim removal and installation

Technical Depth

Depth Level:

Comprehensive: From basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick information retrieval

Print Quality

Printability:

Printable for physical use in a workshop environment

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Base:

EJ253

Engine Description Base:

2.5-liter naturally aspirated flat-four (Boxer) engine

Displacement Base:

2457 cc (149.9 cubic inches)

Bore X Stroke Base:

99.5 mm x 79.0 mm

Compression Ratio Base:

9.7:1

Horsepower Base:

165 hp @ 5,600 rpm (approx.)

Torque Base:

166 lb-ft @ 4,000 rpm (approx.)

Performance

Engine Code Turbo:

EJ255 / EJ257

Engine Description Turbo:

2.5-liter turbocharged flat-four (Boxer) engine (XT models)

Horsepower Turbo:

210-230 hp (XT models, depending on trim/year)

Torque Turbo:

235-250 lb-ft (XT models, depending on trim/year)

Engine Code 2.0L Turbo:

EJ205 (some markets, e.g., Australia/Japan)

Engine Description 2.0L Turbo:

2.0-liter turbocharged flat-four (Boxer) engine

Horsepower 2.0L Turbo:

217 hp @ 5,600 rpm (typical for Forester STi variant)

Torque 2.0L Turbo:

240 lb-ft @ 3,500 rpm (typical for Forester STi variant)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with multi-point injection (MPI)

Fuel Type:

Unleaded gasoline (Octane rating: 87 minimum for NA, 91 recommended for Turbocharged models)

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission

Optional

Transmission Type Optional:

4-speed Automatic Transmission (with Sportshift on some models)

Features

AWD System:

Subaru Symmetrical All-Wheel Drive (standard on all models)

Manual Gear Ratios:

Specific ratios provided in the manual for all gears and final drive.

Automatic Transmission Fluid:

Subaru ATF HP (High Performance)

📐 Dimensions

Exterior

Length:

173.8 inches (4415 mm)

Width:

69.9 inches (1775 mm)

Height:

63.0 inches (1600 mm)

Wheelbase:

103.0 inches (2615 mm)

Ground Clearance:

7.7 inches (195 mm)

Weights

Curb Weight Base:

Approx. 3,200 - 3,400 lbs (1450 - 1540 kg)

Curb Weight Turbo:

Approx. 3,400 - 3,600 lbs (1540 - 1630 kg)

Cargo

Cargo Volume Behind Rear Seats:

30.0 cubic feet (850 liters)

Cargo Volume With Rear Seats Folded:

63.0 cubic feet (1785 liters)

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

5-Star (Driver and Passenger, 2005-2008 models)

IIHS Front Crash Test:

Good (for models tested)

IIHS Side Impact Test:

Good (for models tested)

Active Features

Traction Control:

Standard Traction Control System (TCS)

Electronic Stability Control:

Standard Electronic Stability Control (ESC/VDC - Vehicle Dynamics Control)

Antilock Brakes:

Standard Anti-lock Braking System (ABS)

Passive Features

Airbags:

Frontal airbags, front side-impact airbags, available side-curtain airbags (depending on trim and year)

Seatbelts:

3-point front and rear seatbelts with pretensioners and load limiters

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system

💡 Technology Features

Infotainment

Audio System Options:

Factory fitted CD player with AM/FM radio, optional premium audio systems with subwoofer. Aux input availability varies by trim.

Navigation System:

Optional factory navigation system available on higher trims.

Driver Assistance

Cruise Control:

Standard cruise control

Headlights:

Halogen headlights, available HID (High-Intensity Discharge) headlights on higher trims. Manual covers aiming and bulb replacement.

Connectivity

Auxiliary Input:

Available auxiliary audio input jack on select models.

Power Outlets:

12V power outlets for accessory charging.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 3 months (severe use) / 7,500 miles (12,000 km) or 6 months (normal use) - consult manual for exact specification.

Engine Oil Type Base:

Synthetic 5W-30 (API SG or higher rated)

Engine Oil Type Turbo:

Synthetic 5W-30 or 5W-40 (API SG or higher rated, check manual for specific turbo recommendations)

Engine Oil Capacity Base:

4.4 US quarts (4.2 liters) with filter change

Engine Oil Capacity Turbo:

4.4 US quarts (4.2 liters) with filter change

Engine Oil Filter Part Number Example:

Subaru OEM: 15208AA100 (or equivalent aftermarket)

Timing Belt Replacement:

105,000 miles (168,000 km) or 105 months - CRITICAL for EJ series engines. Manual will detail procedure and inspection intervals.

Transmission Fluid Change Manual:

Check fluid condition regularly, change as per manual schedule (typically around 30,000-60,000 miles or as needed based on usage).

Transmission Fluid Change Automatic:

Check fluid condition regularly, change as per manual schedule (typically around 30,000-60,000 miles or as needed based on usage).

Coolant Type:

Subaru Super Coolant (Blue) or equivalent long-life coolant (50/50 mix with distilled water)

Known Issues

Head Gasket Leaks:

While less prevalent than earlier generations, head gasket leaks can still occur, particularly on naturally aspirated EJ25 engines. The manual provides diagnostic and repair procedures.

Oil Consumption:

Some EJ25 engines, especially those with higher mileage, may exhibit increased oil consumption. Proper monitoring and use of recommended oil viscosity are important. Manual details piston ring inspection.

Turbocharger Issues:

For XT models, turbocharger reliability is generally good, but maintenance (oil changes) is critical. Manual covers turbo inspection and replacement.

Cv Joint Wear:

Front CV joints can wear over time, especially under demanding use. Manual provides replacement procedures.

Brake Wear:

Brake pad and rotor wear is typical for any vehicle; manual details wear limits and replacement.

📚 Vehicle History

Brand Heritage

Company Origins:

Subaru (Fuji Heavy Industries) has a long history in aerospace and automotive manufacturing, known for its boxer engines and AWD technology.

Model Evolution

Forester Introduction:

The Subaru Forester was first introduced in 1997 as a compact crossover SUV, blending the utility of an SUV with the driving characteristics of a car.

Second Generation Launch:

The second generation (SG) was launched for the 2003 model year and received a facelift for 2006, including revised styling and powertrain updates for certain markets.

Key Updates Sg Generation:

Increased wheelbase, revised suspension, introduction of turbocharged XT models with higher performance, improved safety features, and updated interior/exterior styling.

Production

Manufacturing Locations:

Mainly produced in Gunma, Japan. Some assembly may have occurred in other Subaru global facilities.

🏆 Awards & Recognition

Recognitions

Insurance Institute For Highway Safety:

Repeatedly recognized by the IIHS for good crash test performance.

Consumer Reports:

Consistently ranked highly by consumer organizations for reliability and practicality.

Ratings

Kbb Ratings:

Often received favorable ratings from Kelley Blue Book for its segment value and utility.