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Subaru Forester Complete Workshop Service Repair Manual 2005 2006 2007 2008

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🏷️ Basic Information Identification Make: Subaru Model: Forester Model Generation: SG Model Years Covered: 2005, 2006, 2007, 2008 Codes Chassis Code: SG 👋 Introduction Market Position Category: Compact Crossover SUV...
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Subaru Forester Complete Workshop Service Repair Manual 2005 2006 2007 2008
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Model Generation:
SG
Model Years Covered:
2005, 2006, 2007, 2008
Codes
Chassis Code:
SG
👋 Introduction
Market Position
Category:
Compact Crossover SUV
Target Audience:
Families, outdoor enthusiasts, individuals seeking a capable and versatile all-wheel-drive vehicle.
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Nissan X-Trail (Rogue), Mazda CX-5, Ford Escape.
Subaru Advantage:
Standard Symmetrical All-Wheel Drive, Boxer engine for low center of gravity, excellent visibility, reputation for durability and safety.
Key Features
Standard AWD:
All models equipped with Subaru's Symmetrical All-Wheel Drive system.
Boxer Engine:
Horizontally opposed boxer engines offer a lower center of gravity for improved handling and stability.
Practicality:
Spacious interior, good cargo capacity, user-friendly controls, and a focus on functional design.
📋 Manual Details
Coverage Areas
Manual Type:
Complete Workshop Service Repair Manual
Language:
English
Format:
Downloadable PDF
Page Count
Page Count Estimated:
1500+
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul procedures, component testing, timing belt replacement, cylinder head removal/installation, piston and connecting rod assembly, crankshaft and main bearing service, lubrication system.
Engine Management:
EFI system diagnosis and repair, fuel injection, ignition system, sensors (MAF, MAP, O2, Crankshaft Position, Camshaft Position), actuators, ECU diagnosis and component location.
Transmission Manual:
Clutch system, transmission disassembly and reassembly, gear selection mechanisms, component specifications and tolerances.
Transmission Automatic:
Automatic transmission internal components, hydraulic control system, valve body, torque converter, transmission fluid cooler, shift control diagnosis, removal and installation.
Drivetrain AWD:
All-Wheel Drive system operation, front and rear differentials, driveshafts, propeller shaft, viscous coupling unit (VCU) service and testing, center differential (if applicable).
Suspension Steering:
Front and rear suspension components (struts, springs, control arms, ball joints, bushings), wheel alignment specifications, steering rack and linkage, power steering system diagnosis and repair.
Braking System:
Front and rear brake systems (disc and drum configurations), ABS system (components, diagnosis, bleeding procedures), parking brake system, brake fluid specifications, master cylinder and caliper service.
Electrical System:
Battery, charging system (alternator, starter motor), lighting systems (headlights, taillights, interior lights), wiring diagrams for all circuits, fuse box locations and diagrams, horn, wipers, and washers.
HVAC System:
Air conditioning system (refrigerant type, servicing, leak detection), heating system, blower motor, climate control panel, diagnosis of air conditioning faults.
Body And Frame:
Body panel removal and installation, door mechanisms, hood and tailgate, interior trim, bumper assemblies, chassis diagnostics and repair procedures.
Safety Restraints:
Airbag system components, SRS module, seat belt mechanisms, diagnosis of airbag system faults, seat belt replacement procedures.
Procedures Included
Maintenance:
Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement, coolant flush and replacement, brake fluid flush, tire rotation, lubrication points.
Troubleshooting:
Diagnostic flowcharts for common drivability issues, electrical faults, starting problems, braking concerns, and HVAC malfunctions. Includes symptom-based troubleshooting guides.
Repair Overhaul:
Complete procedures for engine rebuilds, transmission overhauls, brake caliper and master cylinder replacement, suspension component replacement, radiator and cooling fan replacement, alternator and starter motor replacement.
Diagnostics:
On-Board Diagnostics (OBD-II) procedures, reading and clearing DTCs (Diagnostic Trouble Codes), sensor data interpretation, using diagnostic scan tools.
Wiring Diagrams:
Comprehensive, system-specific wiring diagrams for all electrical components, including power distribution, grounds, and signal paths.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid level checks to complete engine and transmission rebuilds. Includes detailed torque specifications, component clearances, and testing procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes
Printable:
Yes
Resolution:
High-resolution for clear readability of diagrams and text
Binding Type
Binding:
N/A (Downloadable)
Paper Type
Paper Quality:
N/A (Downloadable)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EJ253 (Naturally Aspirated), EJ255 (Turbocharged - XT models)
Engine Type:
2.5L SOHC Naturally Aspirated Flat-4 Boxer, 2.5L DOHC Turbocharged Flat-4 Boxer (XT)
Displacement:
2457 cc
Performance
Horsepower Na:
173 hp @ 5600 rpm (EJ253)
Torque Na:
166 lb-ft @ 4000 rpm (EJ253)
Horsepower Turbo:
230 hp @ 5600 rpm (EJ255 - XT)
Torque Turbo:
235 lb-ft @ 3600 rpm (EJ255 - XT)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline, 87 octane (91 octane recommended for XT models)
Emission Control:
Catalytic converter, exhaust gas recirculation (EGR), secondary air injection system (on some models/regions).
🔧 Transmission
Standard
Transmission Type:
5-speed Manual (common), 4-speed Automatic (common)
Optional
Transmission Type Optional:
5-speed Manual, 4-speed Automatic with Manual Shift Mode (available on certain trims/years).
Features
AWD Integration:
Integrated with Symmetrical All-Wheel Drive system.
Gear Ratios:
Specific gear ratios provided in manual based on transmission type and model year.
Transmission Fluid Type:
GL-5 Gear Oil for Manual Transmission, Subaru ATF-HP for Automatic Transmission (refer to manual for specific part numbers and capacities).
📐 Dimensions
Exterior
Length:
Approx. 179.5 inches (4560 mm)
Width:
Approx. 70.1 inches (1780 mm)
Height:
Approx. 65.7 inches (1670 mm)
Wheelbase:
Approx. 103.0 inches (2615 mm)
Ground Clearance:
Approx. 8.1 inches (206 mm)
Weights
Curb Weight Min:
Approx. 3310 lbs (1500 kg) (Manual Transmission)
Curb Weight Max:
Approx. 3615 lbs (1640 kg) (Automatic Transmission, XT models)
Cargo
Cargo Volume Seats Up:
Approx. 38.7 cu ft (1096 L)
Cargo Volume Seats Down:
Approx. 67.7 cu ft (1917 L)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (for relevant model years and configurations)
IIHS Front Overlap Crash:
Good (for relevant model years and configurations)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Eeb:
Electronic Brake-force Distribution (EBD)
Traction Control:
Vehicle Stability Control (VSC) and Traction Control System (TCS) standard on most models.
Passive Features
Airbags:
Driver and front passenger airbags, front side-impact airbags, available side curtain airbags.
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
Head Unit:
Standard AM/FM/CD stereo with auxiliary input. Optional premium audio systems and in-dash CD changers available on higher trims.
Display:
Basic LCD display for audio and climate information. Optional navigation systems available on select models.
Driver Assistance
Cruise Control:
Standard cruise control.
Tire Pressure Monitoring:
Available Tire Pressure Monitoring System (TPMS) on some models.
Connectivity
Auxiliary Input:
Standard 3.5mm auxiliary audio input jack for portable music players.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles (6,000 km) or 3.75 months, or 7,500 miles (12,000 km) or 7.5 months with synthetic oil (refer to manual for specific recommendation based on driving conditions).
Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Spark Plugs:
Replace every 60,000 miles (96,000 km) (NGK Platinum or Iridium recommended).
Timing Belt:
Replace every 105,000 miles (168,000 km) or 7 years (whichever comes first). Crucial for EJ engines due to interference design.
Fluid Specifications
Engine Oil:
SAE 5W-30 (API SN or newer) for naturally aspirated models. SAE 5W-30 or 5W-40 synthetic recommended for turbocharged XT models. Capacity: approx. 4.8 US quarts (4.5 L) with filter.
Coolant:
Subaru Super Coolant (Blue) or equivalent silicate-free ethylene glycol coolant. Capacity: approx. 6.9 US quarts (6.5 L).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Subaru Genuine ATF or equivalent Dexron III/Mercon compatible fluid.
Known Issues
Head Gaskets:
While less prevalent than on earlier generations, minor coolant leaks or external oil seeps from head gaskets can occur on high-mileage naturally aspirated EJ253 engines. The manual will detail inspection and replacement procedures.
Turbo Issues Xt:
Turbocharger wastegate rattle or wear can occur on XT models. Proper maintenance and adherence to oil change intervals are crucial for turbo longevity.
Oil Consumption:
Some EJ engines can exhibit increased oil consumption with age. Regular checks and using the correct oil viscosity are recommended.
Rear Wheel Bearings:
Can wear out over time, leading to humming or grinding noises. The manual provides testing and replacement instructions.
📚 Vehicle History
Brand Heritage
Manufacturer:
Subaru Corporation (formerly Fuji Heavy Industries)
Specialty:
Known for its boxer engines and Symmetrical All-Wheel Drive systems across its entire product line.
Model Evolution
First Generation:
1997-2002 (SF chassis)
Second Generation:
2003-2008 (SG chassis) - This generation saw increased dimensions, improved styling, and revised powertrains. The XT model introduced a turbocharged engine.
Third Generation:
2009-2013 (SH chassis) - Redesigned chassis, new engine options, and updated technology.
Production
Manufacturing Location:
Japan (Gunma Plant)
🏆 Awards & Recognition
Recognitions
Safety Awards:
Consistently received high safety ratings from organizations like IIHS and NHTSA, contributing to Subaru's reputation for safety.
SUV Of The Year:
While specific model year awards vary, the Forester line has been recognized for its all-weather capability and practicality.
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