Subaru Forester 2003 2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation: Second Generation (SG) Model Years Covered: 2003, 2004 Codes Chassis Code: SG5, SG9 👋 Introduction Market Position Segment: Compact Crossover SUV...

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标签: 2003 2004 Car Cars Forester Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Generation:

Second Generation (SG)

Model Years Covered:

2003, 2004

Codes

Chassis Code:

SG5, SG9

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Key Selling Points:

Standard Symmetrical AWD, practicality, off-road capability for its class, robust build.

Competitive Analysis

Key Competitors:

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

Key Features

Defining Features:

The second-generation Forester continued Subaru's legacy of offering standard All-Wheel Drive, a horizontally-opposed 'boxer' engine for a lower center of gravity, and a practical, family-oriented design.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete service and repair instructions for the 2003-2004 Subaru Forester.

Engine Coverage:

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

Transmission Coverage:

4-speed Automatic, 5-speed Manual

Drivetrain Coverage:

Symmetrical All-Wheel Drive (AWD) system, differentials, driveshafts.

Body And Chassis Coverage:

Body panels, frame, suspension, steering, brakes, exhaust.

Electrical Coverage:

Wiring diagrams, lighting, instrumentation, audio, comfort systems, ECU diagnostics.

Page Count

Estimated Page Count:

1500-2000+ (typical for comprehensive workshop manuals)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, engine electrical, fuel & emissions, cooling, lubrication, ignition, exhaust systems.

Drivetrain And Suspension:

Clutch, transmission (manual & automatic), transfer case, driveshafts, differentials, axles, front & rear suspension components, wheel bearings.

Brakes And Steering:

Brake system hydraulics, ABS, parking brake, steering gear, power steering system.

Electrical And Electronics:

Battery, charging system, starting system, lighting, instruments, wipers, horn, power windows/locks, SRS (airbag) system, immobilizer, ECU/ECM diagnostics.

Body And Interior:

Body exterior (panels, doors, glass), interior trim, seats, HVAC (Heating, Ventilation, and Air Conditioning) system.

Procedures Included

Maintenance:

Routine maintenance tasks, fluid changes, filter replacements, inspection points.

Repair:

Detailed step-by-step repair procedures for all major components and systems.

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs), diagnostic procedures for electrical and mechanical faults.

Disassembly And Assembly:

Complete instructions for component removal, disassembly, inspection, repair, and reassembly.

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and wiring schematics.

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Printability:

Printable

Print Quality

Image Resolution:

High-resolution, clear diagrams and images.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Naturally Aspirated:

EJ253

Engine Displacement Naturally Aspirated:

2.5 Liters (2457 cc)

Engine Configuration Naturally Aspirated:

Horizontally-opposed (Boxer), 4-cylinder, SOHC (Single Overhead Cam)

Engine Power Naturally Aspirated:

165 hp @ 5600 rpm

Engine Torque Naturally Aspirated:

166 lb-ft @ 3600 rpm

Turbocharged Engine

Engine Code Turbocharged:

EJ255

Engine Displacement Turbocharged:

2.5 Liters (2457 cc)

Engine Configuration Turbocharged:

Horizontally-opposed (Boxer), 4-cylinder, DOHC (Double Overhead Cam), Turbocharged

Engine Power Turbocharged:

210 hp @ 5600 rpm (XT models)

Engine Torque Turbocharged:

235 lb-ft @ 3600 rpm (XT models)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Recommended Octane Naturally Aspirated:

87 AKI

Recommended Octane Turbocharged:

91 AKI (Premium)

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission

Optional

Transmission Type Optional:

4-speed Automatic Transmission

Features

Drivetrain System:

Symmetrical All-Wheel Drive (AWD) - standard on all models.

AWD System Details:

Viscous coupling center differential (manual) or electronically controlled multi-plate transfer clutch (automatic) distributing torque front to rear.

📐 Dimensions

Exterior

Wheelbase:

103.1 inches (2619 mm)

Length:

173.4 inches (4404 mm)

Width:

69.7 inches (1770 mm)

Height:

63.0 inches (1600 mm)

Ground Clearance:

8.1 inches (206 mm)

Weights

Curb Weight Manual:

Approx. 3285 lbs (1490 kg)

Curb Weight Automatic:

Approx. 3350 lbs (1520 kg)

Gross Vehicle Weight Rating:

Approx. 4600 lbs (2087 kg)

Cargo

Cargo Volume Behind Rear Seat:

32.1 cu ft (0.909 m³)

Cargo Volume With Rear Seat Folded:

63.0 cu ft (1.784 m³)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver Rating:

4 Stars (2003 Model Year)

NHTSA Frontal Passenger Rating:

4 Stars (2003 Model Year)

NHTSA Side Front Driver Rating:

5 Stars (2003 Model Year)

NHTSA Side Front Passenger Rating:

5 Stars (2003 Model Year)

NHTSA Side Rear Driver Rating:

4 Stars (2003 Model Year)

NHTSA Side Rear Passenger Rating:

4 Stars (2003 Model Year)

IIHS Frontal Offset Rating:

Good (2003 Model Year)

Active Features

Braking System:

Front ventilated discs, Rear solid discs. Anti-lock Braking System (ABS) standard.

Traction Control:

Optional (usually on higher trims or AWD models).

Passive Features

Airbags:

Front dual-stage airbags. Optional front side-impact airbags.

Seatbelts:

3-point seatbelts with pretensioners and force limiters in all seating positions.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player, often with optional premium audio systems and satellite radio readiness.

Display Technology:

Basic digital or analog instrument cluster, climate control displays. No touchscreens or complex infotainment systems typical of modern vehicles.

Driver Assistance

Standard Anti-lock Braking System (ABS).

Cruise Control:

Standard on most trims.

Connectivity

Auxiliary Input:

Rare, if present, typically an aftermarket addition or limited to specific trim levels.

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 15 months.

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or 15 months.

Spark Plug Replacement:

Every 60,000 miles (96,000 km) for standard models; Platinum/Iridium plugs may have longer intervals, consult manual.

Coolant Flush:

Every 30,000 miles (48,000 km) or 30 months.

Transmission Fluid Change Automatic:

Every 30,000 miles (48,000 km) or 30 months (severe service).

Transmission Fluid Change Manual:

Every 60,000 miles (96,000 km) or 60 months.

Fluid Specifications

Engine Oil Type:

SAE 5W-30, API Service SL or SM rated, ILSAC GF-3 or GF-4 certified.

Engine Oil Capacity:

Approx. 4.8 US quarts (4.5 Liters) with filter change (EJ253).

Coolant Type:

Subaru Super Coolant (Blue) or equivalent (Ethylene Glycol based, 50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 or DOT 4.

Transmission Fluid Automatic:

Subaru ATF-HP (High Performance) or equivalent.

Transmission Fluid Manual:

SAE 75W-90 GL-5 gear oil.

Differential Fluid Front Rear:

SAE 75W-90 GL-5 gear oil.

Known Issues

Head Gaskets:

While less prevalent than in earlier EJ engines, head gasket leaks can still occur, especially in higher-mileage vehicles or those subjected to high heat or stress.

Catalytic Converter:

Can degrade over time, leading to reduced engine performance and potential check engine lights.

Radiator And Hoses:

Plastic radiator tanks can become brittle and crack; rubber hoses can degrade and leak.

Clutch Wear:

Typical wear item in manual transmission vehicles, requiring replacement based on driving habits.

Automatic Transmission Issues:

Some models may experience occasional rough shifting or hesitation; regular fluid maintenance is crucial.

📚 Vehicle History

Brand Heritage

Subaru Dna:

Subaru is renowned for its Symmetrical All-Wheel Drive and horizontally-opposed 'boxer' engines, which contribute to enhanced traction, stability, and a lower center of gravity.

Model Evolution

Generation Introduction:

The second generation Forester (SG) was introduced for the 2003 model year, replacing the first generation (SF). It featured a significant redesign with a stiffer chassis and updated styling.

Mid-Cycle Refresh:

A minor facelift occurred for the 2006 model year, but this manual specifically covers the pre-facelift 2003-2004 models.

Production

Manufacturing Location:

Japan (Gunma Plant)

🏆 Awards & Recognition

Recognitions

Car And Driver Towing Award:

Forester often cited for its capability and AWD system in comparisons.

Ratings

Consumer Reports Reliability:

Generally considered average to good, with some model years showing better reliability than others. Specific issues noted, as detailed in maintenance section.