Subaru Forester 2003 2004 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2003-2004 Generation Generation Designation: Second Generation (SG) Codes Chassis Code: SG 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience:...

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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

Year:

2003-2004

Generation

Generation Designation:

Second Generation (SG)

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Target Audience:

Families, outdoor enthusiasts, individuals seeking AWD capability and practicality.

Competitive Analysis

Key Competitors:

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

Key Features

Defining Feature:

Standard Symmetrical All-Wheel Drive system.

Body Style:

Station Wagon/SUV hybrid design.

Practicality:

Spacious interior, ample cargo volume, high ground clearance for its class.

📋 Manual Details

Coverage Areas

Engine Variants Covered:

2.5L Naturally Aspirated EJ253, 2.5L Turbocharged EJ255

Transmission Variants Covered:

4-Speed Automatic (4EAT), 5-Speed Manual

Drivetrain Covered:

Symmetrical All-Wheel Drive (AWD)

Page Count

Total Pages:

3000+

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanicals (EJ253, EJ255), fuel system, ignition system, cooling system, lubrication system, exhaust system, engine control system (ECU/ECM).

Transmission Drivetrain:

Manual transmission (clutch, gearbox, driveshafts), Automatic transmission (torque converter, valve body, planetary gears), differential systems, transfer case, AWD system.

Chassis Suspension Steering:

Front and rear suspension systems (struts, control arms, bushings), steering system (rack and pinion, power steering), wheel bearings, hubs.

Brakes:

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

Electrical Electronics:

Battery, charging system (alternator), starting system, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams, instrument cluster, body control module (BCM).

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, climate control, refrigerant system, blower motor, condenser, evaporator.

Body Interior:

Exterior body panels, doors, windows, sunroof, interior trim, seats, airbags, body sealant and undercoating.

Procedures Included

Maintenance Inspections:

Scheduled maintenance, fluid level checks, filter replacements, belt inspections, brake pad/rotor checks, tire rotations.

Repair Procedures:

Engine overhaul, transmission repair, suspension component replacement, brake caliper overhaul, starter/alternator replacement, body panel repair.

Diagnostics Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnostics, engine performance issues, transmission shifting problems.

Electrical Diagnostics:

Use of multimeters, oscilloscope use for signal analysis, wiring harness testing, sensor circuit testing.

Specifications Tolerances:

Torque specifications for critical fasteners, engine clearances, valve lash adjustments, suspension alignment angles.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid changes and inspections to full engine and transmission rebuilds, advanced electrical diagnostics, and body repairs.

📊 Manual Specifications

File Format

File Format:

Searchability:

Searchable text, allowing quick navigation to specific topics.

Printability:

Printable pages for convenient workshop use.

Print Quality

Image Resolution:

High-resolution images, diagrams, and illustrations.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Naturally Aspirated:

EJ253

Engine Code Turbocharged:

EJ255

Configuration:

Horizontally-opposed (Boxer) 4-cylinder

Displacement Na:

2.5 Liters (2498 cc)

Displacement Turbo:

2.5 Liters (2498 cc)

Performance

Horsepower Na:

165 hp @ 5600 rpm

Torque Na:

166 lb-ft @ 4000 rpm

Horsepower Turbo:

210 hp @ 5600 rpm (Forester XT)

Torque Turbo:

235 lb-ft @ 3600 rpm (Forester XT)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Required Octane Na:

87 Octane Recommended

Required Octane Turbo:

91 Octane Recommended

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Optional

Transmission Type Optional:

4-Speed Automatic Transmission (4EAT)

Features

AWD System Type:

Symmetrical All-Wheel Drive (variable torque distribution for auto, direct coupling for manual)

Automatic Transmission Modes:

Includes 'Snow/Gravel' mode for improved traction in low-grip conditions.

📐 Dimensions

Exterior

Length:

Approx. 178.0 inches (4520 mm)

Width:

Approx. 69.7 inches (1770 mm)

Height:

Approx. 63.0 inches (1600 mm)

Wheelbase:

Approx. 103.0 inches (2615 mm)

Ground Clearance:

Approx. 7.5 inches (190 mm)

Cargo

Cargo Volume Behind Rear Seat:

Approx. 31.4 cu ft (889 L)

Cargo Volume With Rear Seat Folded:

Approx. 68.5 cu ft (1940 L)

Weights

Curb Weight Manual:

Approx. 3230 lbs (1465 kg)

Curb Weight Automatic:

Approx. 3300 lbs (1497 kg)

Towing Capacity:

2400 lbs (1088 kg) (with proper trailer brakes)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating 2003:

4 out of 5 stars

IIHS Frontal Offset Score:

Good (for 2003/2004 models)

IIHS Side Impact Score:

Good (for models equipped with side airbags)

Active Features

Standard Anti-lock Braking System (ABS)

Standard Symmetrical All-Wheel Drive for enhanced traction and stability.

Passive Features

Airbags Front:

Standard front driver and passenger airbags.

Airbags Side:

Optional front side-impact airbags.

Seatbelts:

3-point front and rear seatbelts with pretensioners.

Child Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional premium audio system (e.g., Rockford Fosgate).

Display Type:

Basic LCD screen for radio and climate control information.

Driver Assistance

Cruise Control:

Standard cruise control on most trims.

Traction Control:

Available Traction Control System (TCS) on some models, works in conjunction with AWD.

Connectivity

Auxiliary Input:

Some models may feature an auxiliary audio input jack.

Remote Keyless Entry:

Available on higher trim levels.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3.75 months (severe conditions) / 7,500 miles or 7.5 months (normal conditions), check manual for specifics.

Engine Air Filter Replacement:

Every 15,000 miles or 15 months.

Cabin Air Filter Replacement:

Every 15,000 miles or 15 months.

Spark Plug Replacement Na:

Typically around 60,000 miles (Iridium spark plugs).

Timing Belt Replacement:

Not applicable, utilizes a timing chain.

Fluid Specifications

Engine Oil Type:

SAE 5W-30, API Certified (check specific year/engine for exact viscosity)

Engine Oil Capacity:

Approx. 4.8 US quarts (4.5 L) with filter (EJ253/EJ255)

Coolant Type:

Subaru Super Coolant (Blue) or equivalent Long Life Antifreeze/Coolant (50/50 mix)

Transmission Fluid Manual:

API GL-5, SAE 75W-90 Gear Oil

Transmission Fluid Automatic:

Subaru Genuine ATF HP or DEXRON III/MERCON compatible (verify manual)

Differential Fluid Front:

API GL-5, SAE 75W-90 Gear Oil

Differential Fluid Rear:

API GL-5, SAE 75W-90 Gear Oil (Viscous coupling unit requires specific procedure)

Brake Fluid Type:

DOT 3 or DOT 4 Brake Fluid

Known Issues

Head Gaskets:

While less prevalent than in earlier EJ engines, head gasket seepage can occur. Manual will detail inspection and replacement.

Oil Consumption:

Some models may experience moderate oil consumption. Manual covers checking and top-off procedures.

Rear Differential Noise:

Potential for bearing noise in the rear differential. Manual details inspection and bearing replacement.

Awt Transmission Behavior:

Occasional rough shifting or delayed engagement can occur. Manual provides diagnostic steps.

📚 Vehicle History

Brand Heritage

Subaru Origin:

Japanese manufacturer with a long history in aviation and automotive engineering, known for its boxer engines and AWD systems.

Model Evolution

Forester Introduction:

First generation debuted in 1997.

Second Generation Launch:

Second generation (SG) launched for the 2003 model year, featuring a significant redesign and styling update.

Powertrain Updates Sg:

Introduction of the turbocharged EJ255 engine in the Forester XT model for increased performance.

Production

Manufacturing Location:

Gunma Plant, Japan

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

The Forester often received good ratings from the IIHS, contributing to its reputation for safety in its class.

Edmunds Reviews:

Consistently praised for its practicality, AWD capability, and comfortable ride in contemporary reviews.

Consumer Reports Ratings:

Generally rated as average to above average in predicted reliability for the period.