🏷️ Basic Information

Make:

Subaru

Model:

Forester

Model Years Covered:

2003, 2004, 2005

Generation:

Second Generation (SG)

Chassis Codes:

SG5, SG9

👋 Introduction

Market Position:

The Subaru Forester, particularly in its second generation, solidified its position as a practical and capable compact SUV known for its standard All-Wheel Drive system and wagon-like driving dynamics, appealing to a segment seeking versatility and all-weather capability.

Competitive Analysis:

Competed against vehicles like the Honda CR-V, Toyota RAV4, Ford Escape, and Mazda Tribute, differentiating itself with Subaru's signature AWD and often a more car-like driving feel compared to truck-based SUVs.

Key Features:

Standard Symmetrical All-Wheel Drive, horizontally opposed ('boxer') engines, comfortable ride, good visibility, ample cargo space for its class.

📋 Manual Details

Coverage Areas:

All systems, including engine, transmission, drivetrain, chassis, body, electrical, HVAC, and emissions.

Page Count:

Estimated 2000+ pages (typical for comprehensive factory service manuals of this era).

Manual Type:

Factory Service and Repair Workshop Manual

Language:

English

Format:

Print

📖 Manual Coverage

Engine:

2.5L Naturally Aspirated (EJ253) and 2.5L Turbocharged (EJ255/EJ257 - XT models).

Transmission:

5-speed Manual, 4-speed Automatic.

Drivetrain:

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

Chassis And Suspension:

Front and rear suspension (struts, control arms, sway bars), steering system, wheel bearings, hub assemblies.

Brakes:

Front disc brakes (ventilated), rear disc brakes, ABS system, parking brake.

Electrical System:

Battery, charging system, starting system, ignition system, lighting, power accessories, wiring diagrams.

Body And Exterior:

Body panels, doors, glass, bumpers, trim, sunroof, roof rails.

Interior:

Seats, dashboard, interior trim, airbags, seatbelts.

HVAC:

Heating, ventilation, and air conditioning system components and operation.

Emissions Control:

Catalytic converter, EVAP system, EGR system, emissions-related sensors.

Diagnostics:

OBD-II system, diagnostic trouble codes (DTCs), troubleshooting procedures.

Maintenance:

Oil and filter change, air filter replacement, cabin air filter replacement, spark plug replacement, fluid level checks and changes.

Repair:

Engine component replacement (e.g., alternator, starter, water pump, head gaskets), transmission service, brake pad and rotor replacement, suspension component replacement, electrical component diagnosis and replacement.

Troubleshooting:

Step-by-step diagnostic procedures for common and complex issues, including intermittent faults.

Specifications:

Torque specifications for all fasteners, fluid capacities, engine timing procedures, component tolerances.

Wiring Diagrams:

Detailed electrical wiring diagrams for all vehicle systems.

Technical Depth:

Comprehensive, covering basic maintenance to complex internal engine and transmission repairs, including diagnostic strategies.

📊 Manual Specifications

File Format:

Likely a high-resolution scan of the original printed manual.

Print Quality:

Original Factory Quality - designed for clarity and detail.

Binding Type:

Typically perfect bound or spiral bound for ease of use in a workshop environment.

Paper Type:

Durable paper stock suitable for workshop conditions.

⚙️ Engine Specifications

Engine Displacement Na:

2.5 Liters (2457cc)

Engine Type Na:

2.5L SOHC EJ253 Naturally Aspirated Flat-4 (Boxer)

Engine Horsepower Na:

Approx. 165 hp @ 5600 rpm

Engine Torque Na:

Approx. 166 lb-ft @ 4000 rpm

Engine Displacement Turbo:

2.5 Liters (2457cc)

Engine Type Turbo:

2.5L DOHC EJ255/EJ257 Turbocharged Flat-4 (Boxer)

Engine Horsepower Turbo:

Approx. 210-230 hp @ 5600 rpm (depending on specific XT trim/year)

Engine Torque Turbo:

Approx. 235-250 lb-ft @ 3000-4000 rpm (depending on specific XT trim/year)

Compression Ratio Na:

9.7:1

Compression Ratio Turbo:

8.2:1 (EJ255/EJ257)

Fuel Type:

Unleaded Gasoline (Premium unleaded recommended for Turbo models)

Fuel Delivery:

Multi-port Fuel Injection (MPI)

ECU Type:

Engine Control Unit (ECU) with integrated immobilizer.

🔧 Transmission

Standard Transmission:

5-Speed Manual

Optional Transmission:

4-Speed Automatic (with lock-up torque converter)

AWD System:

Symmetrical All-Wheel Drive (Active Torque Split AWD for automatics, Viscous Coupling Limited Slip Center Differential for manuals).

Manual Transmission Fluid:

API GL-5, SAE 75W-90 (Subaru extra-S or equivalent recommended)

Automatic Transmission Fluid:

Subaru ATF-HP (or equivalent Dexron III/Mercon compatible fluid, check manual for exact spec)

📐 Dimensions

Wheelbase:

Approx. 103.1 inches (2619 mm)

Length:

Approx. 177.0 inches (4496 mm)

Width:

Approx. 69.7 inches (1770 mm)

Height:

Approx. 63.2 inches (1605 mm)

Ground Clearance:

Approx. 8.1 inches (206 mm)

Cargo Volume Seats Up:

Approx. 30.0 cubic feet (850 liters)

Cargo Volume Seats Down:

Approx. 67.7 cubic feet (1917 liters)

Curb Weight:

Approx. 3200 - 3500 lbs (1450 - 1590 kg), varies by trim and transmission

Towing Capacity:

Typically rated up to 2000 lbs (907 kg), consult specific model documentation for exact rating.

Wheel Bolt Pattern:

5x100

Tire Sizes:

Commonly P215/60R16, P225/55R17 (varies by trim)

🛡️ Safety Features

NHTSA Front Impact Driver:

5-star (2003-2008 models generally rated highly)

NHTSA Front Impact Passenger:

5-star (2003-2008 models generally rated highly)

IIHS Frontal Offset:

Good (for applicable years)

Active Safety:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Brake Assist.

Passive Safety:

Driver and front passenger airbags, side curtain airbags (available on some trims), front and rear crumple zones, body-structure integrity.

💡 Technology Features

Infotainment System:

Basic infotainment systems typically included AM/FM stereo, CD player, and optional cassette player. Speaker configurations varied by trim.

Driver Assistance Features:

Standard ABS, optional cruise control. Advanced driver-assistance systems (ADAS) were not common in this era.

Connectivity Options:

Limited connectivity, primarily focusing on audio input. Optional satellite radio availability.

🔧 Maintenance

Oil Change Interval:

Every 3,750 miles or 3 months (under severe driving conditions) or 7,500 miles/6 months (under normal conditions). Refer to manual for exact specification.

Engine Air Filter Interval:

Every 15,000 miles or 12 months.

Spark Plug Replacement Na:

Approx. 60,000 miles for iridium-tipped plugs.

Spark Plug Replacement Turbo:

Approx. 30,000-60,000 miles for specific turbo plugs, consult manual.

Timing Belt Interval:

Critical: 105,000 miles or 7 years (for models equipped with a timing belt).

Coolant Type:

Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid:

Subaru Genuine Power Steering Fluid or Dexron III/Mercon compatible fluid.

Engine Oil Capacity Na:

Approx. 4.8 US quarts (4.5 liters) with filter change for 2.5L EJ253.

Engine Oil Capacity Turbo:

Approx. 4.8 US quarts (4.5 liters) with filter change for 2.5L Turbocharged engines.

Engine Oil Viscosity:

5W-30 (for most climates, refer to manual for specific recommendations).

Known Issues:

Head gasket leaks (especially on early EJ25 engines, though less prevalent on this generation than previous ones), catalytic converter failure (due to oil consumption), premature wheel bearing wear, potential for minor oil leaks from valve cover gaskets and oil pan gaskets.

Turbo Specific Issues:

Turbocharger bearing wear, intercooler leaks, potential for oil sludge buildup if maintenance is neglected on turbocharged models.

📚 Vehicle History

Brand Heritage:

Subaru, known for its engineering prowess in aviation and its commitment to the boxer engine and All-Wheel Drive, has consistently produced vehicles with distinctive character and capability.

Model Evolution:

The second generation (SG) Forester, introduced for the 2003 model year, received a significant redesign with a larger body, improved interior, and updated styling, while retaining the core Subaru values of AWD and practicality. It built upon the success of the first generation.

Production Years:

2003-2008 (Second Generation)

Manufacturing Locations:

Mainly produced in Japan (Gunma Prefecture).

🏆 Awards & Recognition

Recognitions:

The second-generation Forester was generally well-regarded for its practicality and AWD capability, often praised by automotive journalists for its utility as a small family vehicle. It earned consistent praise for its safety ratings.