Subaru Forester 2005 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2005 Codes Chassis Code: SG 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience: Families, outdoor enthusiasts, individuals seeking AWD...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Target Audience:

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

Competitive Analysis

Competitors:

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

Key Features

All Wheel Drive:

Standard Subaru Symmetrical All-Wheel Drive system provides enhanced traction and stability.

Ground Clearance:

Higher than average ground clearance for its class, aiding in off-road capability.

Practicality:

Spacious interior, versatile cargo area, wagon-like utility.

Engine Options:

Reliable Subaru Boxer engines known for their unique sound and low center of gravity.

📋 Manual Details

Coverage Areas

Coverage:

Complete factory service and repair information for the 2005 Subaru Forester.

Page Count

Estimated Pages:

Hundreds of pages (specific count not provided, but implies comprehensive coverage).

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair procedures, and specifications for EJ253 (2.5L SOHC) and EJ255 (2.5L DOHC Turbo - XT models) engines.

Fuel System:

Fuel injection, fuel pump, injectors, fuel lines, evaporative emissions control (EVAP).

Ignition System:

Ignition coils, spark plugs, timing, ignition control module (ICM).

Exhaust System:

Catalytic converter, mufflers, exhaust manifolds, O2 sensors.

Cooling System:

Radiator, thermostat, water pump, cooling fans, coolant specifications.

Transmission Manual:

Clutch, gearbox, shift linkage, fluid specifications, repair procedures for 5-speed manual transmissions.

Transmission Automatic:

Torque converter, valve body, planetary gears, transmission control module (TCM), fluid specifications, repair procedures for 4-speed automatic transmissions (e.g., 4EAT).

Drivetrain:

All-Wheel Drive (AWD) system, front and rear differentials, driveshafts, CV joints, axle shafts.

Suspension:

Front struts, rear shock absorbers, control arms, sway bars, bushings, wheel alignment specifications.

Steering:

Power steering system, steering rack, tie rods, steering column, fluid type.

Brakes:

Front and rear disc brakes, brake pads, rotors, calipers, master cylinder, brake fluid specifications, ABS system diagnostics.

Electrical System:

Battery, alternator, starter, wiring diagrams, fuses, relays, lighting system.

Body And Chassis:

Body panels, doors, fenders, hood, tailgate, interior trim, chassis components, rust prevention.

HVAC:

Air conditioning system, heater core, blower motor, refrigerant, climate control diagnostics.

Restraints:

Airbag system, SRS module, seatbelt pre-tensioners.

Instrument Panel:

Gauges, warning lights, dashboard indicators, and their functions.

Lighting:

Headlights, taillights, interior lights, fog lights, bulb types and replacement.

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, belt inspection and replacement, spark plug service, brake fluid flush.

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnosis, engine performance issues.

Repair:

Engine component overhaul, transmission rebuilding, suspension component replacement, brake system repair, electrical component repair.

Disassembly Reassembly:

Step-by-step instructions for removing and installing major vehicle components.

Specifications:

Torque specifications for all fasteners, clearances, fluid capacities, engine timing, wheel alignment angles.

Diagnostic Codes:

Listing and explanation of OBD-II diagnostic trouble codes (DTCs) and specific Subaru diagnostic codes.

Wiring Diagrams:

Detailed electrical system wiring diagrams for all major systems, crucial for troubleshooting.

Tire Rotation:

Recommended procedures and patterns for tire rotation.

Wheel Alignment:

Specifications for front and rear wheel alignment parameters.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics.

Engine Rebuild:

Includes specifications and procedures for full engine disassembly, inspection, and reassembly.

Transmission Repair:

Covers internal transmission repairs, valve body service, and torque converter replacement for both manual and automatic transmissions.

Body Repair:

Information on body panel replacement, dent repair, and structural component repair.

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

Printable in its entirety or selected pages, high-resolution for clear text and diagrams.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

Searchability

Text Search:

Likely text-searchable PDF for quick information retrieval.

Accessibility

Downloadable:

Yes, downloadable PDF format.

Content Type

Illustrations Diagrams:

Contains numerous diagrams, illustrations, and schematics to aid in repairs.

⚙️ Engine Specifications

Primary Engine

Engine Code Naturally Aspirated:

EJ253

Engine Description Naturally Aspirated:

2.5L (2457cc) SOHC EJ253 Boxer-4

Bore X Stroke Naturally Aspirated:

99.5 mm x 79.0 mm

Compression Ratio Naturally Aspirated:

9.7:1

Horsepower Naturally Aspirated:

165 hp @ 5600 rpm

Torque Naturally Aspirated:

166 lb-ft @ 4000 rpm

Turbocharged Engine

Engine Code Turbocharged:

EJ255

Engine Description Turbocharged:

2.5L (2457cc) DOHC EJ255 Boxer-4 with Turbocharger

Horsepower Turbocharged:

210 hp @ 5600 rpm (Forester 2.5XT)

Torque Turbocharged:

235 lb-ft @ 3600 rpm (Forester 2.5XT)

Performance

Fuel Requirement:

87 octane unleaded gasoline (91 octane recommended for XT models).

Fuel System

Fuel Delivery:

Multi-point Electronic Fuel Injection (MPI)

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission (available on non-turbo and XT models).

Optional

Transmission Type Optional:

4-Speed Automatic Transmission with Overdrive (available on non-turbo models).

Features

AWD Integration:

Symmetrical All-Wheel Drive system integrated with transmission for optimal power distribution.

Fluid Specifications

Automatic Transmission Fluid:

Subaru ATF HP (or equivalent specified by manufacturer).

Manual Transmission Fluid:

API GL-5, SAE 75W-90 gear oil (Subaru Extra-S or equivalent).

📐 Dimensions

Exterior

Length:

Approx. 178.1 inches (4524 mm)

Width:

Approx. 69.7 inches (1770 mm)

Height:

Approx. 63.0 inches (1600 mm)

Wheelbase:

Approx. 103.1 inches (2619 mm)

Ground Clearance:

Approx. 8.0 inches (203 mm)

Weights

Curb Weight Approx:

3300 - 3550 lbs (1497 - 1610 kg) depending on trim and transmission.

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

5-star (2005 model year ratings).

NHTSA Frontal Passenger:

5-star (2005 model year ratings).

NHTSA Side Driver:

4-star (2005 model year ratings).

NHTSA Side Passenger:

4-star (2005 model year ratings).

NHTSA Rollover:

4-star (2005 model year ratings).

Active Features

Standard Anti-lock Braking System (ABS).

E Brake Force Distribution:

Electronic Brake-force Distribution (EBD).

Passive Features

Airbags:

Driver and front passenger airbags, optional side-impact airbags and curtain airbags.

Seatbelts:

3-point seatbelts with pretensioners and force limiters.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM/CD stereo with available CD changer. Options for premium audio systems.

Driver Assistance

Cruise Control:

Standard cruise control.

Connectivity

Auxiliary Input:

Optional auxiliary audio input jack.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months (normal driving) or 7,500 miles or 7.5 months (severe driving/synthetic oil).

Engine Oil Capacity:

4.5 US quarts (4.3 liters) with filter for 2.5L SOHC, 4.8 US quarts (4.5 liters) with filter for 2.5L DOHC Turbo.

Spark Plug Replacement:

Typically around 60,000 miles for iridium plugs.

Timing Belt Replacement:

Not applicable for the 2005 Forester, as it uses a timing chain.

Fluid Specifications

Engine Oil Spec:

API SN or higher, ILSAC GF-5 or higher, SAE 5W-30 (check owner's manual for variations).

Coolant Spec:

Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant, pre-mixed 50/50 with distilled water.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Known Issues

Head Gaskets:

While less prevalent than in earlier EJ engines, head gasket leaks can still occur, especially in high-mileage or poorly maintained vehicles. The manual provides diagnostic and repair procedures.

Turbo Oil Lines Xt Models:

Turbocharged XT models can be prone to cracked oil feed lines, leading to turbo failure. Regular inspection and replacement are recommended. The manual details their location and replacement.

Rear Wheel Bearings:

Rear wheel bearings can sometimes wear out, causing noise. The manual covers their diagnosis and replacement.

📚 Vehicle History

Brand Heritage

Manufacturer:

Subaru Corporation, known for its pioneering use of All-Wheel Drive in passenger vehicles.

Model Evolution

Generation:

Second generation (SG), produced from 2003-2008.

Facelift:

Received a mid-cycle refresh for the 2006 model year, so the 2005 model is part of the pre-facelift design.

Production

Manufacturing Location:

Japan (Ota, Gunma).

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

While specific awards vary by year and test, the Forester consistently received good to excellent safety ratings from IIHS and NHTSA for its generation.

Kbb Best Resale Value:

Forester often cited for strong resale value within its segment.