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Subaru Forester 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2004 Market Segment: Compact Crossover SUV Generation Generation Code: SG Generation Years: 2003-2008 👋 Introduction Market Position Market Positioning: The 2004...
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Subaru Forester 2004 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Year:
2004
Market Segment:
Compact Crossover SUV
Generation
Generation Code:
SG
Generation Years:
2003-2008
👋 Introduction
Market Position
Market Positioning:
The 2004 Subaru Forester is positioned as a practical, all-wheel-drive (AWD) compact SUV known for its versatility, safety, and go-anywhere capability, appealing to individuals and families seeking a reliable vehicle for diverse weather conditions and light off-road use.
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Mazda Tribute, Ford Escape, Nissan Xterra, Mitsubishi Outlander.
Key Features
Subaru Advantage:
Standard Symmetrical All-Wheel Drive (AWD) system, horizontally opposed 'Boxer' engine for lower center of gravity, excellent visibility, robust build quality.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
Print
Page Count
Estimated Page Count:
Approximately 1500-2000 pages (typical for factory service manuals of this era)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, transmission, driveline (AWD system), exhaust
Chassis:
Suspension (front and rear), steering, brakes (front disc, rear disc), wheels, tires
Electrical:
Battery, charging system, starting system, lighting, ignition system, fuses and relays, dashboard instruments, audio system, power accessories (windows, locks, mirrors), security system
Body:
Exterior body panels, interior trim, doors, windows, seats, HVAC system, body control modules
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Diagnostics:
Troubleshooting charts, symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs)
Repair:
Component removal and installation, adjustments, rebuilding procedures
Technical Specifications:
Torque specifications, clearances, measurements, wiring diagrams, exploded views
Technical Depth
Depth Level:
Comprehensive: Covers basic maintenance, routine service, complex diagnostics, and major component repairs/rebuilds.
📊 Manual Specifications
File Format
Digital Format Options:
Typically available as PDF for digital download or as a physical printed book.
Print Quality
Print Quality Description:
High-quality printing with clear diagrams, schematics, and text.
Binding Type
Binding Type Description:
Durable binding suitable for shop use (e.g., spiral-bound, stitched, or perfect bound).
Paper Type
Paper Type Description:
Durable, often glossy or semi-gloss paper to withstand shop environment and repeated use.
⚙️ Engine Specifications
Primary Engine
Engine Code:
EJ253
Engine Type:
2.5L Naturally Aspirated Flat-4 (Boxer) SOHC
Performance
Horsepower:
165 hp @ 5,600 rpm (approximate)
Torque:
166 lb-ft @ 3,600 rpm (approximate)
Fuel System
Fuel System Type:
Electronic Port Fuel Injection (PFI)
Fuel Type:
Unleaded Gasoline (87 octane minimum)
Engine Management
Engine Control Unit:
ECU/ECM (Engine Control Module)
Cooling System
Coolant Capacity:
6.8 US Quarts (6.4 Liters) - check manual for exact capacity
Lubrication System
Oil Capacity:
4.8 US Quarts (4.5 Liters) with filter change - check manual for exact capacity
Recommended Oil Viscosity:
SAE 5W-30 (check manual for temperature-dependent recommendations)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission
Features
AWD System:
Symmetrical All-Wheel Drive (AWD) - full-time system with viscous coupling limited-slip center differential for manual transmission; active AWD for automatic transmission.
Fluid Specifications
Manual Transmission Fluid Type:
API GL-5 SAE 75W-90 (Subaru Genuine Gear Oil recommended)
Automatic Transmission Fluid Type:
Subaru ATF-HP (High Performance) or equivalent.
📐 Dimensions
Exterior
Length:
177.0 inches (4496 mm)
Width:
69.7 inches (1770 mm)
Height:
63.0 inches (1600 mm)
Wheelbase:
103.0 inches (2616 mm)
Ground Clearance:
7.7 inches (196 mm)
Interior
Passenger Volume:
Approximately 97.1 cubic feet (2749 Liters)
Cargo
Cargo Volume Rear Seats Up:
Approximately 31.1 cubic feet (881 Liters)
Cargo Volume Rear Seats Down:
Approximately 64.6 cubic feet (1829 Liters)
Weights
Curb Weight:
3,250 - 3,390 lbs (1474 - 1538 kg), varies by transmission and trim.
Towing Capacity:
2,400 lbs (1089 kg) - check owner's manual for specific towing requirements and limitations.
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
5-Star rating (driver and passenger)
IIHS Front Offset Crash Test:
Good rating
Active Features
Active Safety Features:
Four-wheel disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution).
Passive Features
Passive Safety Features:
Front airbags, front side-impact airbags, front and rear head curtain airbags (on some trims), LATCH (Lower Anchors and Tethers for Children) system, seatbelt pretensioners.
💡 Technology Features
Infotainment
Infotainment System:
Basic audio system with AM/FM radio, CD player, and optional premium audio. May include auxiliary input on some later models or aftermarket upgrades.
Speaker Configuration:
Standard 4-speaker or optional 6-speaker system.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Primarily relies on ABS and AWD for stability. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist were standard.
Connectivity
Connectivity Options:
Basic, typically no Bluetooth or USB connectivity from the factory. Often relies on aftermarket installations for these features.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 3,750 miles (6,000 km) or 3.75 months (severe driving conditions), or 7,500 miles (12,000 km) or 7.5 months (normal driving conditions). Always consult the owner's manual for specific recommendations.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 15 months, or as needed based on driving conditions.
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or 15 months, or as needed.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for iridium-tipped spark plugs. (Consult manual for exact type and interval).
Timing Belt Replacement:
For earlier Subaru models, timing belt replacement was critical (e.g., 105,000 miles). However, the 2004 Forester EJ253 engine *may* be a Non-Interference engine or have a timing chain depending on specific sub-variants; verification via the manual is essential. Assuming it's belt-driven, typically around 105,000 miles / 7 years.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for specific designation).
Power Steering Fluid Type:
Subaru Automatic Transmission Fluid (ATF) or a compatible Dexron III/Mercon type fluid.
Known Issues
Head Gasket Leaks:
While less prevalent than in some earlier Subaru generations, head gasket leaks can still occur on EJ25 engines. Early detection and repair are crucial to prevent engine damage.
Catalytic Converter:
Some models may experience premature catalytic converter failure, often indicated by a check engine light and P0420 code. This can be due to age, fuel issues, or internal engine problems.
Oil Consumption:
Some EJ25 engines can be prone to higher oil consumption. Regular oil level checks are recommended.
📚 Vehicle History
Brand Heritage
Subaru Heritage:
Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history dating back to the 1910s. It is renowned for its engineering prowess, particularly its horizontally opposed 'Boxer' engines and its pioneering adoption of all-wheel-drive technology in passenger vehicles.
Model Evolution
Forester Introduction:
The Subaru Forester was first introduced for the 1998 model year as a compact crossover SUV, bridging the gap between a station wagon and an SUV. It quickly gained popularity for its unique blend of car-like handling and SUV utility, coupled with standard AWD.
Sg Generation Overview:
The SG generation (2003-2008) saw a significant redesign over the previous SF generation. It adopted a more conventional SUV-like styling with a higher roofline and a bolder grille. This generation also introduced a longer wheelbase and wider track for improved stability and interior space.
Production
Production Locations:
Primarily manufactured in Gunma, Japan.
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
The 2004 Subaru Forester received 'Good' ratings in IIHS front-offset crash tests, contributing to its reputation for safety. While not explicitly labeled 'Top Safety Pick' for this specific year in the same way modern awards are, its performance was commendable.
Ratings
Consumer Reports Reliability:
Reliability ratings can vary by model year and specific components. Consult historical Consumer Reports data for detailed insights, but generally Subaru vehicles are considered reliable with a focus on powertrain durability.
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