🏷️ Basic Information

Make:

Subaru

Model:

Forester

Year:

2004

Chassis Code:

SG

Engine Codes:

EJ253 (2.5L SOHC NA), EJ255 (2.5L DOHC Turbo)

👋 Introduction

Segment:

Compact SUV / Crossover Utility Vehicle (CUV)

Key Differentiators:

Symmetrical All-Wheel Drive (standard), boxer engine, excellent visibility, practical cargo space, reputation for durability and safety.

Competitors 2004:

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

Chassis Design:

Second generation (SG) Forester, known for improved ride comfort and refinement over its predecessor.

Powertrain Standard:

Standard Symmetrical All-Wheel Drive system, enhancing traction and stability in various weather conditions.

📋 Manual Details

Primary Coverage:

North America (NA) and Global Markets

Secondary Coverage:

Specific regional variations may exist, though this manual provides a comprehensive base.

Estimated Pages:

1500-2000 (typical for comprehensive factory service manuals of this era)

Type:

Factory Service Manual (FSM) / Repair Manual

Language:

English

Format:

Likely Digital (PDF) for modern distribution, but originally printed.

📖 Manual Coverage

Powertrain:

Engine mechanical, engine management (ECU, fuel injection, ignition), emissions control, exhaust systems, cooling system, lubrication system, manual transmission, automatic transmission, drive shafts, differentials.

Chassis:

Suspension (front and rear), steering system, braking system (hydraulic, ABS, parking brake), wheels and tires.

Electrical:

Battery, charging system, starting system, lighting systems (headlights, taillights, interior), instrument cluster, audio systems, power accessories (windows, locks, mirrors), HVAC controls, airbag system (SRS), body control module (BCM), engine control module (ECM), transmission control module (TCM).

Body:

Body panels, doors, hood, tailgate, glass, seals, interior trim, seating, bumpers, exterior trim.

Maintenance:

Scheduled maintenance intervals, fluid changes (oil, coolant, transmission, brake, power steering), filter replacements, spark plug service, belt inspection and replacement.

Diagnostics:

Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) and their meanings, testing procedures for sensors and actuators, use of OBD-II scan tools.

Repair:

Component removal and installation, disassembly and reassembly of major systems (e.g., engine rebuild, transmission overhaul, brake caliper replacement, suspension component replacement), body repair procedures.

Technical Specifications:

Torque specifications for all fasteners, clearances and tolerances, diagnostic values, wiring diagrams, vacuum diagrams, component specifications.

Depth:

Comprehensive, covering everything from basic fluid checks and filter changes to complete engine and transmission overhauls, including advanced electrical diagnostics and bodywork.

📊 Manual Specifications

Digital Format Details:

Searchable PDF, allowing quick access to information. Optimized for digital viewing and printing.

Print Quality Notes:

If offered as a printed manual, expect high-quality paper and clear, legible print of diagrams and text. High-resolution scans of original factory documentation.

Printed Binding:

Typically spiral-bound or perfect-bound for durability and ease of use on a workbench.

Printed Paper:

Durable paper stock designed to withstand workshop environments. May include laminated pages for frequently referenced diagrams.

⚙️ Engine Specifications

Engine Type:

Naturally Aspirated Flat-4 (Boxer)

Displacement:

2.5 Liters (2457 cc)

Engine Code Na:

EJ253

Valvetrain Na:

SOHC (Single Overhead Camshaft), 4 valves per cylinder

Horsepower Na:

165 hp @ 5600 rpm (approx.)

Torque Na:

175 lb-ft @ 4000 rpm (approx.)

Engine Type Turbo:

Turbocharged Flat-4 (Boxer)

Displacement Turbo:

2.5 Liters (2457 cc)

Engine Code Turbo:

EJ255

Valvetrain Turbo:

DOHC (Double Overhead Camshaft), 4 valves per cylinder

Horsepower Turbo:

210 hp @ 5600 rpm (approx. for XT models)

Torque Turbo:

235 lb-ft @ 3600 rpm (approx. for XT models)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Fuel:

87 Octane Unleaded (NA), 91 Octane Unleaded (Turbocharged models - XT)

🔧 Transmission

Transmission Type:

5-Speed Manual Transmission

Transmission Type Optional:

4-Speed Automatic Transmission with SportShift (select models/trims)

AWD System:

Symmetrical All-Wheel Drive with either a viscous coupling center differential (manual) or electronically controlled multi-plate transfer clutch (automatic).

Manual Transmission Fluid:

API GL-5, SAE 75W-90 Gear Oil (Check manual for exact Subaru spec, e.g., Subaru Extra-S Gear Oil)

Automatic Transmission Fluid:

Subaru Genuine ATF HP or equivalent (e.g., Dexron III/Mercon compatible fluid, consult manual for exact spec)

📐 Dimensions

Length:

Approximately 176.9 inches (4495 mm)

Width:

Approximately 70.1 inches (1780 mm)

Height:

Approximately 63.4 inches (1610 mm) (unloaded)

Wheelbase:

Approximately 103.1 inches (2619 mm)

Ground Clearance:

Approximately 7.5 inches (190 mm)

Curb Weight:

Approximately 3100-3400 lbs (1406-1542 kg), varies by trim and transmission

Cargo Volume Behind Rear Seats:

Approximately 32.1 cubic feet (0.91 cubic meters)

Cargo Volume With Rear Seats Folded:

Approximately 66.1 cubic feet (1.87 cubic meters)

🛡️ Safety Features

NHTSA Front Impact:

5 Stars (Driver and Passenger)

NHTSA Side Impact:

4 Stars (Front and Rear Passenger)

IIHS Frontal Offset:

Good (for 2004 models, often rated highly)

Active Safety:

Standard Symmetrical All-Wheel Drive, standard Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD).

Passive Safety:

Driver and front passenger airbags, available side-impact airbags, available front and rear side curtain airbags (depending on trim), three-point seatbelts in all seating positions, LATCH child seat anchors.

💡 Technology Features

Audio System:

Standard AM/FM/CD player with 4 or 6 speakers. Higher trims may offer a premium audio system with subwoofer.

Climate Control:

Manual climate control or optional automatic climate control with micron air filter.

ABS:

Standard Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD).

Traction Control:

Not typically standard on this model, but some later revisions or specific trims might have offered it.

Auxiliary Input:

Not standard; may have been an aftermarket addition or available on higher trims/later production runs of this generation.

🔧 Maintenance

Engine Oil Change Interval:

Every 3,750 miles (6,000 km) or 3.75 months (severe driving) / 7,500 miles (12,000 km) or 7.5 months (normal driving), with synthetic oil recommended for longer intervals. Check manual for specific Subaru recommendations.

Engine Coolant Replacement Interval:

Initial replacement at 60,000 miles (96,000 km) or 4 years, then every 30,000 miles (48,000 km) or 2 years thereafter. Use Subaru Super Coolant (Blue).

Spark Plug Replacement Interval:

Approximately 60,000 miles (96,000 km) for iridium-tipped plugs. Consult manual for exact type and interval.

Engine Oil Specification:

SAE 5W-30 (API Service SL or SM, ILSAC GF-3 or GF-4). Subaru recommends synthetic oil. Check dipstick for exact level.

Engine Coolant Specification:

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

Brake Fluid Specification:

SAE J1703 or FMVSS No. 116 DOT 3

Power Steering Fluid Specification:

Subaru Genuine Power Steering Fluid or equivalent ATF Dexron III/Mercon.

Common Wear Items:

Front struts/shocks (due to AWD and typical usage), brake pads and rotors, exhaust system components (muffler, catalytic converter), rear wheel bearings, clutch wear (manual transmission).

Engine Specific Notes:

Head gasket leaks (though less common on the EJ253/EJ255 compared to earlier EJ22/EJ25 variants), oil consumption (especially if not maintained regularly), turbocharger issues on XT models if maintenance is neglected.

Transmission Specific Notes:

Automatic transmission fluid should be changed regularly to prevent wear. Manual transmissions are generally robust but clutch wear is normal.

Oil Filter Example:

Subaru OEM: 15208AA100 (verify for exact model variant)

Air Filter Example:

Subaru OEM: 16546AA020 (verify for exact model variant)

📚 Vehicle History

Manufacturer Origin:

Japan

Key Brand Philosophy:

Focus on horizontally-opposed engines, All-Wheel Drive, durability, and safety.

Generation:

Second Generation (SG) Forester (2003-2008)

Generation Introduction:

The second generation saw a significant redesign, moving away from the wagon-like appearance to a more distinct SUV profile with a taller greenhouse and improved aerodynamics. Offered in naturally aspirated and turbocharged (XT) variants.

Assembly Location:

Gunma, Japan

🏆 Awards & Recognition

IIHS Top Safety Pick:

The 2004 Forester typically received good ratings from IIHS, often qualifying for 'Best Pick' or similar safety accolades for its segment.

Consumer Reports Ratings:

Historically, Subaru Foresters have been praised for reliability and AWD capability, though specific model year ratings can vary.

Emissions Certification:

Meets EPA and California Air Resources Board (CARB) emissions standards for the model year.