Subaru Forester 2004 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2004 Codes Chassis Code: SF 👋 Introduction Market Position Category: Compact Crossover SUV Target Audience: Families, outdoor enthusiasts, individuals seeking a...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Category:

Compact Crossover SUV

Target Audience:

Families, outdoor enthusiasts, individuals seeking a versatile and capable all-weather vehicle.

Competitive Analysis

Key Competitors:

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

Key Features

All Wheel Drive:

Standard Subaru Symmetrical All-Wheel Drive system, offering superior traction and stability in varied conditions.

Ground Clearance:

Higher ground clearance than many competitors, enhancing off-road capability and all-weather driving.

Visibility:

Excellent outward visibility due to large windows and upright cabin design.

Practicality:

Spacious interior, versatile cargo area, and good towing capacity for its class.

📋 Manual Details

Coverage Areas

General Coverage:

This manual provides comprehensive repair and maintenance information for the 2004 Subaru Forester. It is designed for technicians and DIY enthusiasts alike, covering all aspects of vehicle service.

Page Count

Total Pages:

Approximately 2000+

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, searchable)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing belt, oil pump, cooling system, lubrication system, fuel injection system, exhaust system.

Engine Electrical:

Ignition system, starter motor, alternator, battery, engine control unit (ECU), sensors (crankshaft position, camshaft position, oxygen, MAP, IAT), fuel pump control, emissions control systems.

Transmission:

Manual Transmission (MT) and Automatic Transmission (AT) overhaul, fluid changes, internal components, shifting mechanisms, torque converter, valve body (AT), transmission control unit (TCU).

Drivetrain:

All-Wheel Drive (AWD) system, viscous coupling unit, center differential, front and rear drive axles, CV joints, wheel bearings, propeller shaft.

Suspension:

Front and rear suspension components, struts, shocks, control arms, stabilizer bars, bushings, wheel alignment specifications, steering system.

Brakes:

Front and rear brake systems (disc brakes), brake fluid specifications, bleeding procedures, caliper overhaul, rotor replacement, parking brake system, Anti-lock Braking System (ABS) components and diagnostics.

Steering:

Power steering system, hydraulic pump, steering rack, steering column, tie rod ends, steering angle sensor (if applicable).

Electrical Body:

Exterior and interior lighting, power windows, power locks, mirrors, windshield wipers and washers, horn, fuse box diagrams, relay locations, body control module (BCM).

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant type and capacity, compressor, condenser, evaporator, blower motor, climate control panel, diagnostics.

Body Chassis:

Body panel removal and installation, door mechanisms, hood, tailgate, bumpers, interior trim, chassis lubrication, rust prevention.

Diagnostics Troubleshooting:

Diagnostic Trouble Codes (DTCs), OBD-II system, symptom-based troubleshooting, wiring diagrams, component testing procedures.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, cabin air filter replacement, spark plug replacement, fluid level checks and top-offs, tire rotation and pressure checks, brake pad inspection.

Major Repairs:

Engine rebuilds, transmission overhauls, head gasket replacement, timing belt replacement, brake system overhaul, suspension component replacement, fuel pump replacement, exhaust system repair.

Component Replacement:

Detailed instructions for replacing virtually all serviceable components, from sensors and actuators to larger assemblies like alternators, starters, and AC compressors.

Wiring Diagrams:

Comprehensive electrical system wiring diagrams for all major circuits, including engine control, lighting, power accessories, and safety systems.

Troubleshooting Guides:

Systematic troubleshooting flowcharts and guides to help diagnose and resolve common and uncommon vehicle problems based on symptoms.

Torque Specifications:

Essential torque values for all critical fasteners, ensuring proper assembly and preventing component damage.

Technical Depth

Depth:

Comprehensive, covering everything from basic owner maintenance tasks to complete engine and transmission rebuilds. Includes detailed diagnostic procedures for complex electronic systems.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format) is the most common for digital manuals, offering searchability and easy printing.

Print Quality

Print Quality:

High-resolution images and clear text for easy readability and accurate reference.

Binding Type

Binding Type:

N/A (for digital format)

Paper Type

Paper Type:

N/A (for digital format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

EJ253 (2.5L SOHC)

Displacement:

2.5 Liters (2457 cc)

Configuration:

Naturally Aspirated, Boxer (Horizontally Opposed) 4-Cylinder

Bore X Stroke:

99.5 mm x 79.0 mm

Compression Ratio:

9.7:1

Valvetrain:

SOHC (Single Overhead Camshaft), 16 Valves (4 valves per cylinder)

Performance

Horsepower:

165 hp @ 5600 rpm

Torque:

166 lb-ft @ 4000 rpm

Fuel System

Induction:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Recommended Octane:

87 Octane (Minimum)

🔧 Transmission

Standard

Type:

5-Speed Manual Transmission (MT)

Optional

Type:

4-Speed Automatic Transmission (AT) with Traction Control System (TCS)

Features

AWD System:

Symmetrical All-Wheel Drive with viscous coupling center differential.

Automatic Transmission Control:

Electronically controlled, adaptive shift logic.

📐 Dimensions

Exterior

Length:

179.9 inches (4570 mm)

Width:

69.7 inches (1770 mm)

Height:

63.0 inches (1600 mm)

Wheelbase:

103.0 inches (2615 mm)

Ground Clearance:

7.7 inches (195 mm)

Interior

Passenger Volume:

Approximately 96.7 cu ft (2738 L)

Cargo

Cargo Volume Behind Rear Seat:

Approximately 27.7 cu ft (784 L)

Cargo Volume With Rear Seat Folded:

Approximately 67.7 cu ft (1917 L)

Weights

Curb Weight Manual:

Approximately 3375 lbs (1531 kg)

Curb Weight Automatic:

Approximately 3415 lbs (1549 kg)

Gross Vehicle Weight Rating Gvwr:

Approximately 4675 lbs (2120 kg)

Towing Capacity:

2400 lbs (1089 kg)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (Driver), 4-Star (Passenger)

NHTSA Side Impact:

4-Star (Front), 3-Star (Rear)

IIHS Frontal Offset:

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS) on automatic transmission models.

Passive Features

Airbags:

Driver and front passenger airbags, available front side-impact airbags.

Seatbelts:

Three-point seatbelts with pretensioners and load limiters for front seats.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Head Unit:

Factory-installed AM/FM stereo with CD player. Higher trims may have premium audio systems.

Speaker System:

Typically 4 or 6 speaker system depending on trim level.

Driver Assistance

Cruise Control:

Standard cruise control.

Stability Control:

Not commonly available or standard on this model year. Traction control on AT models is the primary electronic stability aid.

Connectivity

Auxiliary Input:

May not be standard; often an dealer-installed option or aftermarket addition.

Bluetooth:

Not available from the factory for this model year.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 3 months, whichever comes first (under normal driving conditions). Every 3,000 miles (4,800 km) or 3 months under severe conditions.

Engine Oil Filter Replacement:

With every oil change.

Engine Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Spark Plug Replacement:

Every 105,000 miles (168,000 km) (Iridium type).

Timing Belt Replacement:

Every 105,000 miles (168,000 km) or 7 years, whichever comes first. Includes idler pulleys and tensioner. **Crucial maintenance item.**

Transmission Fluid Change Manual:

Every 30,000 miles (48,000 km) or 24 months.

Transmission Fluid Change Automatic:

Every 30,000 miles (48,000 km) or 24 months (under normal conditions). More frequently under severe use.

Differential Fluid Change:

Every 30,000 miles (48,000 km) or 24 months (front and rear).

Fluid Specifications

Engine Oil Type:

API SG, SH, SJ, SL or ILSAC GF-2, GF-3 energy-conserving 5W-30 or 10W-30

Engine Oil Capacity:

4.5 US quarts (4.3 L) with filter

Coolant Type:

Subaru Genuine Super Coolant (Blue) or equivalent; mix 50/50 with distilled water.

Transmission Fluid Type Manual:

API GL-4, SAE 75W-90 Gear Oil

Transmission Fluid Type Automatic:

Subaru Genuine ATF HP (or equivalent)

Brake Fluid Type:

FMVSS No. 116 DOT 3

Power Steering Fluid Type:

Subaru Genuine Power Steering Fluid or Dexron III/Mercon ATF

Known Issues

Head Gaskets:

While less prone than some earlier models, head gasket seepage can still occur, especially with high mileage or improper cooling system maintenance. The EJ253 is generally more robust than the EJ25D.

Timing Belt Tensioner:

The timing belt tensioner can fail, leading to belt slippage or breakage. Replacement at recommended intervals is critical.

Rear Wheel Bearings:

Rear wheel bearings can wear out prematurely, causing noise and play.

Cv Joints:

Front CV joint boots can tear, leading to grease loss and eventual joint failure. Regular inspection is recommended.

Evap System Leaks:

Leaks in the Evaporative Emission Control (EVAP) system can cause Check Engine Lights (CEL) due to stored DTCs like P0442.

📚 Vehicle History

Brand Heritage

Subaru Core Values:

Known for its engineering prowess, particularly its Boxer engine and Symmetrical All-Wheel Drive system, emphasizing durability, safety, and capability.

Model Evolution

Generation:

Second Generation (SG) - 2003-2008

Previous Generation:

First Generation (SF) - 1997-2002

Production

Manufacturing Location:

Gunma Plant, Japan

🏆 Awards & Recognition

Recognitions

IIHS Award:

Insurance Institute for Highway Safety (IIHS) Top Safety Pick: The 2004 Forester was recognized for its excellent crash test performance.

Consumer Reports Ratings:

Generally well-regarded for reliability and performance, though specific model year ratings should be checked.