2004 SUBARU FORESTER Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2004 Chassis Code: SF Series (Second Generation) Market Segment: Compact SUV / Crossover 👋 Introduction Market Position Segment Competitors: Honda CR-V,...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Year:

Chassis Code:

SF Series (Second Generation)

Market Segment:

Compact SUV / Crossover

👋 Introduction

Market Position

Segment Competitors:

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

Forester Differentiation:

Standard Symmetrical All-Wheel Drive, Subaru's Boxer engine layout, reputation for durability and off-road capability (for its class).

Competitive Analysis

Key Selling Points 2004:

Enhanced safety features compared to previous generation, refined interior, improved ride comfort, continued AWD prowess.

Key Features

Design Philosophy:

Compact SUV with wagon-like versatility and Subaru's signature AWD system.

Notable Advancements:

Introduction of the 2.5L turbo engine in XT models for increased performance.

📋 Manual Details

Coverage Areas

Vehicle Coverage:

All 2004 Subaru Forester models

Engine Coverage:

2.5L Naturally Aspirated EJ253, 2.5L Turbocharged EJ255

Transmission Coverage:

4-speed automatic, 5-speed manual

Drive Type Coverage:

Symmetrical All-Wheel Drive (AWD)

Page Count

Estimated Page Count:

1500+

Manual Type

Manual Type:

Service and Repair Manual (Factory Style)

Distinction From Owner Manual:

Detailed technical repair and maintenance procedures, not basic operation.

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing belt, lubrication system, cooling system.

Engine Management:

Fuel injection (EFI), ignition system, emission controls, sensors (MAF, MAP, O2, Crankshaft Position), ECU diagnosis.

Transmission Manual:

Clutch system, 5-speed gearbox disassembly, assembly, gear ratios, lubrication.

Transmission Automatic:

4-speed automatic gearbox (e.g., TZ1A) disassembly, assembly, hydraulic controls, torque converter, lubrication, electronic control unit (TCU).

Drivetrain:

Front and rear differentials, driveshafts, CV joints, transfer case, AWD system operation and repair.

Suspension:

Front struts, rear multi-link, springs, shock absorbers, control arms, bushings, wheel alignment specifications.

Brakes:

Front and rear brake systems (discs), ABS (Anti-lock Braking System) components and diagnosis, brake fluid specifications, caliper and rotor replacement.

Steering:

Power steering system (hydraulic), steering rack, column, tie rods, steering angle sensor.

Electrical System:

Battery, charging system (alternator), starter motor, lighting systems (headlights, taillights, interior), wiring diagrams, fuses, relays.

Body And Interior:

Door panels, dashboard removal, seats, carpets, exterior trim, body panel repair, rust prevention, glass replacement.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, A/C compressor, condenser, evaporator, blower motor, climate control operation.

Comfort Convenience:

Power windows, locks, mirrors, remote keyless entry, cruise control, sunroof operation.

Procedures Included

Routine Maintenance:

Oil change intervals, filter replacements (oil, air, cabin), spark plug replacement, fluid checks and changes.

Engine Repair:

Head gasket replacement, timing belt service, piston ring replacement, valve adjustments (if applicable).

Transmission Repair:

Clutch replacement, automatic transmission fluid flush and filter change, valve body diagnosis.

Brake Service:

Brake pad and rotor replacement, brake fluid bleeding, ABS system bleeding procedure.

Suspension Repair:

Strut and shock replacement, ball joint replacement, control arm bushing replacement, wheel bearing replacement.

Electrical Troubleshooting:

Diagnostic trouble codes (DTCs) interpretation, circuit testing, component testing, wiring harness repair.

Diagnostic Procedures:

Step-by-step troubleshooting guides for common and complex issues.

Installation Procedures:

Instructions for replacing major components.

Technical Depth

Depth Of Coverage:

Comprehensive, from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Tools:

References for diagnostic trouble codes (DTCs) and potential diagnostic tool usage (e.g., OBD-II scanner).

Torque Specifications:

Detailed torque values for critical fasteners across all systems.

Special Tools:

Identification of specialized tools required for certain repairs.

📊 Manual Specifications

File Format

File Quality:

High-resolution scans, typically searchable text.

Print Readability:

Designed for clear viewing and printing of diagrams and text.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Naturally Aspirated Engine:

2.5L (2457cc) EJ253 SOHC or DOHC Flat-4 (Boxer)

Turbocharged Engine:

2.5L (2457cc) EJ255 DOHC Turbocharged Flat-4 (Boxer)

Performance Na

Horsepower Na:

165 hp @ 5600 rpm (approx.)

Torque Na:

166 lb-ft @ 4000 rpm (approx.)

Performance Turbo

Horsepower Turbo:

210 hp @ 5600 rpm (approx., XT model)

Torque Turbo:

235 lb-ft @ 3600 rpm (approx., XT model)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Recommended Fuel:

87 Octane (Premium recommended for Turbo models)

Cooling System

Cooling Type:

Liquid-cooled

Lubrication

Oil Type Capacity:

5W-30 synthetic blend, approx. 4.8 quarts (4.5L) with filter.

Timing Belt

Timing Belt Material:

Rubber, reinforced

Timing Belt Replacement Interval:

105,000 miles or 105 months (critical maintenance item).

🔧 Transmission

Standard

Standard Transmission Type:

5-speed manual transmission

Optional

Optional Transmission Type:

4-speed automatic transmission (with Lock-up Torque Converter)

Features

AWD System:

Symmetrical All-Wheel Drive (AWD) with viscous coupling center differential.

Automatic Transmission Mode:

Selectable modes (e.g., Power/Manual)

Fluid Specifications

Manual Transmission Fluid:

Subaru Extra-S Gear Oil API GL-5 75W-90 (or equivalent)

Automatic Transmission Fluid:

Subaru ATF-HP (High Performance) (or equivalent)

📐 Dimensions

Exterior

Length:

179.5 inches (4560 mm)

Width:

69.7 inches (1770 mm)

Height:

63.0 inches (1600 mm)

Wheelbase:

103.0 inches (2615 mm)

Ground Clearance:

7.5 inches (190 mm)

Cargo

Cargo Volume Behind Rear Seat:

34.7 cubic feet (983 liters)

Cargo Volume With Rear Seat Folded:

67.7 cubic feet (1917 liters)

Weights

Curb Weight Approx:

3200 - 3500 lbs (1450 - 1590 kg), depending on trim and drivetrain.

Towing Capacity:

2400 lbs (1089 kg) (with trailer brakes)

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

5-Star (Driver and Passenger)

NHTSA Side Impact Rating:

4-Star (Front and Rear Passengers)

IIHS Front Crash Rating:

Active Features

Active Safety Features:

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

Passive Features

Passive Safety Features:

Front airbags, Side-curtain airbags (optional on some trims), crumple zones, anti-whiplash front head restraints.

Tire Specifications

Standard Tire Size:

215/60R16 or 215/55R17 (depending on trim)

Wheel Bolt Pattern:

5x100mm

💡 Technology Features

Infotainment

Infotainment System:

Basic AM/FM/CD player, optional premium audio systems, cassette player available on some trims.

Display Type:

Analog gauges, basic digital display for odometer and clock.

Driver Assistance

Driver Assistance Features:

ABS, EBD, optional Traction Control System (TCS) on some models.

Connectivity

Connectivity Options:

Limited to basic audio input (CD/cassette); no Bluetooth or USB connectivity in factory form.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 3,750 miles or 3 months (severe service) / 7,500 miles or 6 months (normal service).

Engine Air Filter Replacement:

Every 15,000 miles or 12 months.

Cabin Air Filter Replacement:

Every 15,000 miles or 12 months.

Spark Plug Replacement:

100,000 miles (Iridium type)

Coolant Flush Replacement:

Every 30,000 miles or 24 months.

Fluid Specifications

Brake Fluid:

DOT 3 (or DOT 4 compatible)

Power Steering Fluid:

ATF Dexron II/III (or Subaru compatible)

Windshield Washer Fluid:

Water with washer fluid additive

Known Issues

Head Gasket Leaks:

While less prevalent on this specific generation than earlier ones, head gasket leaks can still occur and are a critical repair.

Crankshaft Position Sensor Failure:

Can lead to stalling or no-start conditions.

Automatic Transmission Issues:

Potential for wear and tear over time, particularly on higher mileage units; fluid and filter changes are crucial.

Suspension Wear:

Bushings and struts can wear, affecting ride quality and alignment.

📚 Vehicle History

Brand Heritage

Subaru Heritage:

Known for Boxer engines and Symmetrical All-Wheel Drive systems, often appealing to outdoor enthusiasts and those in all-weather climates.

Model Evolution

Forester Generation 2:

The 2004 model year represents the second generation (SF series) of the Subaru Forester, which debuted for the 2003 model year with a significant redesign.

2004 Updates:

Minor refinements, including potential new trim packages and feature availability, but largely carried over from the 2003 redesign.

Production

Manufacturing Location:

Gunma Prefecture, Japan

🏆 Awards & Recognition

Recognitions

IIHS Safety Awards:

Consistently earned good ratings from IIHS for front impact protection.

Consumer Reports Ratings:

Generally received average to above-average reliability ratings, with specific model years showing stronger performance.