2003-2008 Subaru Forester Service & Repair Manual
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
2003-2004
PDF Service Manual
GENERAL INFORMATION SECTION (Pub.No.G8080GE1)
ENGINE SECTION 1 (Pub.No.G8080GE2)
ENGINE SECTION 2 (Pub.No.G8080GE3)
ENGINE SECTION 3 (Pub.No.G8080GE4)
TRANSMISSION SECTION (Pub.No.G8080GE5)
CHASSIS SECTION (Pub.No.G8080GE6)
BODY SECTION (Pub.No.G8080GE7)
WIRING SYSTEM SECTION (Pub.No.G8080GE8)
FUJI HEAVY INDUSTRIES LTD. G8080GE1
03-04 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
GENERAL INFORMATION
SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FOREWORD FW
HOW TO USE THIS MANUAL HU
SPECIFICATION SPC
PRECAUTION PC
NOTE NT
IDENTIFICATION ID
RECOMMENDED MATERIAL RM
PRE-DELIVERY INSPECTION PI
PERIODIC MAINTENANCE SERVICE PM
FOREWORD
FW
Page
1. Foreword ..................................................................................................... 2
FW-2
FOREWORD
Foreword
1. Foreword
A: FOREWORD
These manuals are used when performing mainte-
nance, repair, or diagnosis of the Subaru FOREST-
ER.
Applied model: SG***** from 2004MY
The manuals contain the latest information at the
time of publication. Changes in specifications,
methods, etc. may be made without notice.
HOW TO USE THIS MANUAL
HU
Page
1. How to Use This Manual ............................................................................. 2
HU-2
HOW TO USE THIS MANUAL
How to Use This Manual
1. How to Use This Manual
A: HOW TO USE THIS MANUAL
1. STRUCTURE
Each section consists of SCT that are broken down
into SC that are divided into sections for each com-
ponent. The specification, maintenance and other
information for the components are included, and
diagnosis information has also been added where
necessary.
2. INDEX
The first page has an index with tabs.
HU-3
HOW TO USE THIS MANUAL
How to Use This Manual
3. COMPONENTS
Illustrations are listed for each component. The information necessary for repair work (tightening torque,
grease up points, etc.) is described on these illustrations. Information is described using symbol. To order the
parts, refer to parts catalogue.
Example:
HU-00001
(14)
(9)
(8)
(7)
(6)
(10)
(4) (10)
(22)
(11)
(19)
(17)
(15)
(13)
(12)
(18)
(16)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(11)
(10)
(9)
(12)
(13)
(19)
(18)
(20)
(17)
(16)
(24)
(10)
(25)
(5)
(4)
(4)
(4)
(3)
(3)
(3)
(2)
(1)
(21)
(15)
(23)
T7
T2
T2
T2
T2
T2
T2
T4
T5
T5
T8
T6
T6
T6
T11
T10
T1
T1
T3
T3
T3
T1
T9
T4
T5
T5
T3
T4
T3
T2
T4
T2
T1
T3
(20)
(21)
(23)
(22)
(10)
(24)
(25)
(26)
(35)
(34)
(27)
(14)
(28)
(29)
(31)
(32)
(37)
(30)
(33)
(36)
T3
T2 T1
:Selective part
:Replacement part
:Should be lubricated with grease.
:Should be lubricated with oil.
:Sealing point
:Tightening torque .... ,
HU-4
HOW TO USE THIS MANUAL
How to Use This Manual
4. SPECIFICATION
If necessary, specifications are also included.
5. INSPECTION
Inspections are included to be carried out before and after maintenance.
6. MAINTENANCE
• Maintenance instructions for serviceable parts describes work area and detailed steps with illustration. It
also describes the use of special tool, tightening torque, cautions for each procedure.
• If many serviceable parts are included in one service procedure, appropriate reference are provided for
each part.
Example:
(A) Component (D) Caution (G) Tightening torque
(B) Process (E) Tool number of special tool (H) Illustration
(C) Reference (F) Name of special tool
HU-00002
1) Remove the manual transmission assembly
from vehicie. <Ref. to MT-33, REMOVAL, Manual
Transmission Assembly.>
15.Main Shaft Assembly for Sin-
gle-Range
A: REMOVAL
11) Tighten the lock nuts to the specified torque us-
ing ST1 and ST2.
NOTE:
Secure the lock nuts in two Places affer tightening.
ST2 499987003 SOCKET WRENCH
ST1 498937000 TRANSMISSION HOLDER
(A)
(B)
(C)
(D)
(G)
(E) (F)
(H)
Tightening torque:
118 N m (12.0 kgf-m, 86.8 ft-lb)
ST1 ST2
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$30.99
Viewed 71 Times Today
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$30.99
2003-2008 Subaru Forester OEM Service & Repair Manual
Engines Covered:
- 2.0L DOHC H4 (EJ20, H4SO) – Naturally Aspirated
- 2.0L DOHC Turbo H4 (EJ205, H4DOTC) – Turbocharged
- 2.5L SOHC H4 (EJ253, H4SO) – Naturally Aspirated
- 2.5L DOHC Turbo H4 (EJ255, H4DOTC) – Turbocharged
This 2003-2008 Subaru Forester OEM Service & Repair Manual is the official factory manual for the SG-generation Forester, and as such, includes detailed procedures for both naturally aspirated and turbocharged variants of the EJ-series flat-four engines, including EJ20, EJ205, EJ253, and EJ255.
Originally compiled for Subaru dealership technicians, this manual offers comprehensive factory procedures covering mechanical, electrical, and electronic systems. Whether you’re servicing an EJ253 base model or rebuilding a turbocharged EJ255 engine from a Forester XT, this OEM guide ensures accurate specs, diagnostic flowcharts, and step-by-step overhaul instructions.
Content Overview:
- Engine Overhaul & Timing – Complete breakdowns of both SOHC and DOHC boxer engines, with detailed timing belt alignment, valve clearance specs, compression ratios, and firing order.
- Fuel & Air Systems – Diagnostic procedures for injectors, fuel pump testing, pressure specs, airflow meter troubleshooting, and manifold vacuum routing.
- Emission & Control Devices – EVAP system inspection, EGR valve operation, and auxiliary emission components specific to turbo and non-turbo models.
- Chassis & Suspension – Front and rear suspension geometry, wheel bearing service, ride height specs, and subframe component diagrams.
- HVAC & Interior Systems – Blend door operation, heater core replacement, A/C pressure charts, and cabin electronics removal.
- Body Panels & Fitment – Exterior trim, door assembly, hood and tailgate adjustments, and crash repair alignment specs.
- Electrical Diagnostics – Full wiring schematics with connector pinouts, sensor ground maps, relay locations, and ECU reference voltage charts.
This manual is essential for anyone working on the 2003-2008 Subaru Forester, whether maintaining a daily driver or restoring a turbocharged XT. With full factory detail and engine-specific coverage, it's the most reliable reference for SG-platform repair work.
Printable: Yes
Language: English
Compatibility: Works on all electronic devices (Windows, Mac, iOS, Android)
Requirements: PDF reader (e.g. Adobe Reader)
