2004 Subaru Forester Service and Repair Manual

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Factory-Grade Data

2004 Subaru Forester service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • X Sport Utility 4-Door
  • XS Sport Utility 4-Door
  • XT Sport Utility 4-Door

Engines covered

  • 2.5L 2458CC H4 GAS SOHC Naturally Aspirated
  • 2.5L 2458CC H4 GAS DOHC Turbocharged

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2004 Subaru Forester Recalls & Complaints

NHTSA #11V46400006/09/2011Component: SUSPENSION:FRONT:CONTROL ARM:LOWER ARM

SUBARU IS RECALLING CERTAIN MODEL YEAR 2002-2007 IMPREZA, MODEL YEAR 2003-2008 FORESTER, AND MODEL YEAR 2005-2006 SAAB 9-2X VEHICLES MANUFACTURED FROM SEPTEMBER 5, 2000 THROUGH NOVEMBER 26, 2007 ORIGI

Consequence

A BROKEN CONTROL ARM CAN RESULT IN THE LOSS OF CONTROL OF THE VEHICLE, INCREASING THE RISK OF A CRAS

Remedy

SUBARU WILL HANDLE THEIR VEHICLES AND SAAB WILL HANDLE THEIRS. DEALERS WILL INSPECT THE DEGREE OF C

NHTSA #04V47300001/10/2004Component: ENGINE AND ENGINE COOLING

ON CERTAIN PASSENGER AND SPORT UTILITY VEHICLES, THE COVER BOLTS FOR THE ENGINE OIL CONTROL VALVE MAY NOT BE SUFFICIENTLY TIGHTENED, ALLOWING OIL TO LEAK FROM AROUND THE COVER GASKET.

Consequence

IF LEAKING OIL CONTACTS COMPONENTS OPERATING AT HIGH TEMPERATURES, A FIRE COULD RESULT IN THE ENGINE

Remedy

DEALERS WILL INSPECT AND RETIGHTEN THE OIL-FLOW CONTROL VALVE COVER BOLTS. THE RECALL BEGAN ON OCTO

TSB #11032040

This bulletin announces the service manual correction regarding clutch master cylinder reservoir service procedures.

TSB #11032039

This bulletin contains additional information for recommended materials listed in the Service Manuals for individual models.

TSB #11032035

This Bulletin provides the diagnostic procedures to be followed when addressing customer concerns of steering wheel/vehicle body vibration when driving at highway speeds when tire/wheel balance is suspected.

TSB #11032034

This Service Information Bulletin was developed to provide interim guidance for vehicles exhibiting DTC B2A20.

TSB #11030567

This bulletin contains information to help when attempting to complete the STARLINK Telematics subscription process, an Error Code 202 and / or 204 may occur preventing the process from completing successfully

TSB #11030561

This announcement provides information on the use of aftermarket services or tools for programming immobilizer keys/fobs.

TSB #11030560

This bulletin announces the new procedure and Warranty Fail Code for FirstTime air conditioning (A/C) performance concerns possibly resulting from an undetected A/C refrigerant leak.

TSB #11030557

This bulletin contains additional information for recommended materials listed in the Service Manuals for individual models.

Showing the 8 most recent of 134 technical service bulletins on file with NHTSA.

20060202Component: AIR BAGSCrash reported2 injured

DT*: THE CONTACT STATED WHILE DRIVING ON THE HIGHWAY AT 55MPH THE VEHICLE WAS INVOLVED IN AN ACCIDENT. THE AIR BAGS DID NOT DEPLOY. ALTHOUGH SEATBELTS WERE WORN THE TWO OCCUPANTS SUSTAINED INJURIES

20200329Component: ENGINECrash reported1 injured

CAR WAS SHIFTED FROM DRIVE INTO NEUTRAL FOR OPERATOR TO USE A PARKING LOT GATE MACHINE. THE ENGINE SURGED A LITTLE WHILE IN NEUTRAL BUT SETTLED BACK DOWN. WHEN PARKING GATE OPENED THE OPERATOR SHIF

20200329Component: FUEL/PROPULSION SYSTEMCrash reported1 injured

CAR WAS SHIFTED FROM DRIVE INTO NEUTRAL FOR OPERATOR TO USE A PARKING LOT GATE MACHINE. THE ENGINE SURGED A LITTLE WHILE IN NEUTRAL BUT SETTLED BACK DOWN. WHEN PARKING GATE OPENED THE OPERATOR SHIF

20200329Component: POWER TRAINCrash reported1 injured

CAR WAS SHIFTED FROM DRIVE INTO NEUTRAL FOR OPERATOR TO USE A PARKING LOT GATE MACHINE. THE ENGINE SURGED A LITTLE WHILE IN NEUTRAL BUT SETTLED BACK DOWN. WHEN PARKING GATE OPENED THE OPERATOR SHIF

20111113Component: SEAT BELTSCrash reported1 injured

MY 2004 FORESTER 2.5XT SUSTAINED A SIGNIFICANT MOTOR VEHICLE ACCIDENT ON 10/25/11 DAMAGING THE FRONT & REAR END AT A REPAIR COST APPROACHING 9K. MY SEAT BELT FAILED TO HOLD ME IN PLACE -- NO OTHER VE

Showing the 5 most serious of 270 complaints filed with NHTSA.

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