Subaru Forester SG 2002–2008 Workshop Manual

Subaru Forester SG 2002–2008 Workshop Manual is a complete service and repair manual for the Subaru Forester SG (second generation), produced from 2002 to 2008. Includes detailed instructions, technical diagrams and specifications for all vehicle systems.

📌 What's in the manual?

✅ Engines: EJ202, EJ204, EJ252, EJ255 (turbo)

✅ Electrical diagrams and fault diagnostics

✅ Transmission system (manual, automatic, AWD)

✅ Chassis, brake system, steering

✅ Body repair and maintenance

✅ DTC – error codes and their decoding

This manual is ideal for mechanics, Forester SG owners and enthusiasts who want to understand technical features and carry out repairs themselves. 🚗🔧

• Subaru All Models>>
• Forester SG 2002–2008 Wiring Diagram>>

1️⃣ Engine and its problems

🔧 Overheating and broken cylinder head gaskets (especially EJ25)

On naturally aspirated EJ251/EJ253 and turbocharged EJ255, the cylinder head gasket often fails due to overheating and high oil consumption.

Symptoms: overheating, bubbles in the expansion tank, oil in the antifreeze.

How to avoid: temperature control, timely replacement of coolant.

🔧 Oil consumption (turbo versions of EJ255)

Turbocharged engines are prone to increased oil consumption due to the design of the piston rings.

How to avoid: use high-quality 5W-30/40 oil and change it every 5,000–7,000 km.

🔧 AVCS phase shifters (EJ204, EJ255)

Wear out by 150,000 km, knocking sounds when starting, errors in the phase system.

How to avoid: regular oil changes and AVCS diagnostics.

2️⃣ Transaxle/Transmission

🔧 Automatic transmission (4EAT automatic transmission)

Older models may have a delay in gear engagement and kicks.

How to avoid: timely ATF oil change, solenoids check.

🔧 Manual transmission (5MT, 6MT)

On the 5-speed, there may be problems with the input shaft bearing (hum, vibration).

Turbo versions have weak clutch, especially with aggressive driving.

🔧 All-wheel drive (AWD) - vibrations when turning

Reason: wear of the central clutch or rear differential.

How to avoid: change the oil in the gearboxes and check the cardan shaft in time.

3️⃣ Suspension and steering

🔧 Wear of the front silent blocks and stabilizer struts

By 100,000 km, the rear silent blocks of the front levers wear out, and handling deteriorates.

🔧 Steering rack - knocking and oil leakage

Often there is play and knocking at runs over 150,000 km.

🔧 Shock absorbers - quickly fail

Especially if the car is used on bad roads.

4️⃣ Electrics and wiring

🔧 Throttle position sensor (TPS)

Can give unstable speed, dips in traction.

🔧 Oxygen sensors (lambda probes)

Common error P0420 (low catalytic converter efficiency).

🔧 Generator and wiring problems

Contacts and connectors can oxidize, which causes errors.

5️⃣ Body and corrosion

🔧 Rust on sills and rear arches

Especially in cars operated in regions with salty roads.

How to avoid: anti-corrosion treatment, flushing hidden cavities.