Subaru Forester 1999-2002 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation: First Generation (SF Series) Model Years Covered: 1999, 2000, 2001, 2002 Codes Chassis Code: SF5, SF9 👋 Introduction Market Position Vehicle Type: Compact Crossover SUV / Sport Utility Vehicle Key Selling Points: All-Wheel Drive (Symmetrical AWD) standard, practical utility, good visibility, robust build quality. Competitive Analysis Competitors 1999 2002: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra. Key Features Manual Value Proposition: Provides dealership-level repair information, empowering owners and independent mechanics to perform complex diagnostics and repairs, saving on labor costs. 📋 Manual Details Coverage Areas Primary Coverage: North America, Global Markets Market Segment: Compact Crossover SUV Page Count Estimated Pages: Hundreds (exact count not specified, but implies comprehensive coverage) Manual Type Type: Workshop Service Repair Manual (Factory Official) Language Language: English Format Format: Downloadable Digital Format (likely PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Cooling System, Lubrication System, Exhaust System, Transmission (Manual & Automatic) Drivetrain: All-Wheel Drive (AWD) System, Differentials, Drive Shafts, Axles Chassis: Suspension (Front & Rear), Steering System, Brakes (Front & Rear), Wheels & Tires Electrical: Battery, Charging System, Ignition System, Lighting, Instrumentation, HVAC Controls, Audio System, Power Accessories, Engine Control Module (ECM), Body Control Module (BCM) Body: Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim, Bumpers, Roof Rack Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks & Changes, Tune-Ups, Belt Replacement Repair: Engine Overhaul, Transmission Repair/Rebuild, Brake System Repair, Suspension Component Replacement, Steering Component Repair, Electrical Component Diagnosis & Repair, Bodywork Repair Diagnostics: Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Wiring Diagrams, Component Testing Procedures Installation: Component Installation & Removal, Accessory Installation Technical Depth Depth: Comprehensive: Covers everything from routine maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and wiring schematics. 📊 Manual Specifications File Format Digital Format: Likely PDF, optimized for digital viewing and printing. Print Quality Printability: Designed for printing, allowing users to create a physical copy of sections or the entire manual. Binding Type Physical Binding Suggestion: Spiral-bound or three-ring binder recommended for ease of use during repairs. Paper Type Suggested Paper For Printing: Durable, uncoated paper (e.g., 24 lb bond) for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Code Usdm: EJ25 SOHC (2.5L Naturally Aspirated) Engine Description: Horizontally Opposed (Boxer) Four-Cylinder, SOHC, Naturally Aspirated Performance Horsepower Usdm: 165 hp @ 5,600 rpm Torque Usdm: 166 lb-ft @ 4,000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Codes Other Markets Ej20 Turbo Availability: Some international markets may have offered turbocharged EJ20 engines (e.g., GT trims). 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission with Lock-up Torque Converter Features AWD System Integration: Both transmissions are coupled to Subaru's Symmetrical All-Wheel Drive system, featuring viscous coupling center differentials. 📐 Dimensions Exterior Wheelbase Inches: 103.5 Length Inches: 175.0 Width Inches: 69.7 Height Inches: 63.0 Cargo Cargo Volume Cubic Feet: Approx. 30.1 cu ft (with rear seats up) Weights Curb Weight Lbs: 3,130 - 3,365 lbs (approx., depending on trim and transmission) 🛡️ Safety Features Ratings NHTSA Frontal Crash Rating: 4-star (driver and front passenger, 1999-2002 models) Active Features Standard Drivetrain: Symmetrical All-Wheel Drive (AWD) for enhanced traction and stability. Braking System: Front ventilated discs, rear solid discs. Optional ABS (Anti-lock Braking System) available on higher trims. Passive Features Airbags: Driver and front passenger airbags. Seatbelts: Front 3-point height-adjustable seatbelts with pretensioners and load limiters, rear 3-point seatbelts. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player and/or cassette tape, typically 4 or 6 speaker system. Upgrades possible. Driver Assistance ABS Availability: Optional Anti-lock Braking System (ABS) on select trims, particularly for the rear wheels, later models may have 4-wheel ABS. Connectivity Cruise Control: Standard on most trims, electronic cruise control system. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 3,750 miles or 6 months (check manual for specific oil type and conditions). Engine Air Filter Replacement: Every 15,000 - 30,000 miles (refer to manual for conditions). Spark Plug Replacement: 100,000 miles (platinum/iridium tipped plugs). Timing Belt Replacement: 100,000 miles (Non-interference engine, but replacement is crucial for reliability). Fluid Specifications Engine Oil Type: API SG or higher, SAE 5W-30 recommended (check manual for ambient temperature range). Engine Oil Capacity: 4.5 US quarts (with filter) for 2.5L SOHC. Coolant Type: Subaru Super Coolant or equivalent (ethylene glycol-based, Subaru blue). Transmission Fluid Manual: Subaru Extra S (GL-5 75W-90) or equivalent. Transmission Fluid Automatic: Subaru ATF-HP or Dexron III/Mercon compatible fluid (check manual for specifics). Differential Fluid Front Rear: API GL-5, SAE 75W-90. Known Issues Head Gaskets: While later generations are more prone, early EJ25 engines can exhibit head gasket leaks. The manual will detail inspection and replacement procedures. Radiator Leaks: Plastic end tanks on radiators can become...
Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra.
Key Features
Manual Value Proposition:
Provides dealership-level repair information, empowering owners and independent mechanics to perform complex diagnostics and repairs, saving on labor costs.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America, Global Markets
Market Segment:
Compact Crossover SUV
Page Count
Estimated Pages:
Hundreds (exact count not specified, but implies comprehensive coverage)
Comprehensive: Covers everything from routine maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and wiring schematics.
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, optimized for digital viewing and printing.
Print Quality
Printability:
Designed for printing, allowing users to create a physical copy of sections or the entire manual.
Binding Type
Physical Binding Suggestion:
Spiral-bound or three-ring binder recommended for ease of use during repairs.
Paper Type
Suggested Paper For Printing:
Durable, uncoated paper (e.g., 24 lb bond) for workshop environments.
Some international markets may have offered turbocharged EJ20 engines (e.g., GT trims).
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission with Lock-up Torque Converter
Features
AWD System Integration:
Both transmissions are coupled to Subaru's Symmetrical All-Wheel Drive system, featuring viscous coupling center differentials.
📐 Dimensions
Exterior
Wheelbase Inches:
103.5
Length Inches:
175.0
Width Inches:
69.7
Height Inches:
63.0
Cargo
Cargo Volume Cubic Feet:
Approx. 30.1 cu ft (with rear seats up)
Weights
Curb Weight Lbs:
3,130 - 3,365 lbs (approx., depending on trim and transmission)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Rating:
4-star (driver and front passenger, 1999-2002 models)
Active Features
Standard Drivetrain:
Symmetrical All-Wheel Drive (AWD) for enhanced traction and stability.
Braking System:
Front ventilated discs, rear solid discs. Optional ABS (Anti-lock Braking System) available on higher trims.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Front 3-point height-adjustable seatbelts with pretensioners and load limiters, rear 3-point seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with CD player and/or cassette tape, typically 4 or 6 speaker system. Upgrades possible.
Driver Assistance
ABS Availability:
Optional Anti-lock Braking System (ABS) on select trims, particularly for the rear wheels, later models may have 4-wheel ABS.
Connectivity
Cruise Control:
Standard on most trims, electronic cruise control system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,750 miles or 6 months (check manual for specific oil type and conditions).
Engine Air Filter Replacement:
Every 15,000 - 30,000 miles (refer to manual for conditions).
Spark Plug Replacement:
100,000 miles (platinum/iridium tipped plugs).
Timing Belt Replacement:
100,000 miles (Non-interference engine, but replacement is crucial for reliability).
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 5W-30 recommended (check manual for ambient temperature range).
Engine Oil Capacity:
4.5 US quarts (with filter) for 2.5L SOHC.
Coolant Type:
Subaru Super Coolant or equivalent (ethylene glycol-based, Subaru blue).
Transmission Fluid Manual:
Subaru Extra S (GL-5 75W-90) or equivalent.
Transmission Fluid Automatic:
Subaru ATF-HP or Dexron III/Mercon compatible fluid (check manual for specifics).
Differential Fluid Front Rear:
API GL-5, SAE 75W-90.
Known Issues
Head Gaskets:
While later generations are more prone, early EJ25 engines can exhibit head gasket leaks. The manual will detail inspection and replacement procedures.
Radiator Leaks:
Plastic end tanks on radiators can become brittle and leak over time. Manual covers replacement.
Cv Axle Boots:
Front CV axle boots can split, leading to grease loss and eventual joint failure. Manual provides replacement guides.
📚 Vehicle History
Brand Heritage
Subaru Specialty:
Subaru is renowned for its expertise in all-wheel-drive systems and horizontally opposed (boxer) engines, developed from rally racing heritage.
Model Evolution
Forester Concept:
Introduced as a compact SUV that blended the driving characteristics of a car with the utility and higher ground clearance of an SUV. Often described as a 'raised station wagon'.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Consumer Reports Rating:
Forester generally received good ratings for reliability and safety in its class during its production run, though specific annual ratings vary.
Ratings
Edmunds Rating:
Praised for its practicality, AWD system, and refined ride for the era.
Certifications
Safety Certifications:
Compliant with US Federal Motor Vehicle Safety Standards (FMVSS).
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