Subaru Forester 2002 Factory Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2002 Codes Chassis Code: SF Engine Code Primary: EJ253 👋 Introduction Market Position Vehicle Segment: Compact SUV / Crossover Key Selling Points: Symmetrical All-Wheel Drive (AWD), practicality, reliability, good visibility Competitive Analysis Key Competitors 2002: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra Key Features Subaru Advantage: Standard Symmetrical AWD system provides superior traction and stability 📋 Manual Details Coverage Areas Coverage Scope: All repairs and servicing from A-Z Page Count Estimated Pages: High volume (detailed factory specification, likely 1000+ pages when considering all sections) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Management: Fuel injection, ignition, emissions control, ECU diagnostics Engine Mechanical: Disassembly, inspection, reassembly of engine components (pistons, crankshaft, camshafts, cylinder heads) Transmission Manual: Clutch, gearbox, shift mechanisms, drive shafts Transmission Automatic: Hydraulic control, valve body, torque converter, planetary gear sets Drivetrain AWD: Viscous coupling, center differential, rear differential, axles Suspension: Front struts, rear multi-link, springs, shock absorbers, bushings, alignment Brakes: Front discs, rear drums/discs (depending on trim), ABS system, brake hydraulics, parking brake Steering: Power steering system, steering rack, column, linkage Electrical System: Battery, charging system, starter, lighting, power windows, mirrors, locks HVAC: Air conditioning, heater core, blower motor, controls, refrigerant system Body And Interior: Body panels, doors, glass, seats, trim, dashboard Diagnostics: OBD-II codes, troubleshooting flowcharts, diagnostic procedures Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement Scheduled Maintenance: Timing belt replacement, coolant flush, brake fluid flush, transmission fluid change Troubleshooting: Step-by-step guides for diagnosing common and complex issues Component Repair: Detailed instructions for disassembling, repairing, and reassembling all major vehicle components Wiring Diagrams: Comprehensive electrical schematics for all systems Specifications: Torque values, clearances, tolerances, fluid capacities Special Tools: Identification and usage of Subaru-specific tools Technical Depth Depth Level: Expert/Professional (covers complete rebuilds, advanced diagnostics, and OEM specifications) 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text, printable Print Quality Scalability: Scalable for detail viewing of diagrams and schematics Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Naturally Aspirated Boxer (Horizontally Opposed) 4-Cylinder Displacement: 2.5 Liters (2457 cc) Bore X Stroke: 99.5 mm x 79.0 mm Compression Ratio: 9.7:1 Valve Train: DOHC (Dual Overhead Camshafts), 16 Valves (4 valves per cylinder) Performance Horsepower Est: 165 hp @ 5600 rpm Torque Est: 166 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Fuel Octane Requirement: 87 AKI (Octane Rating) 🔧 Transmission Standard Transmission Type: 4-Speed Electronically Controlled Automatic Transmission (ECT) Optional Transmission Type: 5-Speed Manual Transmission Features AWD System: Symmetrical All-Wheel Drive with viscous coupling center differential Fluid Specification Automatic Transmission Fluid: Subaru ATF-HP or equivalent (Check manual for exact specification, e.g., Dexron III compatible but Subaru specific is preferred) Fluid Capacity Automatic Transmission Fluid Capacity Approx: 3.5 - 4.0 Quarts (for drain and fill) 📐 Dimensions Exterior Length: 175.7 inches Width: 67.7 inches Height: 63.2 inches Wheelbase: 103.1 inches Ground Clearance: 7.5 inches Weights Curb Weight Approx: 3131 lbs (Manual) / 3245 lbs (Automatic) Towing Capacity Est: 2000 lbs 🛡️ Safety Features Ratings NHTSA Frontal Crash Test Driver: 4 of 5 stars (2002 Model) NHTSA Frontal Crash Test Passenger: 4 of 5 stars (2002 Model) IIHS Frontal Offset Rating: Good (for its class and time) Active Features ABS: Standard Anti-lock Braking System Traction Control: Available (may vary by trim) Passive Features Airbags Front: Driver and Passenger Frontal Airbags Seatbelts: 3-point seatbelts with pretensioners and load limiters 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with optional premium sound system Climate Control: Manual or automatic climate control depending on trim level Driver Assistance Cruise Control: Standard Connectivity Accessory Power: 12V power outlets 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750 miles or 3.75 months, whichever comes first (severe driving conditions), or 7,500 miles / 7.5 months (normal driving conditions). Check manual for specifics. Engine Oil Filter Replacement: Replace with oil change Engine Oil Type: SAE 5W-30 (API Certified, Synthetic Blend or Full Synthetic recommended) Engine Oil Capacity: 4.5 US quarts (with filter) Engine Air Filter Replacement: Inspect every 7,500 miles, replace as needed or every 15,000 miles. Cabin Air Filter Replacement: Inspect every 7,500 miles, replace as needed or annually. Spark Plug Replacement: Every 60,000 miles (Long-life platinum or iridium recommended) Timing Belt Replacement: Every 105,000 miles or 7 years (critical maintenance item for interference engine) Coolant Replacement: Every 30,000 miles or 3 years (Subaru Super Coolant or equivalent). Brake Fluid Replacement: Every 30,000 miles or 2 years (DOT 3 or DOT 4) Fluid Specifications Power Steering Fluid: Subaru Genuine Power Steering Fluid or equivalent ATF (Check manual) Brake Fluid Type: DOT 3 or...
Symmetrical All-Wheel Drive with viscous coupling center differential
Fluid Specification
Automatic Transmission Fluid:
Subaru ATF-HP or equivalent (Check manual for exact specification, e.g., Dexron III compatible but Subaru specific is preferred)
Fluid Capacity
Automatic Transmission Fluid Capacity Approx:
3.5 - 4.0 Quarts (for drain and fill)
📐 Dimensions
Exterior
Length:
175.7 inches
Width:
67.7 inches
Height:
63.2 inches
Wheelbase:
103.1 inches
Ground Clearance:
7.5 inches
Weights
Curb Weight Approx:
3131 lbs (Manual) / 3245 lbs (Automatic)
Towing Capacity Est:
2000 lbs
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test Driver:
4 of 5 stars (2002 Model)
NHTSA Frontal Crash Test Passenger:
4 of 5 stars (2002 Model)
IIHS Frontal Offset Rating:
Good (for its class and time)
Active Features
ABS:
Standard Anti-lock Braking System
Traction Control:
Available (may vary by trim)
Passive Features
Airbags Front:
Driver and Passenger Frontal Airbags
Seatbelts:
3-point seatbelts with pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional premium sound system
Climate Control:
Manual or automatic climate control depending on trim level
Driver Assistance
Cruise Control:
Standard
Connectivity
Accessory Power:
12V power outlets
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3.75 months, whichever comes first (severe driving conditions), or 7,500 miles / 7.5 months (normal driving conditions). Check manual for specifics.
Engine Oil Filter Replacement:
Replace with oil change
Engine Oil Type:
SAE 5W-30 (API Certified, Synthetic Blend or Full Synthetic recommended)
Engine Oil Capacity:
4.5 US quarts (with filter)
Engine Air Filter Replacement:
Inspect every 7,500 miles, replace as needed or every 15,000 miles.
Cabin Air Filter Replacement:
Inspect every 7,500 miles, replace as needed or annually.
Spark Plug Replacement:
Every 60,000 miles (Long-life platinum or iridium recommended)
Timing Belt Replacement:
Every 105,000 miles or 7 years (critical maintenance item for interference engine)
Coolant Replacement:
Every 30,000 miles or 3 years (Subaru Super Coolant or equivalent).
Brake Fluid Replacement:
Every 30,000 miles or 2 years (DOT 3 or DOT 4)
Fluid Specifications
Power Steering Fluid:
Subaru Genuine Power Steering Fluid or equivalent ATF (Check manual)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Head Gaskets:
While less prevalent than in earlier EJ engines, early second-gen models can still experience head gasket leaks. The manual will detail inspection and replacement procedures.
Rear Wheel Bearings:
Can wear prematurely; manual provides testing and replacement procedures.
Evap System Leaks:
Common cause of Check Engine Lights; manual covers diagnostic procedures for the evaporative emission control system.
📚 Vehicle History
Brand Heritage
Subaru Dna:
Known for Symmetrical AWD, boxer engines, and rally heritage
Model Evolution
Forester Generation Second:
Second Generation (SG) launched for the 2003 model year, this 2002 model is the final year of the first generation (SF).
Production
Production Years First Gen:
1997-2002
Manufacturing Plant:
Gunma Manufacturing Plant, Japan
🏆 Awards & Recognition
Recognitions
Car And Driver 2002:
Named to Car and Driver's Ten Best list for 2002 in the Compact SUV category.
Kbb Ratings:
Generally well-regarded for reliability and resale value by Kelly Blue Book.
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