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1999-2002 Subaru Forester Service Repair Workshop Manual (1999 2000 2001 2002)

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🏷️ Basic Information Identification Make: Subaru Model: Forester Model Generation: SF Series (First Generation) Year Range Covered: 1999-2002 Codes Chassis Code: SF5, SF9 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Target Audience: Families, outdoor enthusiasts, drivers seeking AWD capability in a versatile package Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra Key Features All Wheel Drive: Standard symmetrical All-Wheel Drive (S-AWD) was a defining feature Practicality: Spacious interior, good cargo capacity, raised ride height for light off-road capability Engine Reliability: Boxer engine design known for its low center of gravity and unique character Manual Utility: Essential for owners and independent mechanics to maintain and repair this capable vehicle. 📋 Manual Details Coverage Areas Languages: English Regions Covered: North America, Global (where applicable) Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual / Workshop Manual Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul for EJ25 SOHC and DOHC engines Engine Management: ECU diagnosis, sensor testing, fuel injection system, ignition system Transmission Manual: Service and repair for 5-speed manual transmissions (e.g., TY754) Transmission Automatic: Service and repair for 4-speed automatic transmissions (e.g., TZ103) Drivetrain: All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints Suspension: Front MacPherson struts, rear multi-link suspension, steering system, wheel alignment Brakes: Front vented discs, rear discs or drums, ABS system (if equipped), hydraulic system Electrical System: Wiring diagrams, battery, alternator, starter, lighting, gauges, power accessories Body And Chassis: Body panel removal/installation, interior trim, glass, structural components HVAC: Heating, ventilation, and air conditioning system diagnosis and repair Safety Systems: Airbag system diagnosis and service procedures Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks Troubleshooting: Extensive diagnostic flowcharts for common and uncommon problems Repair: Step-by-step repair instructions for all major vehicle systems Overhaul: Complete engine and transmission overhaul procedures Specifications: Torque specifications, clearances, fluid capacities, technical data Diagnostics: OBD-II diagnostic codes and interpretation, sensor testing procedures Technical Depth Depth: Comprehensive, from basic maintenance to complete engine rebuilds and complex diagnostics Diagrams: High-quality, detailed diagrams and illustrations for all procedures Wiring Diagrams: Complete and detailed electrical wiring schematics for all systems 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text for quick information retrieval Printability: Printable pages for workshop use Print Quality Image Resolution: High-resolution images and diagrams suitable for printing Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ251 Engine Type 1: 2.5L Naturally Aspirated SOHC EJ251 Boxer-4 Displacement 1: 2457 cc (2.5 Liters) Bore X Stroke 1: 99.5 mm x 79.0 mm Compression Ratio 1: 9.0:1 Horsepower 1: 165 hp @ 5,600 rpm Torque 1: 166 lb-ft @ 4,000 rpm Engine Code 2 Engine Code 2: EJ252 Engine Type 2: 2.5L Naturally Aspirated DOHC EJ252 Boxer-4 (for some markets, primarily early models or specific trims) Engine Type 2 Engine Type 2: 2.5L Naturally Aspirated DOHC EJ252 Boxer-4 Displacement 2 Displacement 2: 2457 cc (2.5 Liters) Horsepower 2 Horsepower 2: 167 hp @ 5,600 rpm Torque 2 Torque 2: 166 lb-ft @ 4,000 rpm Performance Redline: 6,000 rpm Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane recommended) Emissions Controls: Catalytic Converter, EGR system 🔧 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 Manual: Symmetrical All-Wheel Drive with viscous coupling center differential AWD System Automatic: Active All-Wheel Drive (requires engine RPM and wheel speed sensor input to manage torque split) Fluid Specs Manual Transmission Fluid: Subaru Extra-S Gear Oil GL-5 SAE 75W-90 (or equivalent) Automatic Transmission Fluid: Subaru ATF-HP (or equivalent Dexron III/Mercon compatible) 📐 Dimensions Exterior Length: 4,450 mm (175.2 in) Width: 1,735 mm (68.3 in) Height: 1,580 mm (62.2 in) Wheelbase: 2,630 mm (103.5 in) Ground Clearance: approx. 190 mm (7.5 in) Weights Curb Weight Manual: approx. 1,410 kg (3,108 lbs) Curb Weight Automatic: approx. 1,440 kg (3,175 lbs) Cargo Cargo Volume Seats Up: approx. 330 L (11.6 cu ft) with seats up Cargo Volume Seats Down: approx. 1,950 L (68.9 cu ft) with seats folded 🛡️ Safety Features Ratings NHTSA Frontal Driver Side: Good (Second Generation, but representative for the era) NHTSA Frontal Passenger Side: Good (Second Generation, but representative for the era) Active Features ABS: Available (Anti-lock Braking System) - 4-wheel disc brakes with ABS standard on higher trims/later years Traction Control: Not typically available on this generation Passive Features Airbags: Driver and Passenger front airbags standard Seatbelts: 3-point front and rear seatbelts with pretensioners Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system not standard on this generation 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional premium audio Driver Assistance Cruise Control: Standard on most trims 🔧 Maintenance Service Intervals...
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1999-2002 Subaru Forester Service Repair Workshop Manual (1999 2000 2001 2002)
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Model Generation:
SF Series (First Generation)
Year Range Covered:
1999-2002
Codes
Chassis Code:
SF5, SF9
👋 Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV
Target Audience:
Families, outdoor enthusiasts, drivers seeking AWD capability in a versatile package
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra
Key Features
All Wheel Drive:
Standard symmetrical All-Wheel Drive (S-AWD) was a defining feature
Practicality:
Spacious interior, good cargo capacity, raised ride height for light off-road capability
Engine Reliability:
Boxer engine design known for its low center of gravity and unique character
Manual Utility:
Essential for owners and independent mechanics to maintain and repair this capable vehicle.
📋 Manual Details
Coverage Areas
Languages:
English
Regions Covered:
North America, Global (where applicable)
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul for EJ25 SOHC and DOHC engines
Engine Management:
ECU diagnosis, sensor testing, fuel injection system, ignition system
Transmission Manual:
Service and repair for 5-speed manual transmissions (e.g., TY754)
Transmission Automatic:
Service and repair for 4-speed automatic transmissions (e.g., TZ103)
Drivetrain:
All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints
Suspension:
Front MacPherson struts, rear multi-link suspension, steering system, wheel alignment
Brakes:
Front vented discs, rear discs or drums, ABS system (if equipped), hydraulic system
Electrical System:
Wiring diagrams, battery, alternator, starter, lighting, gauges, power accessories
Body And Chassis:
Body panel removal/installation, interior trim, glass, structural components
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair
Safety Systems:
Airbag system diagnosis and service procedures
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, tune-ups, fluid checks
Troubleshooting:
Extensive diagnostic flowcharts for common and uncommon problems
Repair:
Step-by-step repair instructions for all major vehicle systems
Overhaul:
Complete engine and transmission overhaul procedures
Specifications:
Torque specifications, clearances, fluid capacities, technical data
Diagnostics:
OBD-II diagnostic codes and interpretation, sensor testing procedures
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine rebuilds and complex diagnostics
Diagrams:
High-quality, detailed diagrams and illustrations for all procedures
Wiring Diagrams:
Complete and detailed electrical wiring schematics for all systems
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text for quick information retrieval
Printability:
Printable pages for workshop use
Print Quality
Image Resolution:
High-resolution images and diagrams suitable for printing
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EJ251
Engine Type 1:
2.5L Naturally Aspirated SOHC EJ251 Boxer-4
Displacement 1:
2457 cc (2.5 Liters)
Bore X Stroke 1:
99.5 mm x 79.0 mm
Compression Ratio 1:
9.0:1
Horsepower 1:
165 hp @ 5,600 rpm
Torque 1:
166 lb-ft @ 4,000 rpm
Engine Code 2
Engine Code 2:
EJ252
Engine Type 2:
2.5L Naturally Aspirated DOHC EJ252 Boxer-4 (for some markets, primarily early models or specific trims)
Engine Type 2
Engine Type 2:
2.5L Naturally Aspirated DOHC EJ252 Boxer-4
Displacement 2
Displacement 2:
2457 cc (2.5 Liters)
Horsepower 2
Horsepower 2:
167 hp @ 5,600 rpm
Torque 2
Torque 2:
166 lb-ft @ 4,000 rpm
Performance
Redline:
6,000 rpm
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Emissions Controls:
Catalytic Converter, EGR system
🔧 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 Manual:
Symmetrical All-Wheel Drive with viscous coupling center differential
AWD System Automatic:
Active All-Wheel Drive (requires engine RPM and wheel speed sensor input to manage torque split)
Fluid Specs
Manual Transmission Fluid:
Subaru Extra-S Gear Oil GL-5 SAE 75W-90 (or equivalent)
Automatic Transmission Fluid:
Subaru ATF-HP (or equivalent Dexron III/Mercon compatible)
📐 Dimensions
Exterior
Length:
4,450 mm (175.2 in)
Width:
1,735 mm (68.3 in)
Height:
1,580 mm (62.2 in)
Wheelbase:
2,630 mm (103.5 in)
Ground Clearance:
approx. 190 mm (7.5 in)
Weights
Curb Weight Manual:
approx. 1,410 kg (3,108 lbs)
Curb Weight Automatic:
approx. 1,440 kg (3,175 lbs)
Cargo
Cargo Volume Seats Up:
approx. 330 L (11.6 cu ft) with seats up
Cargo Volume Seats Down:
approx. 1,950 L (68.9 cu ft) with seats folded
🛡️ Safety Features
Ratings
NHTSA Frontal Driver Side:
Good (Second Generation, but representative for the era)
NHTSA Frontal Passenger Side:
Good (Second Generation, but representative for the era)
Active Features
ABS:
Available (Anti-lock Braking System) - 4-wheel disc brakes with ABS standard on higher trims/later years
Traction Control:
Not typically available on this generation
Passive Features
Airbags:
Driver and Passenger front airbags standard
Seatbelts:
3-point front and rear seatbelts with pretensioners
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system not standard on this generation
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio
Driver Assistance
Cruise Control:
Standard on most trims
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3.75 months, whichever comes first (under severe conditions), or 7,500 miles (12,000 km) / 7.5 months (under normal conditions)
Air Filter Replacement:
Every 30,000 miles (48,000 km)
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for platinum plugs
Timing Belt Replacement:
Every 105,000 miles (168,000 km) or 105 months. Crucial maintenance item for EJ engines.
Fluid Specifications
Engine Oil Type:
API SJ or higher, SAE 5W-30 (preferred) or 10W-30
Engine Oil Capacity:
4.5 US quarts (4.3 L) with filter
Coolant:
Subaru Genuine Antifreeze / Coolant (Blue) or equivalent 50/50 mix
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Head Gaskets:
While not as prevalent as in later generations, early EJ25 engines can be susceptible to head gasket leaks. The manual details inspection and replacement procedures.
Oil Leaks:
Valve cover gasket and oil pan gasket leaks are common with age.
Catalytic Converter:
Can degrade over time, leading to reduced performance and check engine lights.
Suspension Wear:
Bushings, ball joints, and struts can wear, affecting ride and handling.
ABS Sensor Failure:
Wheel speed sensors for the ABS system can fail, triggering ABS warning lights.
📚 Vehicle History
Brand Heritage
Brand Focus:
Subaru is historically known for its pioneering use of All-Wheel Drive in passenger vehicles.
Model Evolution
Introduction Year:
1997
First Generation Name:
SF Series
Segment Creation:
Subaru effectively created the compact crossover segment with the Forester, blending wagon practicality with SUV-like ground clearance and AWD.
Production
Manufacturing Plant:
Ota, Gunma, Japan
🏆 Awards & Recognition
Recognitions
Consumer Guide Best Buy:
Awarded 'Best Buy' status by Consumer Guide Automotive multiple times during its first generation.
Ratings
Kiplinger Ratings:
Often cited for value and practicality.
Certifications
Emissions Certification:
Meets EPA and CARB emission standards for the model years.
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