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Subaru Forester 2002 Complete Factory Service / Repair / Workshop Manual PDF Download

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Basic Information Identification Make: Subaru Model: Forester Year: 2002 Codes Chassis Code: SF/SG Series (Second Generation - SG) Generation Generation Identifier: Second Generation (SG) Generation Years: 2002-2008 Introduction Market Position...
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Subaru Forester 2002 Complete Factory Service / Repair / Workshop Manual PDF Download
Basic Information
Identification
Make: Subaru
Model: Forester
Year: 2002
Codes
Chassis Code: SF/SG Series (Second Generation - SG)
Generation
Generation Identifier: Second Generation (SG)
Generation Years: 2002-2008
Introduction
Market Position
Segment: Compact Crossover SUV
Target Audience: Individuals and families seeking a capable, all-weather, and versatile SUV with a focus on practicality and Subaru's signature Symmetrical All-Wheel Drive system.
Competitive Analysis
Key Competitors 2002: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra
Key Features
Signature Features: Symmetrical All-Wheel Drive (standard on all models), Boxer Engine, Practicality, All-Weather Capability, Increased Ground Clearance for its class.
Manual Value Proposition: Provides comprehensive, factory-level repair and maintenance information, empowering owners and technicians to maintain and repair the vehicle effectively, saving time and money.
Manual Details
Coverage Areas
Covered Models: All Subaru Forester 2002 models
Engine Coverage: 2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255/EJ257)
Page Count
Estimated Page Count: Over 2000 (typical for comprehensive factory manuals)
Manual Type
Manual Type: Factory Service Manual / Workshop Manual / Repair Manual
Language
Language: English
Format
Digital Format: PDF Download
Manual Coverage
Systems Covered
Powertrain: Engine Mechanical, Engine Lubrication, Engine Cooling, Fuel System, Emission Control System, Exhaust System, Ignition System, Starting System, Charging System, Engine Control System (ECU/ECM), Automatic Transmission, Manual Transmission, Transfer Case, Drivetrain (All-Wheel Drive)
Chassis: Suspension System (Front & Rear), Steering System, Brake System (Front & Rear, ABS), Wheels & Tires, Drive Shafts & Axles
Body And Electrical: Body Structure, Exterior Body Panels, Interior Trim, Doors, Windows, Seats, HVAC System (Heating, Ventilation, Air Conditioning), Electrical System, Lighting System, Audio System, Safety Systems (Airbags, Seatbelts), Power Accessories (Windows, Locks, Mirrors)
Procedures Included
Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tire rotation, brake pad replacement, spark plug replacement, battery inspection.
Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical schematics and wiring diagrams, component testing procedures.
Repair: Engine overhaul, transmission repair, brake caliper replacement, suspension component replacement, body panel repair, electrical component repair, HVAC system repair, fuel system component replacement.
Installation: Component installation, accessory installation, sensor replacement, timing belt/chain replacement, clutch replacement, flywheel replacement.
Technical Depth
Depth Of Information: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Includes detailed component removal and installation procedures, specifications, torque values, diagnostic strategies, and wiring diagrams.
Manual Specifications
File Format
File Type: PDF
Searchability: Searchable text
Print Quality
Printability: Printable
Zoom Functionality: Yes (Zoom In/Out)
Binding Type
Binding: Not Applicable (Digital Download)
Paper Type
Paper Quality: Not Applicable (Digital Download)
Engine Specifications
Primary Engine
Engine Code Naturally Aspirated: EJ253
Engine Code Turbocharged: EJ255 (WRX-based, may be present in specific trims)
Engine Layout: Horizontally Opposed (Boxer)
Cylinders: 4
Displacement Na: 2.5 Liters (2457 cc)
Bore X Stroke Na: 99.5 mm x 79.0 mm
Performance
Horsepower Na: Approx. 165 hp @ 5600 rpm
Torque Na: Approx. 166 lb-ft @ 4000 rpm
Horsepower Turbo: Approx. 210-227 hp (depending on specific WRX engine application)
Torque Turbo: Approx. 235-250 lb-ft (depending on specific WRX engine application)
Fuel System
Fuel Delivery: Multi-point Fuel Injection (MPI)
Fuel Type: Unleaded Gasoline
Recommended Octane: 87 Octane (91 Octane recommended for turbocharged models)
Transmission
Standard
Transmission Type: 4-Speed Automatic Transmission (4EAT)
Optional
Transmission Type Optional: 5-Speed Manual Transmission
Features
AWD System Integration: Integrated with Symmetrical All-Wheel Drive system (Active Torque Split AWD for automatic, viscous coupling center diff for manual).
Fluid Specs
Automatic Transmission Fluid: Subaru ATF HP (or equivalent Dexron III/Mercon compatible fluid, refer to manual for exact specification)
Manual Transmission Fluid: Subaru Gear Oil G5 or G5-225 (75W-90 GL-5)
Dimensions
Exterior
Length: Approx. 177.0 inches
Width: Approx. 69.7 inches
Height: Approx. 64.4 inches
Wheelbase: Approx. 103.1 inches
Ground Clearance: Approx. 7.5 inches
Weights
Curb Weight: Approx. 3100 - 3300 lbs (depending on configuration)
Towing Capacity: Approx. 2000 lbs
Cargo
Cargo Volume Behind Rear Seats: Approx. 31.5 cubic feet
Cargo Volume With Rear Seats Folded: Approx. 63.0 cubic feet
Safety Features
Ratings
NHTSA Front Driver Impact: 5 Stars (for 2002 models)
NHTSA Front Passenger Impact: 5 Stars (for 2002 models)
NHTSA Side Driver Impact: 4 Stars (for 2002 models)
NHTSA Side Passenger Impact: 4 Stars (for 2002 models)
IIHS Frontal Offset: Good
Active Features
Standard AWD: Symmetrical All-Wheel Drive
ABS: Anti-lock Braking System (Standard)
Traction Control: Available on some trims
Passive Features
Airbags: Front driver and passenger airbags, available front side-impact airbags
Seatbelts: 3-point seatbelts with pretensioners
Technology Features
Infotainment
Audio System: Factory-installed AM/FM/CD player. Available premium audio systems on higher trims. Manual covers basic operation, replacement, and wiring.
Driver Assistance
ABS: Standard Anti-lock Braking System
Traction Control: Optional on some models, typically paired with the automatic transmission.
Connectivity
Wiring Diagrams: The manual includes detailed electrical wiring diagrams essential for diagnosing and repairing electronic systems, including sensors, lighting, audio, and power accessories.
Sensors
Engine Sensors: Manual covers MAF sensor, MAP sensor, Oxygen sensors (O2 sensors), Crankshaft Position Sensor (CKP), Camshaft Position Sensor (CMP), Coolant Temperature Sensor (ECT), Throttle Position Sensor (TPS).
Maintenance
Service Intervals
Oil Change Interval: Every 3,750 miles or 3 months (severe driving) / Every 7,500 miles or 6 months (normal driving), refer to manual for specific recommendations.
Timing Belt Replacement: Every 105,000 miles or 7 years (for EJ253 engine). Note: Turbocharged models may have different recommendations or chain-driven designs depending on specific engine variant.
Air Filter Replacement: Every 15,000 miles or 1 year
Spark Plug Replacement: Every 30,000 miles (original equipment NGK copper plugs); platinum or iridium plugs may have longer intervals.
Fluid Specifications
Engine Oil Capacity: Approx. 4.8 US quarts (4.5 liters) with filter change (4-cylinder Boxer engine)
Engine Oil Type: 5W-30 Synthetic or Conventional Motor Oil (API Service SG, SH, SJ, SL or ILSAC GF-2, GF-3)
Coolant Type: Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant. Capacity: Approx. 7.5 US quarts (7.1 liters)
Known Issues
Head Gaskets: While the EJ253 is generally more reliable than earlier EJ25s, head gasket leaks (internal or external) can still occur, especially with age and mileage. Manual provides detailed procedures for diagnosis and replacement.
Timing Belt: The timing belt is a critical maintenance item. Failure can lead to catastrophic engine damage. The manual details inspection and replacement procedures.
Catalytic Converter: Early failure or clogging can occur due to rich fuel mixtures or oil consumption. Manual includes diagnostic steps.
Oil Leaks: Common areas for leaks include valve cover gaskets, oil pan gaskets, and front crankshaft/camshaft seals. Manual guides to replacement.
Vehicle History
Brand Heritage
Subaru Heritage: Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history in aviation and automotive manufacturing, known for its horizontally opposed engines and commitment to All-Wheel Drive technology since the Subaru Leone in the 1970s.
Model Evolution
Forester Introduction: The Subaru Forester was introduced in 1997 as a compact crossover SUV, blending the utility of an SUV with the driving characteristics of a car. The 2002 model represents the second generation (SG) of the Forester, featuring a significant redesign and updated powertrains.
Production
Manufacturing Location: Gunma Plant, Japan
Awards & Recognition
Recognitions
Automotive Publications 2002: Often praised by automotive publications for its standard AWD, comfortable ride, and practicality, though sometimes criticized for interior materials and engine refinement compared to some competitors.
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