Subaru Forester 1999-2002 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation: First Generation (SF Series) Applicable Years: 1999, 2000, 2001, 2002 Codes Chassis Codes: SF5, SF9 👋 Introduction Market Position Segment: Compact Crossover SUV Target Demographic: Active individuals, families, outdoor enthusiasts seeking a capable and reliable all-weather vehicle. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra. Unique Selling Proposition: Standard Symmetrical All-Wheel Drive system, robust engineering, practical utility, and Subaru's reputation for durability. Key Features Powertrain: Subaru's Boxer engine and Symmetrical All-Wheel Drive as standard. Design: Higher ground clearance than typical sedans, wagon-like practicality with SUV styling. Safety: Emphasis on all-weather traction and stability. 📋 Manual Details Coverage Areas Primary Coverage: Repair and overhaul of Subaru Forester 1999-2002 models Target Audience: Technicians conversant with general automobile practices Page Count Estimated Pages: 1500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine repair, overhaul, diagnosis, and specifications for all applicable engine variants. Transmission: Service and repair for both automatic (4EAT, 5EAT) and manual transmissions (5MT). Drivetrain: All-Wheel Drive (AWD) system, differentials, driveshafts, and axles. Suspension: Front and rear suspension components, alignment, shock absorbers, springs, bushings, and control arms. Brakes: Disc and drum brake systems, ABS, parking brake, hydraulic circuits, and component replacement. Steering: Power steering system, steering rack, pump, and tie rods. Electrical: Complete electrical system, wiring diagrams, ECU, sensors, lighting, charging system, starting system, and accessories. Fuel System: Fuel pump, injectors, lines, tank, and emissions control systems. Cooling System: Radiator, water pump, thermostat, hoses, and fan operation. HVAC: Heating, ventilation, and air conditioning system diagnosis and repair. Body And Interior: Body panel repair, interior trim, seats, glass, and doors. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, and tune-ups. Troubleshooting: Diagnostic procedures for common and uncommon faults, including symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major mechanical and electrical components. Overhaul: Detailed procedures for engine and transmission rebuilds. Diagnostics: On-board diagnostics (OBD-II) interpretation, sensor data analysis, and fault code diagnosis. Technical Depth Depth: Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds, including detailed wiring diagrams and diagnostic trees. 📊 Manual Specifications File Format File Type: PDF Searchable: Yes (text-based PDF) Printable: Yes Print Quality Quality: High-resolution digital reproduction Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ253 (2.5L SOHC) Engine Displacement 1: 2498 cc (2.5 Liters) Engine Configuration 1: Horizontally Opposed (Boxer) 4-cylinder Bore X Stroke 1: 99.5 mm x 79.0 mm Compression Ratio 1: 9.7:1 Horsepower 1: 165 hp @ 5,600 rpm Torque 1: 166 lb-ft @ 4,000 rpm Engine Variants Engine Code 2: EJ25D (2.5L DOHC Turbocharged - Forester GT/STI) Engine Displacement 2: 2457 cc (2.5 Liters) Horsepower 2: 210-220 hp (approx., depending on market/trim) Torque 2: 200-220 lb-ft (approx., depending on market/trim) Fuel System Fuel Delivery: Electronic Fuel Injection (MPI) Fuel Type: Unleaded gasoline Engine Management ECU: ECU controlled ignition and fuel injection. 🔧 Transmission Standard Transmission Type Std: 5-Speed Manual (5MT) Optional Transmission Type Opt: 4-Speed Automatic (4EAT), later models may have 5-Speed Automatic (5EAT) Features Drivetrain Layout: Symmetrical All-Wheel Drive (Standard on all models) AWD System: Viscous coupling limited-slip center differential with driver-selectable low range (on some manual transmissions). Fluid Specifications Automatic Transmission Fluid: Subaru ATF (or Dexron II/III compatible) Manual Transmission Fluid: GL-5 Hypoid Gear Oil SAE 75W-90 📐 Dimensions Exterior Length: 4,405 mm (173.4 in) Width: 1,735 mm (68.3 in) Height: 1,570 mm (61.8 in) (non-turbo), 1,605 mm (63.2 in) (turbo) Wheelbase: 2,590 mm (102.0 in) Ground Clearance: 195 mm (7.7 in) Interior Seating Capacity: 5 Cargo Cargo Volume Seats Up: Approx. 0.74 m³ (26.2 cu ft) (with rear seats up) Cargo Volume Seats Down: Approx. 1.68 m³ (59.4 cu ft) (with rear seats folded) Weights Curb Weight Min: 1,440 kg (3,175 lbs) Curb Weight Max: 1,580 kg (3,483 lbs) Gross Vehicle Weight Rating: Approx. 1,990 kg (4,387 lbs) Wheels And Tires Wheel Size: 15-inch or 16-inch alloy or steel wheels Tire Size Std: 215/70R15 Tire Size Opt: 215/60R16 Bolt Pattern: 5 x 100 mm Offset: +48 mm 🛡️ Safety Features Ratings NHTSA Front Crash Test: ★★★★ (4-star rating) NHTSA Side Impact Test: ★★★★ (4-star rating) IIHS Frontal Offset: Good Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available on some models/trims Passive Features Airbags: Driver and front passenger airbags; available side airbags on later models/trims. Seatbelts: Three-point seatbelts with pretensioners for front occupants. Body Structure: Reinforced safety cage, crumple zones. 💡 Technology Features Infotainment Head Unit: Factory-fitted AM/FM/CD stereo systems, with cassette players on early models. Aftermarket head unit upgrades are common. Speakers: Typically 4 or 6 speaker systems. Driver Assistance Cruise Control: Standard on most trims. Connectivity Auxiliary Input: Not standard from the...
Fuel pump, injectors, lines, tank, and emissions control systems.
Cooling System:
Radiator, water pump, thermostat, hoses, and fan operation.
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair.
Body And Interior:
Body panel repair, interior trim, seats, glass, and doors.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, and tune-ups.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, including symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major mechanical and electrical components.
Overhaul:
Detailed procedures for engine and transmission rebuilds.
Diagnostics:
On-board diagnostics (OBD-II) interpretation, sensor data analysis, and fault code diagnosis.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds, including detailed wiring diagrams and diagnostic trees.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes (text-based PDF)
Printable:
Yes
Print Quality
Quality:
High-resolution digital reproduction
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EJ253 (2.5L SOHC)
Engine Displacement 1:
2498 cc (2.5 Liters)
Engine Configuration 1:
Horizontally Opposed (Boxer) 4-cylinder
Bore X Stroke 1:
99.5 mm x 79.0 mm
Compression Ratio 1:
9.7:1
Horsepower 1:
165 hp @ 5,600 rpm
Torque 1:
166 lb-ft @ 4,000 rpm
Engine Variants
Engine Code 2:
EJ25D (2.5L DOHC Turbocharged - Forester GT/STI)
Engine Displacement 2:
2457 cc (2.5 Liters)
Horsepower 2:
210-220 hp (approx., depending on market/trim)
Torque 2:
200-220 lb-ft (approx., depending on market/trim)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Engine Management
ECU:
ECU controlled ignition and fuel injection.
🔧 Transmission
Standard
Transmission Type Std:
5-Speed Manual (5MT)
Optional
Transmission Type Opt:
4-Speed Automatic (4EAT), later models may have 5-Speed Automatic (5EAT)
Features
Drivetrain Layout:
Symmetrical All-Wheel Drive (Standard on all models)
AWD System:
Viscous coupling limited-slip center differential with driver-selectable low range (on some manual transmissions).
Fluid Specifications
Automatic Transmission Fluid:
Subaru ATF (or Dexron II/III compatible)
Manual Transmission Fluid:
GL-5 Hypoid Gear Oil SAE 75W-90
📐 Dimensions
Exterior
Length:
4,405 mm (173.4 in)
Width:
1,735 mm (68.3 in)
Height:
1,570 mm (61.8 in) (non-turbo), 1,605 mm (63.2 in) (turbo)
Wheelbase:
2,590 mm (102.0 in)
Ground Clearance:
195 mm (7.7 in)
Interior
Seating Capacity:
5
Cargo
Cargo Volume Seats Up:
Approx. 0.74 m³ (26.2 cu ft) (with rear seats up)
Cargo Volume Seats Down:
Approx. 1.68 m³ (59.4 cu ft) (with rear seats folded)
Weights
Curb Weight Min:
1,440 kg (3,175 lbs)
Curb Weight Max:
1,580 kg (3,483 lbs)
Gross Vehicle Weight Rating:
Approx. 1,990 kg (4,387 lbs)
Wheels And Tires
Wheel Size:
15-inch or 16-inch alloy or steel wheels
Tire Size Std:
215/70R15
Tire Size Opt:
215/60R16
Bolt Pattern:
5 x 100 mm
Offset:
+48 mm
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
★★★★ (4-star rating)
NHTSA Side Impact Test:
★★★★ (4-star rating)
IIHS Frontal Offset:
Good
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available on some models/trims
Passive Features
Airbags:
Driver and front passenger airbags; available side airbags on later models/trims.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
Body Structure:
Reinforced safety cage, crumple zones.
💡 Technology Features
Infotainment
Head Unit:
Factory-fitted AM/FM/CD stereo systems, with cassette players on early models. Aftermarket head unit upgrades are common.
Speakers:
Typically 4 or 6 speaker systems.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Auxiliary Input:
Not standard from the factory; requires aftermarket adapter or head unit replacement.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months, whichever comes first. Check owner's manual for severe driving conditions.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Cabin Air Filter:
Every 15,000 miles (24,000 km) or 12 months (if equipped).
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for iridium-tipped plugs, 30,000 miles (48,000 km) for platinum/copper plugs.
Timing Belt Replacement:
Every 105,000 miles (168,000 km) or 7 years. Crucial for EJ25 engines to prevent catastrophic failure.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (API SJ or higher)
Engine Oil Capacity:
4.5 US quarts (4.3 liters) with filter change
Coolant Type:
Subaru Super Coolant (or equivalent ethylene glycol based coolant with long-life additives), mixed 50/50 with distilled water.
Coolant Capacity:
Approx. 7.0 US quarts (6.6 liters)
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
Subaru Genuine Power Steering Fluid (or Dexron III/Mercon compatible)
Known Issues
Head Gaskets:
The EJ25SOHC (EJ253) engines are prone to head gasket failure, particularly at higher mileage. Look for coolant leaks, white smoke, or oil in coolant.
Timing Belt:
Crucial to adhere to the timing belt replacement interval to prevent severe engine damage from belt breakage.
Oil Leaks:
Valve cover gaskets and oil cooler seals can leak with age.
Automatic Transmission:
Some 4EAT transmissions can develop issues with solenoids or the valve body. Regular fluid changes are important.
Wheel Bearings:
Front wheel bearings can wear out, especially with off-road use or if hit by potholes.
📚 Vehicle History
Brand Heritage
Subaru Specialty:
Subaru's reputation for building durable, reliable vehicles with a focus on all-wheel-drive technology and boxer engines.
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.
Sf Generation:
The 1999-2002 models represent the latter half of the first generation (SF chassis), which received a significant facelift and powertrain updates for the 2001 model year.
Facelift 2001:
Updated exterior styling (headlights, grille, bumpers, hood), revised interior, and optional introduction of the 5-speed automatic transmission.
Production
Manufacturing Plant:
Ota, Gunma Prefecture, Japan
Production Years:
1997-2002 (First Generation)
🏆 Awards & Recognition
Recognitions
Edmunds Rating:
Generally well-regarded for its AWD capability and practicality for its era.
Kbb Rating:
Praised for good value and capability, though fuel economy was average.
Certifications
Safety Certifications:
Met all federal motor vehicle safety standards (FMVSS) for its model years.