🏷️ Basic Information Identification Make: Subaru Model: Forester Product Name: SUBARU FORESTER Service Repair Manual 1999-2002 Generation Generation Code: SF Series (First Generation) Codes Chassis Codes: SF5, SF9 Engine Codes Covered: EJ201, EJ202, EJ251, EJ252, EJ253 (Naturally Aspirated), EJ205 (Turbocharged) 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Target Audience: Families, outdoor enthusiasts, drivers seeking AWD capability and practicality Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra Key Features Differentiating Features: Standard Symmetrical All-Wheel Drive, Boxer engine configuration, practical wagon-like utility Manual Value Proposition Manual Benefit: Empowers owners and technicians with comprehensive, accurate repair and maintenance data for optimal vehicle performance and longevity. 📋 Manual Details Coverage Areas Manual Coverage Scope: All models and engines produced for the 1999-2002 model years Page Count Estimated Page Count: 1500-2500 (typical for comprehensive factory service manuals of this era, exact number not provided but described as 'every single detail') Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital Download (likely PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel injection, ignition, exhaust, emissions control, turbocharging (for EJ205) Transmission Systems: Manual transmission (5-speed), Automatic transmission (4-speed), clutch, drive axles, differentials Drivetrain Systems: Symmetrical All-Wheel Drive (AWD) system, viscous coupling center differential Suspension Steering: Front suspension (MacPherson struts), Rear suspension (Multi-link), power steering system, steering column Braking Systems: Front disc brakes, Rear disc brakes (or drum brakes on some base models), Anti-lock Braking System (ABS) Electrical Systems: Battery, charging system, starting system, lighting, gauges, instruments, power accessories, body control module, engine control module (ECM) wiring diagrams HVAC Systems: Heating, Ventilation, and Air Conditioning (HVAC) system operation and repair Body Chassis: Body construction, exterior trim, interior trim, doors, windows, roof, underbody Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, brake service, tune-ups Repair Procedures: Engine overhaul, transmission rebuild, suspension component replacement, brake caliper service, exhaust system repair, electrical component diagnosis and replacement Troubleshooting Guidance: Diagnostic procedures, symptom-based troubleshooting charts, common problems and solutions Diagnostic Procedures: OBD-II diagnostics, sensor testing, actuator testing, fault code interpretation Technical Depth Diagnostic Capability: Advanced diagnostics including component testing and wiring schematics Rebuild Capability: Complete engine and transmission rebuild procedures with specifications Specification Detail: Detailed torque specifications, clearances, tolerances, and fluid capacities 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Searchable text content for quick information retrieval Printable: Printable pages for on-site workshop use Print Quality Image Resolution: High-resolution diagrams and illustrations Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1 Name: 2.5L DOHC 16-Valve Boxer (EJ251/EJ252/EJ253) Engine 1 Displacement: 2457 cc (2.5 Liters) Engine 1 Horsepower: 165-170 HP (SAE Net, varies slightly by year/spec) Engine 1 Torque: 166-170 lb-ft (SAE Net, varies slightly by year/spec) Optional Engine Engine 2 Name: 2.0L DOHC 16-Valve Turbocharged Boxer (EJ205) Engine 2 Displacement: 1994 cc (2.0 Liters) Engine 2 Horsepower: 210-227 HP (SAE Net, varies slightly by year/spec) Engine 2 Torque: 235-250 lb-ft (SAE Net, varies slightly by year/spec) Performance Fuel Requirement: Unleaded gasoline (87 octane minimum for naturally aspirated, premium recommended for turbocharged) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Sequential Multi-Point Injection Engine Management Engine Control Unit: Subaru Engine Control Module (ECM) Emission Controls: Catalytic converter, Oxygen sensors (O2 sensors), Exhaust Gas Recirculation (EGR) system (on some models) 🔧 Transmission Standard Transmission Type Std: 5-Speed Manual Transmission Optional Transmission Type Opt: 4-Speed Automatic Transmission (with overdrive) Features Drivetrain System: Symmetrical All-Wheel Drive (AWD) with viscous coupling center differential (standard on all trims) Fluid Specs Manual Transmission Fluid: API GL-5, SAE 75W-90 Gear Oil (e.g., Subaru Genuine Gear Oil or equivalent) Automatic Transmission Fluid: Dexron III or equivalent (e.g., Subaru ATF-HP, though Dexron III is more common for this era) Fluid Capacity Manual Transmission Capacity: Approx. 2.3 liters (manual notes capacity, specific part number for fluid usually 80W-90 GL-5) Automatic Transmission Capacity: Approx. 3.5 liters (for drain and fill, total capacity higher) 📐 Dimensions Exterior Wheelbase: 2530 mm (99.6 inches) Length: 4405 mm (173.4 inches) Width: 1735 mm (68.3 inches) Height: 1590 mm (62.6 inches) Cargo Cargo Volume: Approx. 28.4 cu ft (with rear seats up), Approx. 63.0 cu ft (with rear seats folded) Weights Curb Weight: 1400-1550 kg (approx. 3086-3417 lbs, varies by trim and drivetrain) Towing Capacity: 1000 kg (2200 lbs) (with trailer brakes), 750 kg (1650 lbs) (without trailer brakes) 🛡️ Safety Features Ratings NHTSA Frontal Crash: Not directly comparable to modern standards, but generally rated well for its era IIHS Side Impact: Not rated for the 1999-2002 models in a way that directly translates to modern G/A ratings. Active Features Active Safety Features: Standard Symmetrical All-Wheel Drive, Anti-lock Braking System (ABS) (standard on most models, check specific trim) Passive Features...
Symmetrical All-Wheel Drive (AWD) system, viscous coupling center differential
Suspension Steering:
Front suspension (MacPherson struts), Rear suspension (Multi-link), power steering system, steering column
Braking Systems:
Front disc brakes, Rear disc brakes (or drum brakes on some base models), Anti-lock Braking System (ABS)
Electrical Systems:
Battery, charging system, starting system, lighting, gauges, instruments, power accessories, body control module, engine control module (ECM) wiring diagrams
HVAC Systems:
Heating, Ventilation, and Air Conditioning (HVAC) system operation and repair
Body Chassis:
Body construction, exterior trim, interior trim, doors, windows, roof, underbody
Catalytic converter, Oxygen sensors (O2 sensors), Exhaust Gas Recirculation (EGR) system (on some models)
🔧 Transmission
Standard
Transmission Type Std:
5-Speed Manual Transmission
Optional
Transmission Type Opt:
4-Speed Automatic Transmission (with overdrive)
Features
Drivetrain System:
Symmetrical All-Wheel Drive (AWD) with viscous coupling center differential (standard on all trims)
Fluid Specs
Manual Transmission Fluid:
API GL-5, SAE 75W-90 Gear Oil (e.g., Subaru Genuine Gear Oil or equivalent)
Automatic Transmission Fluid:
Dexron III or equivalent (e.g., Subaru ATF-HP, though Dexron III is more common for this era)
Fluid Capacity
Manual Transmission Capacity:
Approx. 2.3 liters (manual notes capacity, specific part number for fluid usually 80W-90 GL-5)
Automatic Transmission Capacity:
Approx. 3.5 liters (for drain and fill, total capacity higher)
📐 Dimensions
Exterior
Wheelbase:
2530 mm (99.6 inches)
Length:
4405 mm (173.4 inches)
Width:
1735 mm (68.3 inches)
Height:
1590 mm (62.6 inches)
Cargo
Cargo Volume:
Approx. 28.4 cu ft (with rear seats up), Approx. 63.0 cu ft (with rear seats folded)
Weights
Curb Weight:
1400-1550 kg (approx. 3086-3417 lbs, varies by trim and drivetrain)
Towing Capacity:
1000 kg (2200 lbs) (with trailer brakes), 750 kg (1650 lbs) (without trailer brakes)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash:
Not directly comparable to modern standards, but generally rated well for its era
IIHS Side Impact:
Not rated for the 1999-2002 models in a way that directly translates to modern G/A ratings.
Active Features
Active Safety Features:
Standard Symmetrical All-Wheel Drive, Anti-lock Braking System (ABS) (standard on most models, check specific trim)
Passive Features
Passive Safety Features:
Driver and front passenger airbags, Side impact door beams, Crumple zones, 3-point seatbelts with pretensioners
Child Safety
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) not standard in this generation. ISOFIX compatible in some regions, requires manual guidance.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional cassette, typically 4 or 6 speaker system depending on trim.
Navigation System:
Optional factory navigation system available on higher trims, typically aftermarket units were more common.
Driver Assistance
Cruise Control:
Standard on most models.
Traction Control:
Not commonly available on these models, AWD is the primary traction enhancer.
Connectivity
Auxiliary Input:
Not typically equipped with factory auxiliary input. Aftermarket adapters or head unit replacements are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3 months (severe driving) / 7,500 miles or 6 months (normal driving), check owner's manual for exact recommendation based on driving conditions and oil type.
Air Filter Replacement:
Every 15,000 miles or 12 months
Spark Plug Replacement:
Every 30,000 miles for platinum-tipped plugs, 60,000 miles for iridium-tipped plugs (check plug type)
Coolant Flush:
Every 30,000 miles or 24 months
Timing Belt Replacement:
Crucial: Every 60,000 to 105,000 miles or 4-7 years (refer to specific manual for exact mileage/time, critical due to interference engine design). Often recommended to replace water pump and idler pulleys simultaneously.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 5W-40 API SG or SH rated (check owner's manual for specific viscosity and API rating for your climate)
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 liters) with filter change
Coolant Type:
Subaru Super Coolant (blue) or equivalent ethylene glycol-based coolant (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 (refer to reservoir cap)
Known Issues
Common Issues:
Head gasket leaks (especially on EJ251/EJ252 engines in earlier iterations, though less prevalent than later generations), exhaust manifold cracks, oil consumption, rear differential whine, ABS sensor failure, catalytic converter issues.
Timing Belt Failure Impact:
Interference engine design means timing belt failure will likely result in catastrophic valve-to-piston damage.
📚 Vehicle History
Brand Heritage
Subaru Heritage:
Founded in 1953, Fuji Heavy Industries (now Subaru Corporation) is known for its pioneering work in all-wheel-drive technology and horizontally-opposed Boxer engines.
Model Evolution
Forester Introduction:
The Subaru Forester was introduced globally in 1997 as a 'sport utility wagon', bridging the gap between traditional station wagons and SUVs.
First Generation Period:
1997-2002 (SF Series)
Production
Manufacturing Locations:
Japan (Ota, Gunma Prefecture), Ecuador, Thailand, Taiwan
Production Years Covered:
1999, 2000, 2001, 2002
🏆 Awards & Recognition
Recognitions
Car And Driver All Stars:
Subaru Forester (often the turbocharged XT models, but the platform was recognized for its capabilities) was a recurring recipient of Car and Driver's '10Best Trucks' list in various years around this period.