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SUBARU FORESTER Digital Workshop Repair Manual 1999-2002

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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation Generation Name: SF Series Codes Model Codes: SF5, SF9 👋 Introduction Market Position Vehicle Segment: Compact SUV/Crossover Target Audience: Active individuals, families, outdoor enthusiasts Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Nissan Xterra, Ford Escape Differentiating Factors: Standard Symmetrical All-Wheel Drive, boxer engine, excellent ground clearance Key Features Powertrain: Horizontally-opposed Boxer engine, Symmetrical All-Wheel Drive Design: Practical, wagon-like SUV with good visibility Durability: Known for robust mechanicals and AWD system Manual Value Proposition: Empowers owners for self-sufficiency in maintenance and repair, saving significant costs. 📋 Manual Details Coverage Areas Years Covered: 1999, 2000, 2001, 2002 Page Count Estimated Pages: 1500+ Manual Type Type: Digital Workshop Repair Manual Language Language: English Format Format: Digital (likely PDF, Searchable) 📖 Manual Coverage Systems Covered Engine Mechanical: Yes (EJ25 SOHC, EJ25 DOHC, EJ25 Turbo DOHC) Engine Performance: Yes (fuel injection, ignition, emissions, cooling, lubrication) Transmission Manual: Yes (5-speed manual) Transmission Automatic: Yes (4-speed automatic, Sportshift) Drivetrain: Yes (All-Wheel Drive system, differentials, driveshafts) Suspension: Yes (front struts, rear multi-link, control arms, bushings) Brakes: Yes (front disc, rear disc, ABS) Steering: Yes (power rack and pinion) Electrical System: Yes (battery, charging system, starting system) Lighting: Yes (headlights, taillights, interior lights) HVAC: Yes (heating, ventilation, air conditioning) Body And Interior: Yes (panels, doors, glass, seats, trim) Safety Systems: Yes (airbags, seatbelts) Diagnostic Troubleshooting: Yes (OBD-II codes, fault finding) Procedures Included Routine Maintenance: Yes (oil changes, filter replacements, fluid checks) Major Repairs: Yes (engine rebuild, transmission overhaul) Component Replacement: Yes (alternator, starter, water pump, belts, hoses) Electrical Diagnosis: Yes (wiring diagrams, component testing) Suspension Repair: Yes (strut replacement, bearing service) Brake Service: Yes (pad and rotor replacement, caliper service) Bodywork Repair: Yes (panel alignment, dent repair guidance) HVAC Service: Yes (recharge, component replacement) Troubleshooting Guides: Yes (step-by-step diagnostics) Technical Depth Depth: Comprehensive (from basic maintenance to full rebuilds) Diagnostics: Advanced (including specific DTCs and testing procedures) Specifications Data: Detailed (torque specs, clearances, fluid capacities, resistance values) Wiring Diagrams: Yes (comprehensive electrical schematics) 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Print Quality Printability: Printable (for individual pages or full document) Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ251 (2.5L SOHC) Engine Code 2: EJ253 (2.5L SOHC, later models) Engine Code 3: EJ255 (2.5L DOHC Turbo, GT/STI variants) Engine Displacement 1: 2457 cc Engine Displacement 2: 2457 cc (Turbo) Performance Horsepower 1: 165 hp @ 5600 rpm (EJ251/253) Torque 1: 166 lb-ft @ 4000 rpm (EJ251/253) Horsepower 2: 227 hp @ 5600 rpm (EJ255 Turbo) Torque 2: 236 lb-ft @ 3000 rpm (EJ255 Turbo) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Ignition System: Distributorless Ignition System (DIS) / Coil-on-Plug 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission (with Sportshift option) Features AWD System: Symmetrical All-Wheel Drive (AWD) with viscous center differential Gear Ratios: Detailed in manual (varies by transmission type) Transmission Fluid Type Auto: Subaru ATF HP (or equivalent) Transmission Fluid Capacity Auto: Approx. 7.5 US quarts (6.9 Liters) Transmission Fluid Type Manual: GL-5 75W-90 Gear Oil 📐 Dimensions Exterior Length: 4410 mm (173.6 in) Width: 1770 mm (69.7 in) Height: 1590 mm (62.6 in) Wheelbase: 2630 mm (103.5 in) Ground Clearance: Approx. 7.5 inches (190 mm) Cargo Cargo Volume Seats Up: Approx. 31.5 cu ft (892 Liters) Cargo Volume Seats Down: Approx. 63.1 cu ft (1787 Liters) Weights Curb Weight Min: 1420 kg (3131 lbs) Curb Weight Max: 1570 kg (3461 lbs) Towing Capacity: 2000 lbs (907 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (for 1999-2002 models based on historical data) NHTSA Front Impact Passenger: Good (for 1999-2002 models based on historical data) IIHS Small Overlap Front: N/A (Test not performed on these model years) Active Features ABS: Standard (4-wheel ABS) Traction Control: Optional (on some models) Passive Features Airbags Front: Standard (driver and passenger) Airbags Side: Optional (on some models/trims) Seatbelts: 3-point front and rear seatbelts 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, optional premium audio Navigation: Not available on most models from this era Driver Assistance Cruise Control: Standard on most trims All Wheel Drive: Standard, a key technological advantage 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-7,500 miles or 6-12 months (depending on oil type and driving conditions) Engine Air Filter: Inspect every 15,000 miles, replace as needed Cabin Air Filter: Replace annually or as needed Spark Plugs: Replace at 60,000 miles (NGK Platinum/Iridium) Timing Belt: Replace at 105,000 miles or 7 years (critical for interference engines) Fluid Specifications Engine Oil: API SG/SH/SJ Certified, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temp) Coolant: Subaru Super Coolant (Blue) or equivalent Ethylene Glycol based coolant (50/50 mix) Brake Fluid:...
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SUBARU FORESTER Digital Workshop Repair Manual 1999-2002
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Generation
Generation Name:
SF Series
Codes
Model Codes:
SF5, SF9
👋 Introduction
Market Position
Vehicle Segment:
Compact SUV/Crossover
Target Audience:
Active individuals, families, outdoor enthusiasts
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Nissan Xterra, Ford Escape
Differentiating Factors:
Standard Symmetrical All-Wheel Drive, boxer engine, excellent ground clearance
Key Features
Powertrain:
Horizontally-opposed Boxer engine, Symmetrical All-Wheel Drive
Design:
Practical, wagon-like SUV with good visibility
Durability:
Known for robust mechanicals and AWD system
Manual Value Proposition:
Empowers owners for self-sufficiency in maintenance and repair, saving significant costs.
📋 Manual Details
Coverage Areas
Years Covered:
1999, 2000, 2001, 2002
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Digital Workshop Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, Searchable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Yes (EJ25 SOHC, EJ25 DOHC, EJ25 Turbo DOHC)
Engine Performance:
Yes (fuel injection, ignition, emissions, cooling, lubrication)
Transmission Manual:
Yes (5-speed manual)
Transmission Automatic:
Yes (4-speed automatic, Sportshift)
Drivetrain:
Yes (All-Wheel Drive system, differentials, driveshafts)
Suspension:
Yes (front struts, rear multi-link, control arms, bushings)
Brakes:
Yes (front disc, rear disc, ABS)
Steering:
Yes (power rack and pinion)
Electrical System:
Yes (battery, charging system, starting system)
Lighting:
Yes (headlights, taillights, interior lights)
HVAC:
Yes (heating, ventilation, air conditioning)
Body And Interior:
Yes (panels, doors, glass, seats, trim)
Safety Systems:
Yes (airbags, seatbelts)
Diagnostic Troubleshooting:
Yes (OBD-II codes, fault finding)
Procedures Included
Routine Maintenance:
Yes (oil changes, filter replacements, fluid checks)
Major Repairs:
Yes (engine rebuild, transmission overhaul)
Component Replacement:
Yes (alternator, starter, water pump, belts, hoses)
Electrical Diagnosis:
Yes (wiring diagrams, component testing)
Suspension Repair:
Yes (strut replacement, bearing service)
Brake Service:
Yes (pad and rotor replacement, caliper service)
Bodywork Repair:
Yes (panel alignment, dent repair guidance)
HVAC Service:
Yes (recharge, component replacement)
Troubleshooting Guides:
Yes (step-by-step diagnostics)
Technical Depth
Depth:
Comprehensive (from basic maintenance to full rebuilds)
Diagnostics:
Advanced (including specific DTCs and testing procedures)
Specifications Data:
Detailed (torque specs, clearances, fluid capacities, resistance values)
Wiring Diagrams:
Yes (comprehensive electrical schematics)
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Print Quality
Printability:
Printable (for individual pages or full document)
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EJ251 (2.5L SOHC)
Engine Code 2:
EJ253 (2.5L SOHC, later models)
Engine Code 3:
EJ255 (2.5L DOHC Turbo, GT/STI variants)
Engine Displacement 1:
2457 cc
Engine Displacement 2:
2457 cc (Turbo)
Performance
Horsepower 1:
165 hp @ 5600 rpm (EJ251/253)
Torque 1:
166 lb-ft @ 4000 rpm (EJ251/253)
Horsepower 2:
227 hp @ 5600 rpm (EJ255 Turbo)
Torque 2:
236 lb-ft @ 3000 rpm (EJ255 Turbo)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Ignition System:
Distributorless Ignition System (DIS) / Coil-on-Plug
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission (with Sportshift option)
Features
AWD System:
Symmetrical All-Wheel Drive (AWD) with viscous center differential
Gear Ratios:
Detailed in manual (varies by transmission type)
Transmission Fluid Type Auto:
Subaru ATF HP (or equivalent)
Transmission Fluid Capacity Auto:
Approx. 7.5 US quarts (6.9 Liters)
Transmission Fluid Type Manual:
GL-5 75W-90 Gear Oil
📐 Dimensions
Exterior
Length:
4410 mm (173.6 in)
Width:
1770 mm (69.7 in)
Height:
1590 mm (62.6 in)
Wheelbase:
2630 mm (103.5 in)
Ground Clearance:
Approx. 7.5 inches (190 mm)
Cargo
Cargo Volume Seats Up:
Approx. 31.5 cu ft (892 Liters)
Cargo Volume Seats Down:
Approx. 63.1 cu ft (1787 Liters)
Weights
Curb Weight Min:
1420 kg (3131 lbs)
Curb Weight Max:
1570 kg (3461 lbs)
Towing Capacity:
2000 lbs (907 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for 1999-2002 models based on historical data)
NHTSA Front Impact Passenger:
Good (for 1999-2002 models based on historical data)
IIHS Small Overlap Front:
N/A (Test not performed on these model years)
Active Features
ABS:
Standard (4-wheel ABS)
Traction Control:
Optional (on some models)
Passive Features
Airbags Front:
Standard (driver and passenger)
Airbags Side:
Optional (on some models/trims)
Seatbelts:
3-point front and rear seatbelts
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio
Navigation:
Not available on most models from this era
Driver Assistance
Cruise Control:
Standard on most trims
All Wheel Drive:
Standard, a key technological advantage
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles or 6-12 months (depending on oil type and driving conditions)
Engine Air Filter:
Inspect every 15,000 miles, replace as needed
Cabin Air Filter:
Replace annually or as needed
Spark Plugs:
Replace at 60,000 miles (NGK Platinum/Iridium)
Timing Belt:
Replace at 105,000 miles or 7 years (critical for interference engines)
Fluid Specifications
Engine Oil:
API SG/SH/SJ Certified, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temp)
Coolant:
Subaru Super Coolant (Blue) or equivalent Ethylene Glycol based coolant (50/50 mix)
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
ATF Dexron III (or equivalent)
Known Issues
Head Gaskets:
Common failure point on EJ series engines, especially at higher mileage. Manual provides repair procedures.
Timing Belt Tensioner:
Potential for failure; proactive replacement recommended with timing belt service.
Oil Leaks:
Can occur from valve cover gaskets, oil pan gaskets, and rear main seals.
Cv Joints:
Wear can occur, especially on lifted or off-road vehicles.
Radiator Leaks:
Plastic end tanks can crack over time.
📚 Vehicle History
Brand Heritage
Manufacturer:
Subaru (part of Fuji Heavy Industries)
Brand Focus:
All-Wheel Drive, boxer engines, practicality, safety
Model Evolution
Introduction Year:
1997 (Globally), 1998 (North America)
Generation 1 Start Year:
1997
Generation 1 End Year:
2002
Next Generation Start Year:
2003
Production
Manufacturing Location:
Gunma, Japan
🏆 Awards & Recognition
Recognitions
Motor Trend SUV Of The Year:
No (Subaru Outback received this for 1996)
Kbb Best Resale Value:
Forester models often cited for strong resale value
Ratings
Consumer Reports Reliability:
Mixed to good ratings for this generation, with specific known issues addressed by the manual.
Certifications
Emissions Standards:
Meets EPA and CARB standards for the specified years
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