Subaru Forester 1999-2002 Service Manual/Repair Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Product Name: Subaru Forester 1999-2002 Service Manual/Repair Manual Codes Chassis Codes: SF Generation Generation Designation: First Generation (SF) Generation Years: 1997-2002 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Key Selling Points: Standard Symmetrical All-Wheel Drive, robust build, practical utility, good visibility. Competitive Analysis Direct Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra. Key Features Engine Offering: Boxer engine architecture providing a lower center of gravity. Drivetrain: Standard Symmetrical All-Wheel Drive (AWD) across all trims, a hallmark of Subaru. 📋 Manual Details Coverage Areas Applicable Years: 1999, 2000, 2001, 2002 Covered Models: Subaru Forester (all trims) Page Count Estimated Page Count: Varies by specific publication, typically 1000+ pages for comprehensive service manuals Manual Type Type: Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full coverage including cylinder head, cylinder block, pistons, crankshaft, camshafts, valve train, timing belt/chain, lubrication system, cooling system. Engine Management: EFI System, SFI System, emission control systems, ECU diagnosis, sensors (knock, camshaft position, speed sensors), fuel system (pump, injectors, tank), ignition system. Transmission: Manual Transaxle System and Automatic Transaxle System coverage including internal components, torque converter, valve body, control cables, fluid specifications. Drivetrain: Front and Rear Axle Hubs, Drive Shafts, Differential Case Assy, Axle Beam components. Suspension: Front Suspension System (arms, stabilizer bar, shock absorber) and Rear Suspension System (coil springs, shock absorbers). Steering: Steering System, Power Steering, Steering Column, Steering Sensor components. Brakes: Brake System, Brake Master Cylinder, Brake Booster, Brake Actuator, Brake Fluid specifications, ABS components (if applicable). Electrical System: Charging System (generator), Starting System (starter), Ignition System, lighting system, audio & visual system, power mirror control, power window, power door lock control. Body Exterior: Hood, Front/Rear Bumper, Front/Rear Door, Back Door, Sun Roof System, Wiper & Washer System, Windshield Glass, Side Mudguard, License Plate Lamp Assy, Combination Lamp Assy. HVAC: Heater Radiator Assy, Heater Or Boost Ventilator Control, Air Conditioning System, Air Conditioning Blower Assy, Air Conditioner Refrigerant specifications. Body Interior Interior Trim: Instrument Panel, Roof Headlining, Center Cluster Module Switch, Seat systems, Interior lighting. Safety Systems Airbag Systems: Supplemental Restraint System (SRS), Air Bag Sensor Front/Rear, Side Air Bag Sensor Assy, Seat Position Air Bag Sensor, Passenger Air Bag Assy, Curtain Shield Air Bag Assy. Procedures Included Routine Maintenance: Oil and filter changes, fluid level checks and replacements, spark plug replacement, air filter replacement, coolant replacement, belt inspection and replacement. Troubleshooting: Diagnostic procedures for various systems, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation. Component Repair: Detailed step-by-step instructions for removal, disassembly, inspection, repair, and reassembly of most vehicle components. Wiring Diagrams: Comprehensive wiring diagrams for all electrical systems, including wire harness repair information. Specifications: Torque specifications, clearances, fluid capacities, pressure readings, electrical component resistances, and other critical technical data. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, advanced diagnostics, and body repair. 📊 Manual Specifications File Format Searchability: Generally searchable PDF format, allowing for quick keyword-based navigation. Printability: Printable, allowing users to print specific sections or the entire manual for physical use. Print Quality Graphic Resolution: High-resolution for clear diagrams and illustrations. Binding Type Binding: N/A (PDF format - digital) Paper Type Paper Type: N/A (PDF format - digital) ⚙️ Engine Specifications Primary Engine Engine Code And Type: EJ251 (2.5L Naturally Aspirated SOHC EJ Series Boxer-4) Performance Horsepower: 165 hp @ 5,600 rpm Torque: 166 lb-ft @ 4,000 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Mechanical Bore X Stroke: 99.5 mm x 79.0 mm Compression Ratio: 9.7:1 Cooling System Cooling Fan System: Engine-driven fan with viscous coupling (mechanically controlled). 🔧 Transmission Standard Transmission Type: 5-Speed Manual Optional Transmission Type: 4-Speed Automatic (4EAT) Features Automatic Transmission Features: Electronically controlled, utilizes a viscous coupling for AWD operation. 📐 Dimensions Exterior Length: 4,405 mm (173.4 in) Width: 1,765 mm (69.5 in) Height: 1,590 mm (62.6 in) Wheelbase: 2,500 mm (98.4 in) Weights Curb Weight: Approx. 1,400 - 1,500 kg (3,086 - 3,307 lbs) Cargo Cargo Volume: Approx. 0.88 m³ (31 cu ft) behind rear seats, expandable with seats folded. 🛡️ Safety Features Ratings NHTSA Frontal Crash Test: Likely 4-star rating for driver and passenger based on contemporary testing for similar vehicles (specific ratings may vary). Passive Features Airbags: Frontal airbags for driver and passenger, optional side airbags. Seatbelts: Three-point seatbelts with pretensioners and load limiters in front. Child Seat Anchors: LATCH (Lower Anchors and Tethers for Children) system. Active Features ABS: Anti-lock Braking System (ABS) available, typically standard on higher trims. 💡 Technology Features Infotainment Audio System: Base models often featured a single-CD or cassette player with AM/FM radio. Higher trims could include premium audio systems. Driver Assistance ABS: Anti-lock Braking System (ABS) was an option, not always standard on base...
Manual Transaxle System and Automatic Transaxle System coverage including internal components, torque converter, valve body, control cables, fluid specifications.
Drivetrain:
Front and Rear Axle Hubs, Drive Shafts, Differential Case Assy, Axle Beam components.
Suspension:
Front Suspension System (arms, stabilizer bar, shock absorber) and Rear Suspension System (coil springs, shock absorbers).
Steering:
Steering System, Power Steering, Steering Column, Steering Sensor components.
Charging System (generator), Starting System (starter), Ignition System, lighting system, audio & visual system, power mirror control, power window, power door lock control.
Body Exterior:
Hood, Front/Rear Bumper, Front/Rear Door, Back Door, Sun Roof System, Wiper & Washer System, Windshield Glass, Side Mudguard, License Plate Lamp Assy, Combination Lamp Assy.
HVAC:
Heater Radiator Assy, Heater Or Boost Ventilator Control, Air Conditioning System, Air Conditioning Blower Assy, Air Conditioner Refrigerant specifications.
Supplemental Restraint System (SRS), Air Bag Sensor Front/Rear, Side Air Bag Sensor Assy, Seat Position Air Bag Sensor, Passenger Air Bag Assy, Curtain Shield Air Bag Assy.
Procedures Included
Routine Maintenance:
Oil and filter changes, fluid level checks and replacements, spark plug replacement, air filter replacement, coolant replacement, belt inspection and replacement.
Troubleshooting:
Diagnostic procedures for various systems, symptom-based troubleshooting guides, DTC (Diagnostic Trouble Code) interpretation.
Component Repair:
Detailed step-by-step instructions for removal, disassembly, inspection, repair, and reassembly of most vehicle components.
Wiring Diagrams:
Comprehensive wiring diagrams for all electrical systems, including wire harness repair information.
Specifications:
Torque specifications, clearances, fluid capacities, pressure readings, electrical component resistances, and other critical technical data.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, advanced diagnostics, and body repair.
📊 Manual Specifications
File Format
Searchability:
Generally searchable PDF format, allowing for quick keyword-based navigation.
Printability:
Printable, allowing users to print specific sections or the entire manual for physical use.
Print Quality
Graphic Resolution:
High-resolution for clear diagrams and illustrations.
Binding Type
Binding:
N/A (PDF format - digital)
Paper Type
Paper Type:
N/A (PDF format - digital)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
EJ251 (2.5L Naturally Aspirated SOHC EJ Series Boxer-4)
Performance
Horsepower:
165 hp @ 5,600 rpm
Torque:
166 lb-ft @ 4,000 rpm
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Mechanical
Bore X Stroke:
99.5 mm x 79.0 mm
Compression Ratio:
9.7:1
Cooling System
Cooling Fan System:
Engine-driven fan with viscous coupling (mechanically controlled).
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual
Optional
Transmission Type:
4-Speed Automatic (4EAT)
Features
Automatic Transmission Features:
Electronically controlled, utilizes a viscous coupling for AWD operation.
📐 Dimensions
Exterior
Length:
4,405 mm (173.4 in)
Width:
1,765 mm (69.5 in)
Height:
1,590 mm (62.6 in)
Wheelbase:
2,500 mm (98.4 in)
Weights
Curb Weight:
Approx. 1,400 - 1,500 kg (3,086 - 3,307 lbs)
Cargo
Cargo Volume:
Approx. 0.88 m³ (31 cu ft) behind rear seats, expandable with seats folded.
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test:
Likely 4-star rating for driver and passenger based on contemporary testing for similar vehicles (specific ratings may vary).
Passive Features
Airbags:
Frontal airbags for driver and passenger, optional side airbags.
Seatbelts:
Three-point seatbelts with pretensioners and load limiters in front.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
Active Features
ABS:
Anti-lock Braking System (ABS) available, typically standard on higher trims.
💡 Technology Features
Infotainment
Audio System:
Base models often featured a single-CD or cassette player with AM/FM radio. Higher trims could include premium audio systems.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an option, not always standard on base models.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors were available, often standard on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3.75 months, whichever comes first.
Timing Belt Replacement:
Recommended every 105,000 miles (168,000 km) or 105 months. Critical for EJ25 engines.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-30 viscosity grade. Check owner's manual for specific ambient temperature recommendations.
Engine Coolant:
Subaru Super Coolant (blue) or equivalent 50/50 mixture with distilled water.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 Gear Oil.
Transmission Fluid Automatic:
Subaru ATF-HP or equivalent DEXRON II/III compatible fluid.
Brake Fluid:
DOT 3 or DOT 4.
Known Issues
Head Gaskets:
While less prevalent in the SOHC EJ251 compared to early DOHC versions, coolant leaks and head gasket failures can still occur due to age and mileage.
Timing Belt:
Failure to replace the timing belt at recommended intervals can lead to catastrophic engine damage (interference engine).
Oil Consumption:
Some EJ25 engines may exhibit increased oil consumption as they age; regular checks are advised.
📚 Vehicle History
Brand Heritage
Brand Focus:
Subaru is renowned for its Symmetrical All-Wheel Drive system and horizontally opposed ('boxer') engines.
Model Evolution
First Generation Launch:
The first generation Forester (SF) debuted in 1997, blending SUV-like styling with a car-like driving experience.
Mid-Cycle Refresh:
A significant refresh occurred for the 2001 model year, featuring updated styling (headlights, grille, bumpers) and improved interior amenities.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Segment Popularity:
Consistently praised for its AWD capability and practicality in automotive reviews of its era.