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SUBARU FORESTER Service Repair Manual 99-02

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๐Ÿท๏ธ Basic Information Identification Make: Subaru Model: Forester Years Covered: 1999-2002 Generation: SF Series (Second Generation) Codes Chassis Codes: SF5, SF9 ๐Ÿ‘‹ Introduction Market Position Vehicle Segment: Compact Crossover SUV / Station Wagon Key Selling Points: Standard Symmetrical All-Wheel Drive, practicality, cargo space, good visibility, robust build quality. Competitive Analysis Competitors 1999-2002: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra. Key Features Powertrain Emphasis: Subaru's signature Boxer engine and Symmetrical AWD system. Utility Focus: Designed for active lifestyles, offering versatility and capability beyond typical sedans. ๐Ÿ“‹ Manual Details Coverage Areas Engine Variants Covered: 2.5L EJ25 SOHC & DOHC Naturally Aspirated & Turbocharged (EJ251, EJ253, EJ255, EJ205) Transmission Variants Covered: 4-speed Automatic (4EAT), 5-speed Manual Drivetrain Variants Covered: Symmetrical All-Wheel Drive (AWD) Page Count Estimated Pages: Hundreds (specific count not provided, but indicative of comprehensive coverage) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF ๐Ÿ“– Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions, diagnostics, timing belt replacement, piston/ring/valve service, cylinder head overhaul Transmission: Automatic Transmission (4EAT) overhaul, maintenance, diagnostics, valve body repair, torque converter; Manual Transmission overhaul, maintenance, diagnostics, clutch service Drivetrain: Front axle, rear axle, driveshafts, differentials, propeller shaft, AWD system components Suspension: Front struts/coil springs, rear struts/coil springs, control arms, ball joints, bushings, sway bars, wheel bearings Brakes: Front disc brakes, rear disc/drum brakes (depending on model/trim), ABS system (if equipped), brake fluid specifications, caliper, rotor, pad service, bleeding procedures Steering: Power steering system, steering rack, tie rod ends, steering column Electrical: Battery, charging system (alternator), starting system (starter), lighting, instrumentation, power accessories, wiring diagrams, fuse box locations, ECU/ECM diagnostics HVAC: Air conditioning system, heater core, blower motor, refrigerant handling, cabin air filter replacement Body: Exterior panels, interior trim, doors, glass, sunroof, body sealing, paint repair guidance Chassis And Frame: Frame construction, unibody structure, corrosion protection Procedures Included Maintenance: Oil change, filter replacement, fluid checks and changes (coolant, brake, power steering, transmission), spark plug replacement, air filter replacement, timing belt inspection/replacement, tune-up procedures Diagnostics: Troubleshooting guides for common problems, diagnostic trouble codes (DTCs), on-board diagnostics (OBD-I/OBD-II), symptom-based troubleshooting Repair: Component removal, installation, overhaul, and replacement for all major systems Rebuild: Engine rebuilding, transmission rebuilding, differential rebuilds Adjustment: Valve clearance adjustment, parking brake adjustment Troubleshooting Specifics: Detailed steps for diagnosing and repairing issues related to starting, running rough, overheating, transmission slippage, electrical faults, etc. Technical Depth Level: Comprehensive Professional Level: Covers everything from basic routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications. Diagrams Included: Detailed schematics, wiring diagrams, exploded views, torque specifications, and step-by-step illustrated repair procedures. ๐Ÿ“Š Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (standard for high-quality PDF manuals) Print Quality Clarity: High-resolution digital scans, ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital PDF Format) Paper Type Paper Quality: N/A (Digital PDF Format) โš™๏ธ Engine Specifications Primary Engine Engine Code Base: EJ25 Engine Displacement Base: 2.5 Liters (2457 cc) Engine Configuration Base: Horizontally-opposed (Boxer), 4-cylinder, SOHC Performance Horsepower Base Na: Approx. 165 hp @ 5,500-6,000 rpm (EJ251/EJ253) Torque Base Na: Approx. 162 lb-ft @ 4,000 rpm (EJ251/EJ253) Horsepower Turbocharged: Approx. 210-220 hp @ 5,600-6,000 rpm (EJ205/EJ255 - WRX/GT models, often included in performance manuals) Torque Turbocharged: Approx. 236-250 lb-ft @ 3,000-4,000 rpm (EJ205/EJ255) Fuel System Fuel Delivery: Electronic Multi-point Fuel Injection (MPI) Fuel Type: Unleaded gasoline (87 octane recommended for NA, 91+ for Turbocharged) Engine Components Timing System: Timing Belt (requiring periodic replacement) Engine Management: ECU (Engine Control Unit) / ECM (Engine Control Module) ๐Ÿ”ง Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission (4EAT) with Lock-up Torque Converter Features AWD Integration: Integrated with Subaru's Symmetrical All-Wheel Drive system. Manual transmissions typically featured a viscous coupling center differential, while automatics used an electronically controlled multi-plate clutch AWD system. Fluid Specifications Manual Transmission Fluid: Subaru Extra-S Gear Oil (or equivalent API GL-5, SAE 75W-90) Automatic Transmission Fluid: Subaru ATF HP (or equivalent Dexron-III/Mercon) ๐Ÿ“ Dimensions Exterior Length: Approx. 175.6 inches (4460 mm) Width: Approx. 66.7 inches (1695 mm) Height: Approx. 63.0 inches (1600 mm) Wheelbase: Approx. 103.0 inches (2615 mm) Weights Curb Weight Base: Approx. 3,100 - 3,300 lbs (1400 - 1500 kg) depending on trim and transmission Cargo Cargo Volume Rear Seats Up: Approx. 30.0 cu ft (850 L) Cargo Volume Rear Seats Folded: Approx. 67.0 cu ft (1900 L) ๐Ÿ›ก๏ธ Safety Features Ratings NHTSA Front Impact Driver: 4-star (for models equipped with airbags) NHTSA Front Impact Passenger: 4-star (for models equipped with airbags) Active Features Braking System: Standard 4-wheel disc brakes on most trims; some base models may have rear drums. Optional Anti-lock Braking System (ABS). Traction Control: Not commonly available on this generation, AWD is the primary traction enhancement. Passive Features Airbags: Driver and front...
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SUBARU FORESTER Service Repair Manual 99-02
๐Ÿท๏ธ Basic Information
Identification
Make:
Subaru
Model:
Forester
Years Covered:
1999-2002
Generation:
SF Series (Second Generation)
Codes
Chassis Codes:
SF5, SF9
๐Ÿ‘‹ Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV / Station Wagon
Key Selling Points:
Standard Symmetrical All-Wheel Drive, practicality, cargo space, good visibility, robust build quality.
Competitive Analysis
Competitors 1999-2002:
Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra.
Key Features
Powertrain Emphasis:
Subaru's signature Boxer engine and Symmetrical AWD system.
Utility Focus:
Designed for active lifestyles, offering versatility and capability beyond typical sedans.
๐Ÿ“‹ Manual Details
Coverage Areas
Engine Variants Covered:
2.5L EJ25 SOHC & DOHC Naturally Aspirated & Turbocharged (EJ251, EJ253, EJ255, EJ205)
Transmission Variants Covered:
4-speed Automatic (4EAT), 5-speed Manual
Drivetrain Variants Covered:
Symmetrical All-Wheel Drive (AWD)
Page Count
Estimated Pages:
Hundreds (specific count not provided, but indicative of comprehensive coverage)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
๐Ÿ“– Manual Coverage
Systems Covered
Engine:
Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions, diagnostics, timing belt replacement, piston/ring/valve service, cylinder head overhaul
Transmission:
Automatic Transmission (4EAT) overhaul, maintenance, diagnostics, valve body repair, torque converter; Manual Transmission overhaul, maintenance, diagnostics, clutch service
Drivetrain:
Front axle, rear axle, driveshafts, differentials, propeller shaft, AWD system components
Suspension:
Front struts/coil springs, rear struts/coil springs, control arms, ball joints, bushings, sway bars, wheel bearings
Brakes:
Front disc brakes, rear disc/drum brakes (depending on model/trim), ABS system (if equipped), brake fluid specifications, caliper, rotor, pad service, bleeding procedures
Steering:
Power steering system, steering rack, tie rod ends, steering column
Electrical:
Battery, charging system (alternator), starting system (starter), lighting, instrumentation, power accessories, wiring diagrams, fuse box locations, ECU/ECM diagnostics
HVAC:
Air conditioning system, heater core, blower motor, refrigerant handling, cabin air filter replacement
Body:
Exterior panels, interior trim, doors, glass, sunroof, body sealing, paint repair guidance
Chassis And Frame:
Frame construction, unibody structure, corrosion protection
Procedures Included
Maintenance:
Oil change, filter replacement, fluid checks and changes (coolant, brake, power steering, transmission), spark plug replacement, air filter replacement, timing belt inspection/replacement, tune-up procedures
Diagnostics:
Troubleshooting guides for common problems, diagnostic trouble codes (DTCs), on-board diagnostics (OBD-I/OBD-II), symptom-based troubleshooting
Repair:
Component removal, installation, overhaul, and replacement for all major systems
Rebuild:
Engine rebuilding, transmission rebuilding, differential rebuilds
Adjustment:
Valve clearance adjustment, parking brake adjustment
Troubleshooting Specifics:
Detailed steps for diagnosing and repairing issues related to starting, running rough, overheating, transmission slippage, electrical faults, etc.
Technical Depth
Level:
Comprehensive Professional Level: Covers everything from basic routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.
Diagrams Included:
Detailed schematics, wiring diagrams, exploded views, torque specifications, and step-by-step illustrated repair procedures.
๐Ÿ“Š Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (standard for high-quality PDF manuals)
Print Quality
Clarity:
High-resolution digital scans, ensuring clarity of text and diagrams.
Binding Type
Binding:
N/A (Digital PDF Format)
Paper Type
Paper Quality:
N/A (Digital PDF Format)
โš™๏ธ Engine Specifications
Primary Engine
Engine Code Base:
EJ25
Engine Displacement Base:
2.5 Liters (2457 cc)
Engine Configuration Base:
Horizontally-opposed (Boxer), 4-cylinder, SOHC
Performance
Horsepower Base Na:
Approx. 165 hp @ 5,500-6,000 rpm (EJ251/EJ253)
Torque Base Na:
Approx. 162 lb-ft @ 4,000 rpm (EJ251/EJ253)
Horsepower Turbocharged:
Approx. 210-220 hp @ 5,600-6,000 rpm (EJ205/EJ255 - WRX/GT models, often included in performance manuals)
Torque Turbocharged:
Approx. 236-250 lb-ft @ 3,000-4,000 rpm (EJ205/EJ255)
Fuel System
Fuel Delivery:
Electronic Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane recommended for NA, 91+ for Turbocharged)
Engine Components
Timing System:
Timing Belt (requiring periodic replacement)
Engine Management:
ECU (Engine Control Unit) / ECM (Engine Control Module)
๐Ÿ”ง Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission (4EAT) with Lock-up Torque Converter
Features
AWD Integration:
Integrated with Subaru's Symmetrical All-Wheel Drive system. Manual transmissions typically featured a viscous coupling center differential, while automatics used an electronically controlled multi-plate clutch AWD system.
Fluid Specifications
Manual Transmission Fluid:
Subaru Extra-S Gear Oil (or equivalent API GL-5, SAE 75W-90)
Automatic Transmission Fluid:
Subaru ATF HP (or equivalent Dexron-III/Mercon)
๐Ÿ“ Dimensions
Exterior
Length:
Approx. 175.6 inches (4460 mm)
Width:
Approx. 66.7 inches (1695 mm)
Height:
Approx. 63.0 inches (1600 mm)
Wheelbase:
Approx. 103.0 inches (2615 mm)
Weights
Curb Weight Base:
Approx. 3,100 - 3,300 lbs (1400 - 1500 kg) depending on trim and transmission
Cargo
Cargo Volume Rear Seats Up:
Approx. 30.0 cu ft (850 L)
Cargo Volume Rear Seats Folded:
Approx. 67.0 cu ft (1900 L)
๐Ÿ›ก๏ธ Safety Features
Ratings
NHTSA Front Impact Driver:
4-star (for models equipped with airbags)
NHTSA Front Impact Passenger:
4-star (for models equipped with airbags)
Active Features
Braking System:
Standard 4-wheel disc brakes on most trims; some base models may have rear drums. Optional Anti-lock Braking System (ABS).
Traction Control:
Not commonly available on this generation, AWD is the primary traction enhancement.
Passive Features
Airbags:
Driver and front passenger airbags standard on most models.
Seatbelts:
3-point front and rear seat belts, driver's seat belt pretensioner.
๐Ÿ’ก Technology Features
Infotainment
Audio System:
Typically a 1-DIN or 2-DIN AM/FM stereo with CD player. Some models offered premium audio systems.
Navigation:
Rarely offered, if at all, on this generation. Aftermarket solutions were more common.
Driver Assistance
Cruise Control:
Standard on most trims.
Power Features:
Power windows, power door locks, power mirrors were common options or standard on higher trims.
Connectivity
Auxiliary Input:
Not standard; often required aftermarket modification for audio device connectivity.
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months, whichever comes first (under normal driving conditions).
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 60 months (critical maintenance item to prevent catastrophic engine damage).
Engine Coolant Change:
Initially at 30,000 miles (48,000 km) or 24 months, then every 15,000 miles (24,000 km) or 12 months thereafter.
Transmission Fluid Change Auto:
Every 30,000 miles (48,000 km) or 24 months.
Transmission Fluid Change Manual:
Every 60,000 miles (96,000 km) or 48 months.
Fluid Specifications
Engine Oil Spec:
API SJ or higher, ILSAC GF-2, SAE 5W-30 (preferred) or 10W-30.
Engine Oil Capacity:
Approx. 4.8 US quarts (4.5 L) with filter change.
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free, long-life ethylene glycol based coolant.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Head Gaskets:
While less prevalent than in later generations with the EJ25, some early EJ25 engines can experience head gasket leaks. The manual will detail inspection and replacement procedures.
Automatic Transmission:
The 4EAT can sometimes develop issues with solenoids or valve bodies, particularly with delayed engagement or rough shifts. The manual's diagnostic section is crucial here.
Suspension Wear:
Worn bushings, ball joints, and wheel bearings are common wear items on higher mileage vehicles of this era. The manual provides specs for replacement.
๐Ÿ“š Vehicle History
Brand Heritage
Subaru Legacy Connection:
Based on the Subaru Impreza/Legacy platform, sharing many components and engineering principles.
Model Evolution
Generation Launch:
The second generation (SF Series facelift) was introduced for the 1998 model year in Japan and globally for 1999.
Design Changes Vs First Gen:
Updated exterior styling, revised interior, improved NVH (Noise, Vibration, Harshness), and some powertrain enhancements.
Production
Manufacturing Location:
Gunma Plant, Japan
๐Ÿ† Awards & Recognition
Recognitions
Car And Driver ะฉะตะฝะธั:
Often featured in '10Best' lists for SUVs or all-around vehicles during its production run, praised for its AWD system and utility.
Ratings
Ieda Safety Awards:
Subaru vehicles of this era were generally well-regarded for their build quality and safety, though specific awards might vary by year and region.
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