Subaru Forester 1999 Digital Factory Repair Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 1999 Codes Chassis Code: SF Engine Codes: EJ25 SOHC, EJ25 DOHC Turbo (for specific market variants) 👋 Introduction Market Position Segment: Compact Crossover SUV Usp: Standard Symmetrical All-Wheel Drive, excellent visibility, practical cargo space, boxer engine. Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Jeep Cherokee. Key Features Powertrain Advantage: Subaru's signature Boxer engine provides a lower center of gravity, enhancing handling and stability. AWD Advantage: Symmetrical AWD system offers superior traction and stability in various weather conditions compared to many front-wheel-drive based competitors. Practicality: Spacious interior for its class, good cargo capacity, and comfortable ride for daily use and light off-roading. Manual Value Proposition Diy Enablement: Empowers owners to perform extensive maintenance and repairs, saving money and increasing vehicle longevity. Diagnostic Power: Provides the technical information needed to accurately diagnose and fix issues, often beyond the capabilities of generic repair guides. 📋 Manual Details Coverage Areas Coverage: All workshop procedures, maintenance, diagnostics, repair, and overhaul for the 1999 Subaru Forester. Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (likely PDF or similar e-book format) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, repair of internal components (pistons, rings, bearings, crankshaft, camshafts, valves), cylinder head, block, timing belt/chain, seals, and gaskets. Engine Management: Fuel injection system, ignition system, emissions control systems (EVAP, EGR), sensors (O2, MAF, TPS, crank/cam position), actuators, engine control module (ECM) diagnostics and troubleshooting. Transmission Manual: Clutch operation, gear shifting mechanisms, transmission overhaul, fluid types, maintenance, and repair for 5-speed manual transmissions. Transmission Automatic: Automatic transmission operation, fluid types, maintenance, torque converter, valve body, transmission control module (TCM) diagnostics, repair, and overhaul for 4-speed automatic transmissions. Drivetrain AWD: Subaru's Symmetrical All-Wheel Drive (AWD) system, viscous coupling, center differential, front and rear differentials, drive shafts, axle shafts, maintenance, and repair. Suspension: Front and rear suspension components (struts, shocks, springs, control arms, bushings), alignment specifications, wheel bearing replacement, and troubleshooting. Brakes: Front and rear brake systems (discs, pads, calipers, rotors, drums, shoes), hydraulic system (master cylinder, brake lines, booster), parking brake, ABS system operation, diagnostics, and repair. Steering: Power steering system (pump, reservoir, lines, rack and pinion), steering column, tie rod ends, maintenance, and repair. Electrical System: 12V battery system, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams for all circuits. Body Exterior: Body panel removal and installation, doors, hood, tailgate, bumpers, glass, seals, trim, rust prevention, and repair. Body Interior: Dashboard removal, seating systems, interior trim, headliner, carpets, airbags, climate control panel, and accessory components. HVAC: Air conditioning system operation, refrigerant handling, compressor, condenser, evaporator, heater core, blower motor, climate control system, diagnostics, and repair. Safety Systems: Airbag system (SRS) operation, diagnostics, and component replacement, seatbelt mechanisms. Diagnostics Troubleshooting: Diagnostic trouble codes (DTCs), common problems and solutions, systematic troubleshooting procedures for all major systems. Procedures Included Scheduled Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, brake fluid flushes, transmission fluid changes, differential fluid changes, timing belt inspection/replacement intervals. Engine Repair: Head gasket replacement, piston ring replacement, bearing replacement, valve adjustment, timing belt replacement (critical procedure), engine mounts. Transmission Repair: Clutch replacement, manual transmission overhaul, automatic transmission clutch pack replacement, valve body repair, torque converter replacement. Brake Repair: Brake pad and rotor replacement, brake caliper overhaul, brake line replacement, master cylinder replacement, brake booster replacement, ABS sensor replacement. Suspension Steering Repair: Strut/shock absorber replacement, control arm bushing replacement, ball joint replacement, tie rod end replacement, wheel bearing replacement, power steering pump replacement, rack and pinion replacement. Electrical Diagnostics: Using wiring diagrams, testing circuits, component testing, troubleshooting electrical faults, starter and alternator testing, battery testing. Body Work: Body panel alignment, door mechanism repair, tailgate hinge and latch repair, bumper cover replacement, glass and seal replacement. HVAC Repair: Refrigerant system evacuation and recharge, leak detection, component replacement (compressor, condenser, evaporator, drier), heater core replacement, blower motor replacement. Airbag System Service: SRS component diagnosis, airbag module replacement, seatbelt pretensioner replacement (with specific safety precautions). Wheel Alignment: Front and rear wheel alignment specifications (camber, caster, toe) and procedures. Technical Depth Depth: Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) - commonly used for digital manuals. Searchability: Likely searchable text within the PDF, allowing for quick access to specific topics. Printability: Printable, allowing users to print specific sections or the entire manual for workshop use. Print Quality Quality: High-resolution, ensuring clarity of diagrams, illustrations, and text. Binding Type Binding: N/A (Digital format; if printed, typically coil-bound or perfect bound for durability in a workshop environment). Paper Type Paper Quality: N/A...
Fuel injection system, ignition system, emissions control systems (EVAP, EGR), sensors (O2, MAF, TPS, crank/cam position), actuators, engine control module (ECM) diagnostics and troubleshooting.
Transmission Manual:
Clutch operation, gear shifting mechanisms, transmission overhaul, fluid types, maintenance, and repair for 5-speed manual transmissions.
Transmission Automatic:
Automatic transmission operation, fluid types, maintenance, torque converter, valve body, transmission control module (TCM) diagnostics, repair, and overhaul for 4-speed automatic transmissions.
Drivetrain AWD:
Subaru's Symmetrical All-Wheel Drive (AWD) system, viscous coupling, center differential, front and rear differentials, drive shafts, axle shafts, maintenance, and repair.
Suspension:
Front and rear suspension components (struts, shocks, springs, control arms, bushings), alignment specifications, wheel bearing replacement, and troubleshooting.
Brakes:
Front and rear brake systems (discs, pads, calipers, rotors, drums, shoes), hydraulic system (master cylinder, brake lines, booster), parking brake, ABS system operation, diagnostics, and repair.
Steering:
Power steering system (pump, reservoir, lines, rack and pinion), steering column, tie rod ends, maintenance, and repair.
Electrical System:
12V battery system, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), fuses, relays, wiring diagrams for all circuits.
Body Exterior:
Body panel removal and installation, doors, hood, tailgate, bumpers, glass, seals, trim, rust prevention, and repair.
Body Interior:
Dashboard removal, seating systems, interior trim, headliner, carpets, airbags, climate control panel, and accessory components.
HVAC:
Air conditioning system operation, refrigerant handling, compressor, condenser, evaporator, heater core, blower motor, climate control system, diagnostics, and repair.
Safety Systems:
Airbag system (SRS) operation, diagnostics, and component replacement, seatbelt mechanisms.
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), common problems and solutions, systematic troubleshooting procedures for all major systems.
Brake pad and rotor replacement, brake caliper overhaul, brake line replacement, master cylinder replacement, brake booster replacement, ABS sensor replacement.
Suspension Steering Repair:
Strut/shock absorber replacement, control arm bushing replacement, ball joint replacement, tie rod end replacement, wheel bearing replacement, power steering pump replacement, rack and pinion replacement.
Electrical Diagnostics:
Using wiring diagrams, testing circuits, component testing, troubleshooting electrical faults, starter and alternator testing, battery testing.
Body Work:
Body panel alignment, door mechanism repair, tailgate hinge and latch repair, bumper cover replacement, glass and seal replacement.
HVAC Repair:
Refrigerant system evacuation and recharge, leak detection, component replacement (compressor, condenser, evaporator, drier), heater core replacement, blower motor replacement.
Front and rear wheel alignment specifications (camber, caster, toe) and procedures.
Technical Depth
Depth:
Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format) - commonly used for digital manuals.
Searchability:
Likely searchable text within the PDF, allowing for quick access to specific topics.
Printability:
Printable, allowing users to print specific sections or the entire manual for workshop use.
Print Quality
Quality:
High-resolution, ensuring clarity of diagrams, illustrations, and text.
Binding Type
Binding:
N/A (Digital format; if printed, typically coil-bound or perfect bound for durability in a workshop environment).
Paper Type
Paper Quality:
N/A (Digital format; if printed, would ideally be on durable, gloss or semi-gloss paper for resistance to grease and shop elements).
Completeness
Scope:
Complete factory service manual, equivalent to what authorized Subaru dealerships utilize.
⚙️ Engine Specifications
Primary Engine
Engine Code:
EJ25
Engine Type:
Naturally Aspirated, SOHC Boxer-4 (Flat-4)
Displacement:
2.5 Liters (2457 cc)
Bore X Stroke:
99.5 mm x 79.0 mm
Compression Ratio:
9.7:1
Horsepower:
165 hp @ 5,600 rpm
Torque:
162 lb-ft @ 4,000 rpm
Performance
Fuel Type:
Unleaded Gasoline (87 Octane Recommended)
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
Ignition System:
Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Coil-near-Plug (CNP) depending on specific build.
All transmissions are integrated with Subaru's Symmetrical All-Wheel Drive system. Automatic transmission utilizes a viscous coupling center differential. Manual transmission typically uses a viscous limited-slip center differential.
📐 Dimensions
Exterior
Length:
175.8 inches (4465 mm)
Width:
67.9 inches (1725 mm)
Height:
63.2 inches (1605 mm)
Wheelbase:
103.0 inches (2616 mm)
Ground Clearance:
7.5 inches (190 mm)
Weights
Curb Weight Approx:
3200 - 3400 lbs (1451 - 1542 kg), varies by trim and transmission
Cargo
Cargo Volume Behind Rear Seats:
35.7 cu ft (1011 L)
Cargo Volume With Rear Seats Folded:
67.7 cu ft (1917 L)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4 Stars
NHTSA Frontal Impact Passenger:
4 Stars
NHTSA Side Impact Driver:
4 Stars
NHTSA Side Impact Rear Passenger:
4 Stars
IIHS Frontal Offset:
Good (GM - Good, A - Acceptable, M - Marginal, P - Poor)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Passive Features
Airbags:
Driver and front passenger airbags, optional side-impact airbags (check specific trim).
Seatbelts:
3-point front seat belts with pretensioners, rear 3-point seat belts.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/Cassette player with optional CD player. Speaker configuration typically 4 or 6 speakers.
Display:
Basic analog gauges, HVAC controls, and radio display. No integrated navigation or touchscreens.
Driver Assistance
Traction Control:
Not typically available on base models; some higher trims might have basic traction assistance integrated with AWD. ABS is standard.
Connectivity
Bluetooth:
Not available from factory.
Usb:
Not available from factory.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3.75 months (severe duty) or 7,500 miles or 7.5 months (normal duty) - consult manual for definitive intervals based on driving conditions.
Timing Belt Replacement:
Typically every 90,000-105,000 miles or 7 years. Critically important for EJ25 engines. Refer to manual for exact interval and inspection procedures.
Transmission Fluid Change Auto:
Every 30,000 - 60,000 miles, or as per severe duty schedule. Use only specified ATF.
Transmission Fluid Change Manual:
Every 60,000 miles. Use specified gear oil.
Fluid Specifications
Engine Oil:
API SG or higher, SAE 5W-30 or 10W-30 (check owner's manual for viscosity based on ambient temperature). Capacity: Approx. 4.5 quarts with filter.
Coolant:
Subaru Super Coolant (blue) or equivalent silicate-free, long-life coolant. 50/50 mix with distilled water. Capacity: Approx. 7.1 quarts.
Automatic Transmission Fluid:
Subaru ATF-HP (or equivalent Dexron-III/Mercon compatible fluid if specified in manual for this era).
Manual Transmission Fluid:
API GL-5, SAE 75W-90 gear oil.
Differential Fluid:
API GL-5, SAE 75W-90 gear oil for front and rear differentials.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Head Gaskets:
While less prevalent in the '99 model compared to later generations, head gasket leaks can still occur, especially in the naturally aspirated EJ25. Turbo models are more susceptible.
Timing Belt:
Critical to replace at recommended intervals. Failure leads to catastrophic engine damage due to interference design.
Cv Axles:
Front CV boots can wear and tear, leading to CV joint failure. Check for cracks and grease leakage.
Rear Main Seal:
Can develop leaks over time.
Suspension Components:
Bushing wear in control arms and sway bars can lead to clunks and poor handling.
📚 Vehicle History
Brand Heritage
Subaru Heritage:
Subaru, a division of Fuji Heavy Industries, has a long history of producing aircraft and, since the mid-20th century, automobiles known for their engineering prowess, particularly their boxer engines and All-Wheel Drive systems.
Model Evolution
First Generation Sf:
The first generation Subaru Forester (SF) debuted in 1997 in Japan and 1998 in North America, bridging the gap between a station wagon and an SUV. The 1999 model year represents a refinement of this initial design.
Production
Manufacturing Location:
Gunma Plant, Japan
Production Years Sf Generation:
1997-2002
🏆 Awards & Recognition
Recognitions
Motor Trend SUV Of The Year:
2000 MotorTrend Sport/Utility of the Year (for the 2000 model year, but relevant to the platform).
Car And Driver 10Best:
Selected as one of Car and Driver's 10Best lists multiple times in its early years for value, capability, and fun-to-drive nature.
Ratings
Kelley Blue Book Value:
Maintains good resale value due to Subaru's reputation for durability and AWD capability.
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