Subaru Forester Service Repair Workshop Manual 1999-2002
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🏷️ Basic Information Identification Make: Subaru Model: Forester Model Generation: SF (First Generation) Model Years Covered: 1999, 2000, 2001, 2002 Codes Chassis Codes: SF5, SF9 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Key Selling Points: Standard Symmetrical All-Wheel Drive, excellent visibility, practical cargo space, reliable powertrain. Competitive Analysis Competitors 1999-2002: Toyota RAV4, Honda CR-V, Nissan Xterra, Ford Escape, Mazda Tribute. Key Features Forester Attributes: Hatchback utility with SUV-like ground clearance, praised for its go-anywhere capability in adverse weather conditions. Manual Value Proposition Target Audience: DIY enthusiasts, independent repair shops, Subaru owners seeking in-depth maintenance and repair knowledge. 📋 Manual Details Coverage Areas Geographical Coverage: North America (implied by year range and typical manual distribution) Page Count Estimated Page Count: 1500-2000 (typical for comprehensive service manuals of this era) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: All engine variants, including diagnostics, maintenance, repair, overhaul, specifications, and troubleshooting. Transmission: Both automatic (4-speed) and manual (5-speed) transmissions, including removal, installation, overhaul, diagnostics, and fluid specifications. Drivetrain: All-Wheel Drive (AWD) system, including differentials, driveshafts, CV joints, and related components. Brakes: Front disc, rear disc (or drum on some base models), ABS, parking brake systems, including hydraulic components, ABS modulator, and component replacement. Suspension: Front McPherson struts, rear multi-link or trailing arm suspension, including component replacement, alignment specifications, and troubleshooting. Steering: Power steering system, including pump, rack and pinion, hoses, and fluid specifications. Electrical System: Comprehensive coverage of starter, alternator, battery, ignition system, lighting, power windows, locks, mirrors, and accessory circuits. Climate Control: HVAC system, including A/C compressor, refrigerant, heater core, blower motor, and controls. Fuel System: Fuel pump, injectors, fuel lines, fuel filter replacement, and evaporative emission control (EVAP) system. Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, and oxygen sensors. Cooling System: Radiator, water pump, thermostat, hoses, coolant specifications, and bleeding procedures. Body And Chassis: Body panel removal and installation, door mechanisms, glass replacement, frame specifications, and corrosion protection. Safety Systems: Airbag system diagnostics and replacement, seatbelt mechanisms. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, brake fluid flush, coolant flush, transmission fluid changes, differential fluid changes, power steering fluid changes. Troubleshooting: Diagnostic flowcharts for common and uncommon issues across all major systems, including engine performance, electrical faults, and drivability problems. Component Repair And Overhaul: Detailed step-by-step instructions for engine rebuilds, transmission overhauls, brake caliper replacement, suspension component rebuilds, etc. Diagnostics: OBD-II diagnostic codes, diagnostic procedures for specific systems, use of diagnostic tools. Installation And Removal: Step-by-step guides for removing and installing virtually all major and minor components. Specifications And Tolerances: Torque specifications, measurement tolerances, clearances for engine, transmission, suspension, brakes, and body components. Technical Depth Depth: Comprehensive, covering everything from basic fluid changes and filter replacements to full engine and transmission rebuilds, complex electrical diagnostics, and chassis repairs. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Quality: High-resolution scans, clear text, and legible diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code And Type: EJ253 (Naturally Aspirated 2.5L SOHC Boxer-4) Engine Code And Type Turbo: EJ255 (Turbocharged 2.5L SOHC Boxer-4) - Turbo models (e.g., Forester S/TB) Performance Horsepower Na: 165 hp @ 5,600 rpm (approx.) Torque Na: 166 lb-ft @ 3,600 rpm (approx.) Horsepower Turbo: 210-230 hp @ 5,600 rpm (approx.) Torque Turbo: 235-250 lb-ft @ 3,600 rpm (approx.) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded gasoline Recommended Octane Na: 87 (or higher) Recommended Octane Turbo: 91 (or higher) 🔧 Transmission Standard Transmission Type Na: 4-speed automatic (4EAT) Optional Transmission Type Manual: 5-speed manual (5MT) Features AWD System: Symmetrical All-Wheel Drive with viscous coupling center differential (manual) or electronically controlled active torque split (automatic). Transmission Fluid Type: Dexron III/Mercon (for automatic), Subaru Extra-S Gear Oil or equivalent (for manual) 📐 Dimensions Exterior Length: 175.1 inches Width: 69.7 inches Height: 63.0 inches Wheelbase: 103.0 inches Ground Clearance: 7.5 inches Weights Curb Weight Approx: 3150 - 3350 lbs (depending on configuration) Cargo Cargo Volume Behind Rear Seats: 33.0 cu ft (approx.) Cargo Volume With Rear Seats Folded: 65.9 cu ft (approx.) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Not rated or 4-star (varies by year/testing protocol) NHTSA Front Impact Passenger: Not rated or 4-star (varies by year/testing protocol) IIHS Side Impact: Acceptable (often for models with optional side airbags) Active Features ABS: Standard on most models, 4-wheel disc with ABS. Traction Control: Not generally available on these models. Passive Features Airbags: Dual front airbags standard. Optional side airbags available on select trims/years. Seatbelts: 3-point front and rear seatbelts, pre-tensioners for front seats. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD or Cassette/CD players, optional premium sound systems. Display Technology: Basic digital...
North America (implied by year range and typical manual distribution)
Page Count
Estimated Page Count:
1500-2000 (typical for comprehensive service manuals of this era)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
All engine variants, including diagnostics, maintenance, repair, overhaul, specifications, and troubleshooting.
Transmission:
Both automatic (4-speed) and manual (5-speed) transmissions, including removal, installation, overhaul, diagnostics, and fluid specifications.
Drivetrain:
All-Wheel Drive (AWD) system, including differentials, driveshafts, CV joints, and related components.
Brakes:
Front disc, rear disc (or drum on some base models), ABS, parking brake systems, including hydraulic components, ABS modulator, and component replacement.
Suspension:
Front McPherson struts, rear multi-link or trailing arm suspension, including component replacement, alignment specifications, and troubleshooting.
Steering:
Power steering system, including pump, rack and pinion, hoses, and fluid specifications.
Electrical System:
Comprehensive coverage of starter, alternator, battery, ignition system, lighting, power windows, locks, mirrors, and accessory circuits.
Climate Control:
HVAC system, including A/C compressor, refrigerant, heater core, blower motor, and controls.
Fuel System:
Fuel pump, injectors, fuel lines, fuel filter replacement, and evaporative emission control (EVAP) system.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, and oxygen sensors.
Cooling System:
Radiator, water pump, thermostat, hoses, coolant specifications, and bleeding procedures.
Body And Chassis:
Body panel removal and installation, door mechanisms, glass replacement, frame specifications, and corrosion protection.
Safety Systems:
Airbag system diagnostics and replacement, seatbelt mechanisms.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, spark plug replacement, brake fluid flush, coolant flush, transmission fluid changes, differential fluid changes, power steering fluid changes.
Troubleshooting:
Diagnostic flowcharts for common and uncommon issues across all major systems, including engine performance, electrical faults, and drivability problems.
Component Repair And Overhaul:
Detailed step-by-step instructions for engine rebuilds, transmission overhauls, brake caliper replacement, suspension component rebuilds, etc.
Diagnostics:
OBD-II diagnostic codes, diagnostic procedures for specific systems, use of diagnostic tools.
Installation And Removal:
Step-by-step guides for removing and installing virtually all major and minor components.
Specifications And Tolerances:
Torque specifications, measurement tolerances, clearances for engine, transmission, suspension, brakes, and body components.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid changes and filter replacements to full engine and transmission rebuilds, complex electrical diagnostics, and chassis repairs.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Quality:
High-resolution scans, clear text, and legible diagrams.
Not rated or 4-star (varies by year/testing protocol)
NHTSA Front Impact Passenger:
Not rated or 4-star (varies by year/testing protocol)
IIHS Side Impact:
Acceptable (often for models with optional side airbags)
Active Features
ABS:
Standard on most models, 4-wheel disc with ABS.
Traction Control:
Not generally available on these models.
Passive Features
Airbags:
Dual front airbags standard. Optional side airbags available on select trims/years.
Seatbelts:
3-point front and rear seatbelts, pre-tensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD or Cassette/CD players, optional premium sound systems.
Display Technology:
Basic digital clock and radio displays. No advanced color screens.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Auxiliary Input:
Not standard; aftermarket solutions may exist.
Bluetooth:
Not available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 3.75 months (severe conditions) / 7,500 miles or 7.5 months (normal conditions, check manual for exact specs).
Engine Air Filter Replacement:
Every 15,000 miles or 15 months.
Cabin Air Filter Replacement:
Not standard on all trims during this period; if equipped, typically every 15,000 miles or 15 months.
Spark Plug Replacement:
Every 60,000 miles (NGK Platinum or Iridium recommended).
Coolant Replacement:
Initial 60,000 miles or 4 years, then every 30,000 miles or 2 years thereafter.
Transmission Fluid Change Auto:
Every 30,000 miles or 30 months.
Transmission Fluid Change Manual:
Every 30,000 miles or 30 months.
Fluid Specifications
Engine Oil Type Na:
SAE 5W-30 Synthetic (API SG or higher)
Engine Oil Type Turbo:
SAE 5W-30 Synthetic (API SG or higher)
Engine Oil Capacity Na:
4.5 US quarts (with filter)
Engine Oil Capacity Turbo:
4.5 US quarts (with filter)
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free antifreeze/coolant
Known Issues
Head Gasket Leaks:
While more prevalent in later EJ25 engines, early signs or coolant consumption can indicate potential head gasket issues. The manual will detail diagnostic procedures.
Catalytic Converter Failure:
Can occur due to engine misfires or excessive oil consumption; manual covers exhaust system diagnostics.
Automatic Transmission Issues:
Occasional reports of hesitation or slipping, particularly with higher mileage. Manual provides detailed repair and diagnosis.
📚 Vehicle History
Brand Heritage
Subaru Reputation:
Known for its pioneering use of Symmetrical All-Wheel Drive across its entire lineup and its horizontally opposed 'Boxer' engines.
Model Evolution
Forester Genesis:
The Forester was introduced in 1997 in Japan and globally in 1998 as a compact crossover SUV, blending wagon practicality with SUV capability.
Sf Generation Updates:
The 1999-2002 models represent the latter part of the first generation (SF chassis). Minor styling updates and feature adjustments occurred during this period, with a more significant facelift around 2001.
Production
Assembly Location:
Ota City, Gunma Prefecture, Japan
🏆 Awards & Recognition
Recognitions
Car And Driver Best SUV:
Frequently listed by automotive publications as a capable and practical compact SUV.
Consumer Reports Reliability:
Generally good reliability ratings for Subaru models of this era, with specific notes on potential head gasket concerns for the EJ25 engine.
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