1999-2004 Subaru Forester Service Repair Workshop Manual Dow

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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation Code: SF/SG Codes Platform Code: SF (1997-2002), SG (2002-2008) Chassis Code: SF5, SF9, SG5, SG9 👋 Introduction Market Position Segment: Compact Crossover SUV Unique Selling Proposition: Standard Symmetrical All-Wheel Drive, horizontally opposed 'Boxer' engine, excellent safety record, practicality for outdoor activities Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra (early models) Key Features Vehicle Type: Station Wagon/SUV Crossover Drivetrain: Standard Symmetrical All-Wheel Drive (AWD) Engine Layout: Front-engine, horizontally opposed (Boxer) 📋 Manual Details Coverage Areas Covered Years: 1999, 2000, 2001, 2002, 2003, 2004 Engine Coverage: 2.5L EJ25 SOHC/DOHC Naturally Aspirated and Turbocharged (EJ251, EJ252, EJ253, EJ255, EJ257) Transmission Coverage: 4-Speed Automatic (4EAT), 5-Speed Manual Drivetrain Coverage: All-Wheel Drive (AWD) - Symmetrical AWD System Trim Level Coverage: All factory trim levels Page Count Estimated Pages: Over 1500 (typical for a comprehensive service manual) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, overhaul, component testing, lubrication, cooling, fuel delivery, emissions control (EGTS, catalytic converter), timing belt/chain replacement Engine Electrical: Ignition system, starting system, charging system, ECM/ECU, sensors (MAF, MAP, O2, Crankshaft Position, Camshaft Position), wiring diagrams, troubleshooting Transmission Manual: Clutch system, gearbox disassembly, assembly, operation, maintenance, fluid specifications Transmission Automatic: 4EAT system operation, hydraulic control, valve body, torque converter, overhaul, maintenance, fluid specifications, troubleshooting Drivetrain AWD: Symmetrical AWD system components, front/rear differentials, center differential, driveshafts, universal joints, maintenance Suspension: Front MacPherson struts, rear multi-link suspension, springs, shock absorbers, control arms, bushings, alignment procedures Steering: Power steering system, steering rack, tie rods, steering column, troubleshooting Brakes: Front vented disc, rear solid disc (or optional rear disc), ABS system, brake fluid specifications, bleeding procedures, component replacement (pads, rotors, calipers) Body: Exterior panel removal/installation, interior trim, doors, windows, sunroof, body sealing, corrosion protection HVAC: Air conditioning system, heating system, climate control, refrigerant, component servicing Electrical Body: Lighting (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, fuse box, relay locations, wiring diagrams Safety Restraints: Airbag system (SRS), seat belts, component locations, servicing precautions Procedures Included Maintenance Procedures: Oil and filter changes, air filter replacement, spark plug replacement, fluid checks and top-offs, brake inspection, tire rotation Diagnostic Procedures: DTC (Diagnostic Trouble Code) retrieval and interpretation, on-board diagnostics (OBD-II), symptom-based troubleshooting charts Repair Procedures: Step-by-step instructions for component removal, replacement, and reassembly Troubleshooting Guides: System-specific troubleshooting flowcharts and symptom-to-cause guides Torque Specifications: Detailed torque values for critical fasteners across all systems Technical Depth Depth: Comprehensive: Covers everything from routine maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical system tracing 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text for quick information retrieval Printability: Printable pages for offline use Print Quality Image Resolution: High-resolution images, diagrams, and schematics Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Naturally Aspirated: EJ251, EJ253 Engine Code Turbocharged: EJ255, EJ257 (for XT models) Displacement: 2.5 Liters (2498 cc) Bore X Stroke: 99.5 mm x 80.0 mm Compression Ratio Na: 9.7:1 (EJ251/EJ253) Compression Ratio Turbo: 8.5:1 (EJ255/EJ257) Performance Horsepower Na: 165 hp @ 5600 rpm (EJ251/EJ253) Torque Na: 166 lb-ft @ 4000 rpm (EJ251/EJ253) Horsepower Turbo: 210 hp @ 5600 rpm (EJ255) / 230 hp @ 5600 rpm (EJ257 - XT models) Torque Turbo: 235 lb-ft @ 3600 rpm (EJ255) / 235 lb-ft @ 3600 rpm (EJ257 - XT models) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline (87 octane recommended for NA, 91+ recommended for Turbocharged models) Emissions Control: Catalytic converter, EGR, Positive Crankcase Ventilation (PCV) 🔧 Transmission Standard Type: 5-speed Manual Transmission Optional Type: 4-speed Automatic Transmission (4EAT) Features Automatic Mode: Full-time Symmetrical AWD with electronically controlled multi-plate transfer clutch Manual Gear Ratios: Specific ratios vary by year/model, detailed in manual Automatic Gear Ratios: Specific ratios vary by year/model, detailed in manual Transmission Fluid Type Manual: API GL-5 Gear Oil (e.g., 75W-90) Transmission Fluid Type Automatic: Subaru Genuine ATF HP (or equivalent) 📐 Dimensions Exterior Length: Approx. 176.0-178.0 inches (depending on year/trim) Width: Approx. 69.7 inches Height: Approx. 63.0-64.0 inches (depending on roof rails) Wheelbase: Approx. 103.0 inches Ground Clearance: Approx. 7.7 inches Cargo Cargo Volume Seats Up: Approx. 31.5 cu ft Cargo Volume Seats Down: Approx. 67.0 cu ft Weights Curb Weight: Approx. 3150-3400 lbs (depending on configuration) Towing Capacity: 2400 lbs (with appropriate towing package/hitch) 🛡️ Safety Features Ratings NHTSA Rollover Rating: 4 Stars (Frontal Impact Passenger, Frontal Impact Driver, Side Impact Front Passenger, Side Impact Rear Passenger) Active Features Braking System: Front ventilated discs, rear solid discs; optional Anti-lock Braking System (ABS) Drivetrain Stability: Symmetrical All-Wheel Drive for enhanced traction and stability Passive Features Airbags: Front airbags, optional side airbags (depending...

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Vendor:

Sku: 406842

Collections: ALL Subaru

Availability: In stock

Tags: 1999 2000 2001 2002 2003 2004 Car Cars Forester Misc Subaru

Product variants

Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Generation Code:

SF/SG

Codes

Platform Code:

SF (1997-2002), SG (2002-2008)

Chassis Code:

SF5, SF9, SG5, SG9

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Unique Selling Proposition:

Standard Symmetrical All-Wheel Drive, horizontally opposed 'Boxer' engine, excellent safety record, practicality for outdoor activities

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra (early models)

Key Features

Vehicle Type:

Station Wagon/SUV Crossover

Drivetrain:

Standard Symmetrical All-Wheel Drive (AWD)

Engine Layout:

Front-engine, horizontally opposed (Boxer)

📋 Manual Details

Coverage Areas

Covered Years:

1999, 2000, 2001, 2002, 2003, 2004

Engine Coverage:

2.5L EJ25 SOHC/DOHC Naturally Aspirated and Turbocharged (EJ251, EJ252, EJ253, EJ255, EJ257)

Transmission Coverage:

4-Speed Automatic (4EAT), 5-Speed Manual

Drivetrain Coverage:

All-Wheel Drive (AWD) - Symmetrical AWD System

Trim Level Coverage:

All factory trim levels

Page Count

Estimated Pages:

Over 1500 (typical for a comprehensive service manual)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, overhaul, component testing, lubrication, cooling, fuel delivery, emissions control (EGTS, catalytic converter), timing belt/chain replacement

Engine Electrical:

Ignition system, starting system, charging system, ECM/ECU, sensors (MAF, MAP, O2, Crankshaft Position, Camshaft Position), wiring diagrams, troubleshooting

Transmission Manual:

Clutch system, gearbox disassembly, assembly, operation, maintenance, fluid specifications

Transmission Automatic:

4EAT system operation, hydraulic control, valve body, torque converter, overhaul, maintenance, fluid specifications, troubleshooting

Drivetrain AWD:

Symmetrical AWD system components, front/rear differentials, center differential, driveshafts, universal joints, maintenance

Suspension:

Front MacPherson struts, rear multi-link suspension, springs, shock absorbers, control arms, bushings, alignment procedures

Steering:

Power steering system, steering rack, tie rods, steering column, troubleshooting

Brakes:

Front vented disc, rear solid disc (or optional rear disc), ABS system, brake fluid specifications, bleeding procedures, component replacement (pads, rotors, calipers)

Body:

Exterior panel removal/installation, interior trim, doors, windows, sunroof, body sealing, corrosion protection

HVAC:

Air conditioning system, heating system, climate control, refrigerant, component servicing

Electrical Body:

Lighting (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, fuse box, relay locations, wiring diagrams

Safety Restraints:

Airbag system (SRS), seat belts, component locations, servicing precautions

Procedures Included

Maintenance Procedures:

Oil and filter changes, air filter replacement, spark plug replacement, fluid checks and top-offs, brake inspection, tire rotation

Diagnostic Procedures:

DTC (Diagnostic Trouble Code) retrieval and interpretation, on-board diagnostics (OBD-II), symptom-based troubleshooting charts

Repair Procedures:

Step-by-step instructions for component removal, replacement, and reassembly

Troubleshooting Guides:

System-specific troubleshooting flowcharts and symptom-to-cause guides

Torque Specifications:

Detailed torque values for critical fasteners across all systems

Technical Depth

Depth:

Comprehensive: Covers everything from routine maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical system tracing

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text for quick information retrieval

Printability:

Printable pages for offline use

Print Quality

Image Resolution:

High-resolution images, diagrams, and schematics

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Naturally Aspirated:

EJ251, EJ253

Engine Code Turbocharged:

EJ255, EJ257 (for XT models)

Displacement:

2.5 Liters (2498 cc)

Bore X Stroke:

99.5 mm x 80.0 mm

Compression Ratio Na:

9.7:1 (EJ251/EJ253)

Compression Ratio Turbo:

8.5:1 (EJ255/EJ257)

Performance

Horsepower Na:

165 hp @ 5600 rpm (EJ251/EJ253)

Torque Na:

166 lb-ft @ 4000 rpm (EJ251/EJ253)

Horsepower Turbo:

210 hp @ 5600 rpm (EJ255) / 230 hp @ 5600 rpm (EJ257 - XT models)

Torque Turbo:

235 lb-ft @ 3600 rpm (EJ255) / 235 lb-ft @ 3600 rpm (EJ257 - XT models)

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane recommended for NA, 91+ recommended for Turbocharged models)

Emissions Control:

Catalytic converter, EGR, Positive Crankcase Ventilation (PCV)

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Optional

Type:

4-speed Automatic Transmission (4EAT)

Features

Automatic Mode:

Full-time Symmetrical AWD with electronically controlled multi-plate transfer clutch

Manual Gear Ratios:

Specific ratios vary by year/model, detailed in manual

Automatic Gear Ratios:

Specific ratios vary by year/model, detailed in manual

Transmission Fluid Type Manual:

API GL-5 Gear Oil (e.g., 75W-90)

Transmission Fluid Type Automatic:

Subaru Genuine ATF HP (or equivalent)

📐 Dimensions

Exterior

Length:

Approx. 176.0-178.0 inches (depending on year/trim)

Width:

Approx. 69.7 inches

Height:

Approx. 63.0-64.0 inches (depending on roof rails)

Wheelbase:

Approx. 103.0 inches

Ground Clearance:

Approx. 7.7 inches

Cargo

Cargo Volume Seats Up:

Approx. 31.5 cu ft

Cargo Volume Seats Down:

Approx. 67.0 cu ft

Weights

Curb Weight:

Approx. 3150-3400 lbs (depending on configuration)

Towing Capacity:

2400 lbs (with appropriate towing package/hitch)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4 Stars (Frontal Impact Passenger, Frontal Impact Driver, Side Impact Front Passenger, Side Impact Rear Passenger)

Active Features

Braking System:

Front ventilated discs, rear solid discs; optional Anti-lock Braking System (ABS)

Drivetrain Stability:

Symmetrical All-Wheel Drive for enhanced traction and stability

Passive Features

Airbags:

Front airbags, optional side airbags (depending on trim/year)

Seatbelts:

3-point height-adjustable front seat belts with pretensioners, rear 3-point seat belts

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium sound systems

Display:

Basic digital/analog climate controls and audio display

Driver Assistance

Available Anti-lock Braking System (ABS)

Traction Control:

Not typically available on these models

Connectivity

Auxiliary Input:

Not typically available, aftermarket solutions often used

Usb Port:

Not typically available, aftermarket solutions often used

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months (severe conditions) / 7,500 miles or 6 months (normal conditions), consult manual for specific recommendation

Air Filter Replacement:

Every 15,000 miles or 12 months

Spark Plug Replacement:

Every 60,000 miles (copper plugs) / 100,000 miles (iridium plugs, if applicable)

Timing Belt Replacement:

Every 105,000 miles or 105 months (critical maintenance item for EJ engines)

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (API SN or higher recommended, ILSAC GF-5 or higher)

Engine Coolant Type:

Subaru Super Coolant (Blue) or equivalent silicate-free, long-life antifreeze/coolant (50/50 mix)

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Head Gaskets:

Premature failure of head gaskets, especially on earlier naturally aspirated EJ25 engines (can be identified by coolant leaks or oil/coolant mixing). Manual details inspection and replacement.

Oil Consumption:

Some EJ engines may exhibit higher than normal oil consumption. Manual provides diagnostic steps.

Turbocharger Issues:

Turbo seals or bearing wear on turbocharged models can occur if not properly maintained (e.g., oil changes).

Automatic Transmission Behavior:

Occasional harsh shifts or slipping in 4EAT can be related to valve body issues or fluid degradation. Manual covers diagnosis.

📚 Vehicle History

Brand Heritage

Foundation:

Fuji Heavy Industries, Ltd. (now Subaru Corporation), established 1953

Core Technologies:

Boxer engine, Symmetrical AWD, aerospace engineering background

Model Evolution

First Generation Launch:

1997 (Globally), 1998 (North America) - SF chassis

Second Generation Launch:

2002 (Globally), 2003 (North America) - SG chassis (covering later years of this manual)

Production

Manufacturing Location:

Gunma Prefecture, Japan

🏆 Awards & Recognition

Recognitions

Icam Safety Award:

Insurance Institute for Highway Safety (IIHS) 'Top Safety Pick' awards in various years for the Forester, indicating good crashworthiness.

Car Of The Year:

While not specific to every trim, the Forester has received various 'SUV of the Year' or 'Crossover of the Year' awards from automotive publications over its history.