1999-2004 Subaru Forester Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 1999-2004 Codes Chassis Code: SF5, SF9, SG5, SG9 (for later models within the range, though the core focus is SF) Generation Generation Designation: First Generation (SF) and early Second Generation (SG) 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Key Selling Points: Symmetrical All-Wheel Drive, Boxer Engine, Practicality, Reliability Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra Key Features All Wheel Drive: Standard Symmetrical All-Wheel Drive (SAWD) on most models, providing enhanced traction and stability. Engine Layout: Horizontally-opposed (Boxer) engine layout, contributing to a lower center of gravity and improved handling. Practicality: Spacious interior, elevated driving position, versatile cargo area, and a reputation for family-friendly utility. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: Digital Download (PDF) Page Count: Estimated 2000+ pages (comprehensive factory-level detail) Availability: Instant Download Guarantee: 30-Day Money Back Guarantee 📖 Manual Coverage Systems Covered Powertrain: Engine (EJ25, EJ251, EJ253, EJ255, EJ257, EJ20 - Naturally Aspirated and Turbocharged), Transmission (Manual and Automatic), Drivetrain (All-Wheel Drive System) Chassis: Suspension (Front MacPherson Struts, Rear Multi-link), Steering (Power Rack and Pinion), Brakes (Front Ventilated Discs, Rear Discs, ABS) Electrical: Wiring Diagrams, Electrical Components, Lighting, Ignition System, Charging System, Engine Control Unit (ECU), Body Control Modules Body And Interior: Body Panels, Doors, Glass, Seats, HVAC System, Dashboard, Trim Procedures Included Maintenance: Routine Service, Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks and Changes Diagnostics And Troubleshooting: DTC Codes, Symptom-based Troubleshooting, Component Testing Repair And Overhaul: Engine Rebuilds, Transmission Overhauls, Suspension Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Replacement Technical Specifications: Torque Values, Clearances, Timing Specifications, Fluid Capacities Technical Depth Depth Of Information: Factory-level repair procedures, detailed diagnostic flowcharts, specific torque specifications, wiring diagrams for all systems, component-level disassembly and reassembly instructions. 📊 Manual Specifications File Format File Format: PDF Searchability: Text-searchable PDF allowing for quick keyword lookups. Print Quality: High-resolution scans suitable for printing individual pages or sections. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ251 (2.5L SOHC, Naturally Aspirated) Engine Code 2: EJ253 (2.5L DOHC, Naturally Aspirated - later models) Engine Code 3: EJ255 (2.5L DOHC, Turbocharged - Forester XT) Engine Code 4: EJ20 (2.0L SOHC/DOHC, Naturally Aspirated and Turbocharged - specific markets) Performance Horsepower Na: Approx. 165-175 hp (for 2.5L SOHC/DOHC NA) Torque Na: Approx. 170-180 lb-ft (for 2.5L SOHC/DOHC NA) Horsepower Turbo: Approx. 210-230 hp (for 2.5L Turbocharged XT models) Torque Turbo: Approx. 230-250 lb-ft (for 2.5L Turbocharged XT models) Fuel System Fuel Induction: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane minimum, higher recommended for turbo models) Engine Features Timing Drive: Timing Belt (requiring periodic replacement) 🔧 Transmission Standard Type Standard: 5-Speed Manual Transmission Optional Type Optional: 4-Speed Automatic Transmission (with AWD coupling) Features AWD System Manual: Full-Time Symmetrical All-Wheel Drive with viscous coupling center differential. AWD System Automatic: Active Automatic All-Wheel Drive system (Variable Transfer Clutch - VTC). Fluid Specifications Manual Transmission Fluid: API GL-5, SAE 75W-90 Gear Oil (check specific viscosity for climate) Automatic Transmission Fluid: Subaru ATF-HP (High Performance) or equivalent Dexron III/Mercon compatible fluid. 📐 Dimensions Exterior Length: Approx. 175.8 inches (4465 mm) Width: Approx. 69.7 inches (1770 mm) Height: Approx. 62.0 inches (1575 mm) Wheelbase: Approx. 103.0 inches (2615 mm) Ground Clearance: Approx. 7.5 - 8.0 inches (190-203 mm) depending on tire size and suspension. Weights Curb Weight: Approx. 3100 - 3400 lbs (1406 - 1542 kg) depending on configuration. Cargo Cargo Volume Behind Rear Seats: Approx. 30.0 - 32.0 cubic feet (850 - 906 liters) Cargo Volume With Rear Seats Folded: Approx. 65.0 - 68.0 cubic feet (1841 - 1926 liters) 🛡️ Safety Features Ratings NHTSA Frontal Impact Driver: 4 Stars (1999-2002 models) NHTSA Frontal Impact Passenger: 4 Stars (1999-2002 models) NHTSA Side Impact Front Driver: 4 Stars (2003-2004 models, with side airbags) NHTSA Side Impact Front Passenger: 4 Stars (2003-2004 models, with side airbags) Passive Features Airbags: Front airbags standard. Optional side airbags available on later models. Seatbelts: 3-point front and rear seatbelts with pretensioners and load limiters. Active Features ABS: Anti-lock Braking System (ABS) standard on most models. Traction Control: Traction Control System (TCS) available on some models, especially later ones. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM stereo with CD player. Cassette player may be present on earlier models. Speaker configuration varies by trim level. Climate Control: Manual or automatic climate control systems, depending on trim. HVAC system maintenance and component replacement are detailed. Driver Assistance Cruise Control: Standard cruise control functionality. Keyless Entry: Available keyless entry and security systems. Connectivity Power Accessories: Power windows, power door locks, and power mirrors are common features, especially on higher trims. 🔧 Maintenance Service Intervals Oil Change Interval:...

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Type: Car

Vendor:

Sku: 293310

Collections: ALL Subaru

Availability: In stock

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

Product variants

Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Year:

1999-2004

Codes

Chassis Code:

SF5, SF9, SG5, SG9 (for later models within the range, though the core focus is SF)

Generation

Generation Designation:

First Generation (SF) and early Second Generation (SG)

👋 Introduction

Market Position

Vehicle Segment:

Compact Crossover SUV

Key Selling Points:

Symmetrical All-Wheel Drive, Boxer Engine, Practicality, Reliability

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra

Key Features

All Wheel Drive:

Standard Symmetrical All-Wheel Drive (SAWD) on most models, providing enhanced traction and stability.

Engine Layout:

Horizontally-opposed (Boxer) engine layout, contributing to a lower center of gravity and improved handling.

Practicality:

Spacious interior, elevated driving position, versatile cargo area, and a reputation for family-friendly utility.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital Download (PDF)

Page Count:

Estimated 2000+ pages (comprehensive factory-level detail)

Availability:

Instant Download

Guarantee:

30-Day Money Back Guarantee

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (EJ25, EJ251, EJ253, EJ255, EJ257, EJ20 - Naturally Aspirated and Turbocharged), Transmission (Manual and Automatic), Drivetrain (All-Wheel Drive System)

Chassis:

Suspension (Front MacPherson Struts, Rear Multi-link), Steering (Power Rack and Pinion), Brakes (Front Ventilated Discs, Rear Discs, ABS)

Electrical:

Wiring Diagrams, Electrical Components, Lighting, Ignition System, Charging System, Engine Control Unit (ECU), Body Control Modules

Body And Interior:

Body Panels, Doors, Glass, Seats, HVAC System, Dashboard, Trim

Procedures Included

Maintenance:

Routine Service, Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Checks and Changes

Diagnostics And Troubleshooting:

DTC Codes, Symptom-based Troubleshooting, Component Testing

Repair And Overhaul:

Engine Rebuilds, Transmission Overhauls, Suspension Component Replacement, Brake System Repairs, Electrical Component Diagnosis and Replacement

Technical Specifications:

Torque Values, Clearances, Timing Specifications, Fluid Capacities

Technical Depth

Depth Of Information:

Factory-level repair procedures, detailed diagnostic flowcharts, specific torque specifications, wiring diagrams for all systems, component-level disassembly and reassembly instructions.

📊 Manual Specifications

File Format

File Format:

Searchability:

Text-searchable PDF allowing for quick keyword lookups.

Print Quality:

High-resolution scans suitable for printing individual pages or sections.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ251 (2.5L SOHC, Naturally Aspirated)

Engine Code 2:

EJ253 (2.5L DOHC, Naturally Aspirated - later models)

Engine Code 3:

EJ255 (2.5L DOHC, Turbocharged - Forester XT)

Engine Code 4:

EJ20 (2.0L SOHC/DOHC, Naturally Aspirated and Turbocharged - specific markets)

Performance

Horsepower Na:

Approx. 165-175 hp (for 2.5L SOHC/DOHC NA)

Torque Na:

Approx. 170-180 lb-ft (for 2.5L SOHC/DOHC NA)

Horsepower Turbo:

Approx. 210-230 hp (for 2.5L Turbocharged XT models)

Torque Turbo:

Approx. 230-250 lb-ft (for 2.5L Turbocharged XT models)

Fuel System

Fuel Induction:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane minimum, higher recommended for turbo models)

Engine Features

Timing Drive:

Timing Belt (requiring periodic replacement)

🔧 Transmission

Standard

Type Standard:

5-Speed Manual Transmission

Optional

Type Optional:

4-Speed Automatic Transmission (with AWD coupling)

Features

AWD System Manual:

Full-Time Symmetrical All-Wheel Drive with viscous coupling center differential.

AWD System Automatic:

Active Automatic All-Wheel Drive system (Variable Transfer Clutch - VTC).

Fluid Specifications

Manual Transmission Fluid:

API GL-5, SAE 75W-90 Gear Oil (check specific viscosity for climate)

Automatic Transmission Fluid:

Subaru ATF-HP (High Performance) or equivalent Dexron III/Mercon compatible fluid.

📐 Dimensions

Exterior

Length:

Approx. 175.8 inches (4465 mm)

Width:

Approx. 69.7 inches (1770 mm)

Height:

Approx. 62.0 inches (1575 mm)

Wheelbase:

Approx. 103.0 inches (2615 mm)

Ground Clearance:

Approx. 7.5 - 8.0 inches (190-203 mm) depending on tire size and suspension.

Weights

Curb Weight:

Approx. 3100 - 3400 lbs (1406 - 1542 kg) depending on configuration.

Cargo

Cargo Volume Behind Rear Seats:

Approx. 30.0 - 32.0 cubic feet (850 - 906 liters)

Cargo Volume With Rear Seats Folded:

Approx. 65.0 - 68.0 cubic feet (1841 - 1926 liters)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

4 Stars (1999-2002 models)

NHTSA Frontal Impact Passenger:

4 Stars (1999-2002 models)

NHTSA Side Impact Front Driver:

4 Stars (2003-2004 models, with side airbags)

NHTSA Side Impact Front Passenger:

4 Stars (2003-2004 models, with side airbags)

Passive Features

Airbags:

Front airbags standard. Optional side airbags available on later models.

Seatbelts:

3-point front and rear seatbelts with pretensioners and load limiters.

Active Features

Anti-lock Braking System (ABS) standard on most models.

Traction Control:

Traction Control System (TCS) available on some models, especially later ones.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with CD player. Cassette player may be present on earlier models. Speaker configuration varies by trim level.

Climate Control:

Manual or automatic climate control systems, depending on trim. HVAC system maintenance and component replacement are detailed.

Driver Assistance

Cruise Control:

Standard cruise control functionality.

Keyless Entry:

Available keyless entry and security systems.

Connectivity

Power Accessories:

Power windows, power door locks, and power mirrors are common features, especially on higher trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first, under severe driving conditions; 7,500 miles (12,000 km) or 12 months under normal conditions (check owner's manual for specifics).

Timing Belt Replacement:

Every 105,000 miles (168,000 km) or 105 months. This is a critical maintenance item due to the interference engine design.

Spark Plug Replacement:

Typically every 60,000 - 100,000 miles (96,000 - 160,000 km) depending on spark plug type (standard copper vs. platinum/iridium). Check manual for exact recommendation.

Fluid Specifications

Engine Oil Capacity:

Approx. 4.5 US quarts (4.3 liters) with filter for 2.5L engines. Always check dipstick.

Engine Oil Type:

API SN or SP, ILSAC GF-5 or GF-6, SAE 0W-20 or 5W-30. Consult manual for exact viscosity based on climate and engine. 5W-30 is common.

Coolant Type:

Subaru Super Coolant (Blue) or a high-quality ethylene glycol-based coolant with Subaru anti-corrosion additives. Typically a 50/50 mix with distilled water.

Known Issues

Head Gaskets:

While not as prevalent as in some later EJ25 engines, early EJ25 engines can be prone to head gasket failure. Regular coolant level checks are important.

Crankshaft Position Sensor:

Failure of the crankshaft position sensor can lead to intermittent stalling or no-start conditions. Often identified by a check engine light.

Oxygen Sensors:

Oxygen sensors can fail over time, affecting fuel economy and emissions. The manual details diagnostic procedures for these.

Automatic Transmission Behavior:

Some automatic transmissions might exhibit firmer shifts over time; proper fluid maintenance is key.

📚 Vehicle History

Brand Heritage

Subaru Core Values:

Subaru is renowned for its commitment to Symmetrical All-Wheel Drive, Boxer engines, safety, and building vehicles with robust capabilities, particularly in adverse weather conditions.

Model Evolution

First Generation Launch:

The first-generation Subaru Forester (SF chassis) was introduced in Japan in 1997 and launched in North America for the 1998 model year. It was designed to bridge the gap between a station wagon and an SUV.

Facelift And Second Gen Transition:

The first generation received a significant facelift for the 2001 model year, including revised styling and interior. The second generation (SG chassis) began production in 2002 for the 2003 model year, with this manual covering the transition and early SG models.

Production

Manufacturing Locations:

Primary production for North American market was in Gunma, Japan.

🏆 Awards & Recognition

Recognitions

Insurance Institute For Highway Safety:

The Forester has historically performed well in IIHS crash tests, earning 'Good' ratings in frontal offset tests for its segment, particularly the later models within this range.

Consumer Reports:

Often cited for its practicality and reliability, though specific ratings can vary by model year and powertrain. This manual provides the data to keep it running optimally.