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Subaru Forester Complete Workshop Service Repair Manual 1998 1999 2000 2001 2002 2003 2004

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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation Generation Name: SF Generation Years: 1997-2002 Codes Chassis Codes: SF5, SF9 👋 Introduction Market Position Segment: Compact Crossover SUV Usp: Symmetrical All-Wheel Drive (standard on most models), boxer engine, cargo versatility, excellent visibility Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra Key Features Powertrain Layout: Front-engine, Symmetrical All-Wheel Drive Body Styles: 5-door SUV Driving Dynamics: Comfortable ride, stable handling, capable in various weather conditions 📋 Manual Details Coverage Areas Model Years Covered: 1998, 1999, 2000, 2001, 2002, 2003, 2004 Regions Covered: Global (North America, Europe, Asia, etc. specifications may vary slightly) Page Count Estimated Page Count: Extensive (typically over 1500 pages for a complete set) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (EJ25, EJ20), Fuel & Emissions, Cooling System, Lubrication System, Ignition System, Turbocharger System (where applicable), Exhaust System, Manual Transmission, Automatic Transmission, Drivetrain (AWD System, Differentials, Axles, Driveshafts) Chassis: Suspension (Front & Rear), Steering System, Brake System (Front & Rear Disc/Drum, ABS), Wheels & Tires Electrical: Wiring Diagrams, Lighting System, Ignition System, Starting System, Charging System, Audio System, HVAC Controls, Power Accessories (Windows, Locks, Mirrors), SRS Airbag System, Body Control Modules, Instrument Cluster Body: Body Exterior (Panels, Doors, Hood, Hatch, Bumpers), Body Interior (Trim, Seats, Headliner), HVAC System (Components, Operation), Glass, Seals Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, tune-ups), Fluid checks and changes, Belt inspection and replacement, Spark plug replacement, Air filter replacement Repair Engine: Engine overhaul, Cylinder head removal/installation, Piston and connecting rod service, Crankshaft service, Timing belt/chain replacement, Turbocharger rebuild/replacement, Engine diagnostics Repair Transmission: Transmission disassembly/assembly, Clutch replacement, Torque converter service, Gearbox repairs, Automatic transmission diagnosis and repair Repair Brakes: Brake pad and rotor replacement, Brake caliper service, Brake line and hose replacement, ABS system diagnosis and repair Repair Electrical: Component testing and replacement (alternator, starter, sensors), Wiring harness repair, Troubleshooting electrical faults using diagrams, Audio system upgrades Body Repair: Panel replacement, Door hinge and lock repair, Interior trim panel installation, Glass replacement Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics) Diagnostic Information: Troubleshooting flowcharts, Symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs) and their meaning, Component testing procedures Specifications: Torque specifications for all fasteners, Clearances and tolerances for engine and transmission components, Fluid capacities and types, Electrical resistance and voltage values 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text (allows for quick finding of specific terms and procedures) Print Quality Image Resolution: High resolution for clear diagrams and illustrations Scalability: Scalable for printing individual pages or sections at desired size Binding Type Binding Type: Not applicable for digital format; printable on demand Paper Type Paper Type: Not applicable for digital format; intended for digital viewing or printing on standard paper ⚙️ Engine Specifications Primary Engine Engine Code 1: EJ251 (2.5L SOHC Naturally Aspirated) Engine Code 2: EJ25D (2.5L DOHC Naturally Aspirated - earlier models) Engine Code 3: EJ205 (2.0L DOHC Turbocharged - GT/GT-B models) Performance 2.5L Na Horsepower Ej251: 165 hp @ 5600 rpm Torque Ej251: 166 lb-ft @ 4000 rpm Performance 2.0L Turbo Horsepower Ej205: 210 hp @ 5600 rpm Torque Ej205: 236 lb-ft @ 3000 rpm Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Layout Cylinders: 4-Cylinder Boxer (Horizontally Opposed) Displacement: 2.5 Liters (2457 cc) for EJ25 variants; 2.0 Liters (1994 cc) for EJ20 variants 🔧 Transmission Standard Transmission Type 1: 5-Speed Manual Transmission Optional Transmission Type 2: 4-Speed Automatic Transmission (with overdrive) Features AWD System: Symmetrical All-Wheel Drive (Active on manual, viscous coupling with electronic control on automatic) Fluid Specifications Manual Transmission Fluid: API GL-5, SAE 75W-90 (Subaru Genuine Gear Oil recommended) Automatic Transmission Fluid: Subaru ATF-HP (High Performance) or equivalent (check owner's manual for exact specification) 📐 Dimensions Exterior Length Length Approx: 175.1 inches (4445 mm) Exterior Width Width Approx: 67.1 inches (1704 mm) Exterior Height Height Approx: 63.0 inches (1600 mm) (without roof rails) Wheelbase Wheelbase Approx: 103.0 inches (2616 mm) Cargo Volume Cargo Behind Rear Seat: 30.0 cubic feet (850 liters) (approximate) Cargo With Rear Seat Folded: 68.5 cubic feet (1940 liters) (approximate) Weights Curb Weight Approx: 3100-3400 lbs (1406-1542 kg) depending on trim and transmission 🛡️ Safety Features Ratings NHTSA Frontal Driver: 4-Star (for models equipped with front airbags) NHTSA Frontal Passenger: 4-Star (for models equipped with front airbags) IIHS Side Impact: Good (for models tested) Active Features Traction Control: Standard on most AWD models ABS: Anti-lock Braking System (standard on most trims) Passive Features Airbags: Frontal airbags (driver and passenger), optional side airbags on some later models Seatbelts: 3-point seatbelts with pretensioners and force limiters 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM/CD player with 4 or 6...
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Subaru Forester Complete Workshop Service Repair Manual 1998 1999 2000 2001 2002 2003 2004
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Generation
Generation Name:
SF
Generation Years:
1997-2002
Codes
Chassis Codes:
SF5, SF9
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Usp:
Symmetrical All-Wheel Drive (standard on most models), boxer engine, cargo versatility, excellent visibility
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra
Key Features
Powertrain Layout:
Front-engine, Symmetrical All-Wheel Drive
Body Styles:
5-door SUV
Driving Dynamics:
Comfortable ride, stable handling, capable in various weather conditions
📋 Manual Details
Coverage Areas
Model Years Covered:
1998, 1999, 2000, 2001, 2002, 2003, 2004
Regions Covered:
Global (North America, Europe, Asia, etc. specifications may vary slightly)
Page Count
Estimated Page Count:
Extensive (typically over 1500 pages for a complete set)
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (EJ25, EJ20), Fuel & Emissions, Cooling System, Lubrication System, Ignition System, Turbocharger System (where applicable), Exhaust System, Manual Transmission, Automatic Transmission, Drivetrain (AWD System, Differentials, Axles, Driveshafts)
Chassis:
Suspension (Front & Rear), Steering System, Brake System (Front & Rear Disc/Drum, ABS), Wheels & Tires
Electrical:
Wiring Diagrams, Lighting System, Ignition System, Starting System, Charging System, Audio System, HVAC Controls, Power Accessories (Windows, Locks, Mirrors), SRS Airbag System, Body Control Modules, Instrument Cluster
Body:
Body Exterior (Panels, Doors, Hood, Hatch, Bumpers), Body Interior (Trim, Seats, Headliner), HVAC System (Components, Operation), Glass, Seals
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, tune-ups), Fluid checks and changes, Belt inspection and replacement, Spark plug replacement, Air filter replacement
Repair Engine:
Engine overhaul, Cylinder head removal/installation, Piston and connecting rod service, Crankshaft service, Timing belt/chain replacement, Turbocharger rebuild/replacement, Engine diagnostics
Repair Transmission:
Transmission disassembly/assembly, Clutch replacement, Torque converter service, Gearbox repairs, Automatic transmission diagnosis and repair
Repair Brakes:
Brake pad and rotor replacement, Brake caliper service, Brake line and hose replacement, ABS system diagnosis and repair
Repair Electrical:
Component testing and replacement (alternator, starter, sensors), Wiring harness repair, Troubleshooting electrical faults using diagrams, Audio system upgrades
Body Repair:
Panel replacement, Door hinge and lock repair, Interior trim panel installation, Glass replacement
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds, advanced electrical diagnostics)
Diagnostic Information:
Troubleshooting flowcharts, Symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs) and their meaning, Component testing procedures
Specifications:
Torque specifications for all fasteners, Clearances and tolerances for engine and transmission components, Fluid capacities and types, Electrical resistance and voltage values
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Searchable text (allows for quick finding of specific terms and procedures)
Print Quality
Image Resolution:
High resolution for clear diagrams and illustrations
Scalability:
Scalable for printing individual pages or sections at desired size
Binding Type
Binding Type:
Not applicable for digital format; printable on demand
Paper Type
Paper Type:
Not applicable for digital format; intended for digital viewing or printing on standard paper
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EJ251 (2.5L SOHC Naturally Aspirated)
Engine Code 2:
EJ25D (2.5L DOHC Naturally Aspirated - earlier models)
Engine Code 3:
EJ205 (2.0L DOHC Turbocharged - GT/GT-B models)
Performance 2.5L Na
Horsepower Ej251:
165 hp @ 5600 rpm
Torque Ej251:
166 lb-ft @ 4000 rpm
Performance 2.0L Turbo
Horsepower Ej205:
210 hp @ 5600 rpm
Torque Ej205:
236 lb-ft @ 3000 rpm
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Layout
Cylinders:
4-Cylinder Boxer (Horizontally Opposed)
Displacement:
2.5 Liters (2457 cc) for EJ25 variants; 2.0 Liters (1994 cc) for EJ20 variants
🔧 Transmission
Standard
Transmission Type 1:
5-Speed Manual Transmission
Optional
Transmission Type 2:
4-Speed Automatic Transmission (with overdrive)
Features
AWD System:
Symmetrical All-Wheel Drive (Active on manual, viscous coupling with electronic control on automatic)
Fluid Specifications
Manual Transmission Fluid:
API GL-5, SAE 75W-90 (Subaru Genuine Gear Oil recommended)
Automatic Transmission Fluid:
Subaru ATF-HP (High Performance) or equivalent (check owner's manual for exact specification)
📐 Dimensions
Exterior Length
Length Approx:
175.1 inches (4445 mm)
Exterior Width
Width Approx:
67.1 inches (1704 mm)
Exterior Height
Height Approx:
63.0 inches (1600 mm) (without roof rails)
Wheelbase
Wheelbase Approx:
103.0 inches (2616 mm)
Cargo Volume
Cargo Behind Rear Seat:
30.0 cubic feet (850 liters) (approximate)
Cargo With Rear Seat Folded:
68.5 cubic feet (1940 liters) (approximate)
Weights
Curb Weight Approx:
3100-3400 lbs (1406-1542 kg) depending on trim and transmission
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
4-Star (for models equipped with front airbags)
NHTSA Frontal Passenger:
4-Star (for models equipped with front airbags)
IIHS Side Impact:
Good (for models tested)
Active Features
Traction Control:
Standard on most AWD models
ABS:
Anti-lock Braking System (standard on most trims)
Passive Features
Airbags:
Frontal airbags (driver and passenger), optional side airbags on some later models
Seatbelts:
3-point seatbelts with pretensioners and force limiters
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM/CD player with 4 or 6 speakers. Available premium audio systems.
Climate Control:
Manual HVAC controls with optional automatic climate control on higher trims.
Driver Assistance
Cruise Control:
Standard on most trims
Visibility:
Excellent outward visibility due to large greenhouse and raised seating position.
Connectivity
Auxiliary Input:
Not typically standard on base models; aftermarket solutions available.
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months for severe driving; 7,500 miles (12,000 km) or 6 months for normal driving (consult manual for specifics)
Service Intervals Filters
Oil Filter Part Number:
Subaru 15208AA100 (example, verify for specific model year)
Air Filter Part Number:
Subaru 16546AA100 (example, verify for specific model year)
Service Intervals Timing Belt
Timing Belt Replacement Interval:
Every 60,000 miles (96,000 km) or 4-5 years (crucial for EJ engines to prevent catastrophic failure)
Fluid Specifications
Engine Oil Specification:
API SM/SN, SAE 5W-30 or 10W-30 (refer to owner's manual for exact viscosity and API rating)
Coolant Specification:
Subaru Super Coolant (blue) or equivalent silicate-free, long-life coolant. Capacity: ~7.1 qts (6.7 L)
Brake Fluid Specification:
DOT 3 or DOT 4
Known Issues
Head Gaskets:
Susceptibility to head gasket leaks, especially on earlier EJ25D engines. The EJ251 and later variants are generally more robust, but vigilance is still recommended.
Timing Belt Tensioner:
Failure of the timing belt tensioner can lead to belt slippage or breakage, causing severe engine damage.
Rear Main Seal:
Potential for rear main crankshaft seal leaks over time.
Suspension Components:
Wear on ball joints, tie rod ends, and bushings can occur with mileage, affecting ride and handling.
📚 Vehicle History
Brand Heritage
Subaru Focus:
Known for Symmetrical All-Wheel Drive, horizontally opposed boxer engines, and rally racing heritage
Model Evolution
Forester Launch:
First generation (SF) launched in 1997, bridging the gap between a wagon and an SUV.
Mid Cycle Refresh:
Minor styling updates and feature enhancements occurred throughout the SF generation, including the facelift around 2001.
Production
Manufacturing Plant:
Gunma Plant, Japan
🏆 Awards & Recognition
Recognitions
Car And Driver Best:
Car and Driver's '10Best Trucks' multiple times during its early production years.
IIHS Top Safety Pick:
Earned good ratings in IIHS crash tests, contributing to its reputation for safety.
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