(75 MB) 1999-2002 Subaru Forester-Complete Factory Service Manual (FSM)/Repair Manual/Workshop Manual 99 2000 2001 02 (ZIP-PDF Format)

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🏷️ Basic Information Identification Make: Subaru Model: Forester Model Years Covered: 1999, 2000, 2001, 2002 Codes Chassis Codes: SF Series (First Generation) Engine Codes Covered: EJ253 (2.5L SOHC NA), EJ255 (2.5L DOHC Turbo - XT models) 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV / Station Wagon Target Audience: Families, outdoor enthusiasts, drivers seeking all-wheel drive capability and practicality. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra. Key Features Drivetrain Advantage: Standard Symmetrical All-Wheel Drive (AWD) across most trims, providing superior traction and stability compared to many front-wheel-drive competitors. Practicality: Spacious interior for its class, generous cargo volume, good ground clearance for light off-roading and adverse weather conditions. Engine Performance: Reliable Subaru Boxer engines known for their low center of gravity, contributing to balanced handling. 📋 Manual Details Coverage Areas Main Coverage Areas: Engine Mechanical, Engine Control System, Fuel System, Exhaust System, Transmission (Manual & Automatic), Drivetrain (AWD System), Suspension, Steering, Brakes (ABS), Body & Chassis, HVAC System, Electrical System, Body Electronics, Diagnostics, Troubleshooting, Specifications Page Count Estimated Page Count: 1000-1500 (typical for comprehensive FSM) Manual Type Manual Type: Factory Service Manual (FSM) / Repair Manual / Workshop Manual Language Language: English Format Digital Format: ZIP archive containing PDF files 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed disassembly, assembly, inspection, and torque specifications for EJ253 and EJ255 engines, including cylinder heads, pistons, crankshaft, camshafts, timing belt/chain, oil pump, and lubrication system. Engine Control System: ECU operation, sensor diagnostics (MAF, O2, TPS, CKP, CMP), actuator control (injectors, ignition coils), emissions control systems (EGR, PCV), diagnostic trouble codes (DTCs) and their interpretation. Fuel System: Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, evaporative emission control (EVAP) system, fuel tank and lines. Transmission Drivetrain: Manual transmission (5-speed) and automatic transmission (4-speed) operation, maintenance, diagnostics, and repair. Includes transfer clutch, differentials (front and rear), and driveshafts. Suspension Steering: Front and rear suspension components (struts, springs, control arms, bushings), alignment specifications, power steering system (pump, rack and pinion, hoses). Brakes: Disc brake systems (front and rear), ABS system (sensors, modulator, hydraulic unit), brake fluid specifications, bleeding procedures, parking brake. Electrical System: Battery, charging system (alternator), starting system (starter motor), ignition system, lighting system, fuses, relays, wiring diagrams, component locations. HVAC Body: Air conditioning system (refrigerant, compressor, evaporator, condenser), heating system, ventilation, body panel removal/installation, interior trim, door mechanisms, glass replacement. Procedures Included Routine Maintenance: Oil change intervals and specifications, filter replacement (oil, air, cabin), spark plug replacement, coolant flush, brake fluid replacement, drive belt inspection and replacement. Diagnostics Troubleshooting: Step-by-step diagnostic flowcharts for common symptoms, electrical troubleshooting using wiring diagrams, component testing procedures, OBD-II diagnostic scanner usage. Major Repairs: Engine rebuilds, cylinder head removal and repair, transmission overhaul, brake caliper replacement, suspension component replacement, turbocharger (if applicable) servicing. Component Replacement: Detailed instructions for replacing common wear items and major components such as alternators, water pumps, radiators, fuel pumps, clutch assemblies, CV joints, and body panels. Technical Depth Depth Of Coverage: Comprehensive from basic maintenance to advanced engine and transmission diagnostics and repair. Includes detailed specifications, torque values, and schematics. 📊 Manual Specifications File Format File Format Details: PDF (Portable Document Format). High-resolution scans of original factory documents, ensuring clarity and readability. Likely includes searchable text capabilities if OCR was applied during conversion. Print Quality Scan Quality: High Quality. Implies clear text, legible diagrams, and accurate reproduction of original content. Binding Type Binding Type: Digital (Not applicable for physical binding). Paper Type Paper Type: Digital (Not applicable for physical paper type). ⚙️ Engine Specifications Primary Engine Engine Displacement: 2.5 Liters (2457 cc) Engine Configuration: Horizontally Opposed (Boxer) Four-Cylinder Valve Mechanism: SOHC (Single Overhead Camshaft) for NA models (EJ253), DOHC (Dual Overhead Camshaft) for Turbo models (EJ255). Performance Horsepower Na: Approx. 165 hp @ 5,600 rpm (EJ253) Torque Na: Approx. 166 lb-ft @ 4,000 rpm (EJ253) Horsepower Turbo Xt: Approx. 177 hp @ 5,600 rpm (EJ255 - specific model/year variations apply) Torque Turbo Xt: Approx. 177 lb-ft @ 3,200 rpm (EJ255 - specific model/year variations apply) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Maintenance Specs Oil Capacity Quarts: 4.7 quarts (4.5 liters) with filter change (EJ253/EJ255) Recommended Oil Viscosity: 5W-30 (check manual for specific temperature ranges) Spark Plug Type: NGK Platinum or Iridium recommended (e.g., PFR5BG-11) 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Transmission Optional Optional Transmission Type: 4-Speed Electronically Controlled Automatic Transmission Features AWD System: Symmetrical All-Wheel Drive (AWD) with viscous coupling center differential and rear differential. Maintenance Specs Manual Transmission Fluid Capacity: Approx. 2.0 liters Manual Transmission Fluid Type: GL-5 Gear Oil (e.g., 75W-90) Automatic Transmission Fluid Capacity: Approx. 3.8 liters (drain and fill) Automatic Transmission Fluid Type: Subaru ATF-HP (or equivalent Dexron III/Mercon compatible) 📐 Dimensions Exterior Length: Approx. 175.6 inches (4460 mm) Width: Approx. 69.7 inches (1770 mm)...

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Model Years Covered:

1999, 2000, 2001, 2002

Codes

Chassis Codes:

SF Series (First Generation)

Engine Codes Covered:

EJ253 (2.5L SOHC NA), EJ255 (2.5L DOHC Turbo - XT models)

👋 Introduction

Market Position

Vehicle Segment:

Compact Crossover SUV / Station Wagon

Target Audience:

Families, outdoor enthusiasts, drivers seeking all-wheel drive capability and practicality.

Competitive Analysis

Key Competitors:

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

Key Features

Drivetrain Advantage:

Standard Symmetrical All-Wheel Drive (AWD) across most trims, providing superior traction and stability compared to many front-wheel-drive competitors.

Practicality:

Spacious interior for its class, generous cargo volume, good ground clearance for light off-roading and adverse weather conditions.

Engine Performance:

Reliable Subaru Boxer engines known for their low center of gravity, contributing to balanced handling.

📋 Manual Details

Coverage Areas

Main Coverage Areas:

Engine Mechanical, Engine Control System, Fuel System, Exhaust System, Transmission (Manual & Automatic), Drivetrain (AWD System), Suspension, Steering, Brakes (ABS), Body & Chassis, HVAC System, Electrical System, Body Electronics, Diagnostics, Troubleshooting, Specifications

Page Count

Estimated Page Count:

1000-1500 (typical for comprehensive FSM)

Manual Type

Manual Type:

Factory Service Manual (FSM) / Repair Manual / Workshop Manual

Language

Language:

English

Format

Digital Format:

ZIP archive containing PDF files

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed disassembly, assembly, inspection, and torque specifications for EJ253 and EJ255 engines, including cylinder heads, pistons, crankshaft, camshafts, timing belt/chain, oil pump, and lubrication system.

Engine Control System:

ECU operation, sensor diagnostics (MAF, O2, TPS, CKP, CMP), actuator control (injectors, ignition coils), emissions control systems (EGR, PCV), diagnostic trouble codes (DTCs) and their interpretation.

Fuel System:

Fuel pump, fuel filter, fuel injectors, fuel pressure regulator, evaporative emission control (EVAP) system, fuel tank and lines.

Transmission Drivetrain:

Manual transmission (5-speed) and automatic transmission (4-speed) operation, maintenance, diagnostics, and repair. Includes transfer clutch, differentials (front and rear), and driveshafts.

Suspension Steering:

Front and rear suspension components (struts, springs, control arms, bushings), alignment specifications, power steering system (pump, rack and pinion, hoses).

Brakes:

Disc brake systems (front and rear), ABS system (sensors, modulator, hydraulic unit), brake fluid specifications, bleeding procedures, parking brake.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), ignition system, lighting system, fuses, relays, wiring diagrams, component locations.

HVAC Body:

Air conditioning system (refrigerant, compressor, evaporator, condenser), heating system, ventilation, body panel removal/installation, interior trim, door mechanisms, glass replacement.

Procedures Included

Routine Maintenance:

Oil change intervals and specifications, filter replacement (oil, air, cabin), spark plug replacement, coolant flush, brake fluid replacement, drive belt inspection and replacement.

Diagnostics Troubleshooting:

Step-by-step diagnostic flowcharts for common symptoms, electrical troubleshooting using wiring diagrams, component testing procedures, OBD-II diagnostic scanner usage.

Major Repairs:

Engine rebuilds, cylinder head removal and repair, transmission overhaul, brake caliper replacement, suspension component replacement, turbocharger (if applicable) servicing.

Component Replacement:

Detailed instructions for replacing common wear items and major components such as alternators, water pumps, radiators, fuel pumps, clutch assemblies, CV joints, and body panels.

Technical Depth

Depth Of Coverage:

Comprehensive from basic maintenance to advanced engine and transmission diagnostics and repair. Includes detailed specifications, torque values, and schematics.

📊 Manual Specifications

File Format

File Format Details:

PDF (Portable Document Format). High-resolution scans of original factory documents, ensuring clarity and readability. Likely includes searchable text capabilities if OCR was applied during conversion.

Print Quality

Scan Quality:

High Quality. Implies clear text, legible diagrams, and accurate reproduction of original content.

Binding Type

Binding Type:

Digital (Not applicable for physical binding).

Paper Type

Paper Type:

Digital (Not applicable for physical paper type).

⚙️ Engine Specifications

Primary Engine

Engine Displacement:

2.5 Liters (2457 cc)

Engine Configuration:

Horizontally Opposed (Boxer) Four-Cylinder

Valve Mechanism:

SOHC (Single Overhead Camshaft) for NA models (EJ253), DOHC (Dual Overhead Camshaft) for Turbo models (EJ255).

Performance

Horsepower Na:

Approx. 165 hp @ 5,600 rpm (EJ253)

Torque Na:

Approx. 166 lb-ft @ 4,000 rpm (EJ253)

Horsepower Turbo Xt:

Approx. 177 hp @ 5,600 rpm (EJ255 - specific model/year variations apply)

Torque Turbo Xt:

Approx. 177 lb-ft @ 3,200 rpm (EJ255 - specific model/year variations apply)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Maintenance Specs

Oil Capacity Quarts:

4.7 quarts (4.5 liters) with filter change (EJ253/EJ255)

Recommended Oil Viscosity:

5W-30 (check manual for specific temperature ranges)

Spark Plug Type:

NGK Platinum or Iridium recommended (e.g., PFR5BG-11)

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual Transmission

Optional

Optional Transmission Type:

4-Speed Electronically Controlled Automatic Transmission

Features

AWD System:

Symmetrical All-Wheel Drive (AWD) with viscous coupling center differential and rear differential.

Maintenance Specs

Manual Transmission Fluid Capacity:

Approx. 2.0 liters

Manual Transmission Fluid Type:

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

Automatic Transmission Fluid Capacity:

Approx. 3.8 liters (drain and fill)

Automatic Transmission Fluid Type:

Subaru ATF-HP (or equivalent Dexron III/Mercon compatible)

📐 Dimensions

Exterior

Length:

Approx. 175.6 inches (4460 mm)

Width:

Approx. 69.7 inches (1770 mm)

Height:

Approx. 63.0 inches (1600 mm)

Wheelbase:

Approx. 103.0 inches (2615 mm)

Ground Clearance:

Approx. 7.7 inches (196 mm)

Interior

Passenger Volume:

Approx. 99.7 cu ft

Cargo

Cargo Volume Behind Rear Seat:

Approx. 35.1 cu ft

Cargo Volume With Rear Seat Folded:

Approx. 68.4 cu ft

Weights

Curb Weight Approx:

3200 - 3400 lbs (depending on trim and transmission)

Towing Capacity:

Typically rated up to 2000 lbs (check specific year/trim for confirmation)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

Likely received 4-star ratings for driver and passenger in frontal impact tests (based on era standards).

IIHS Side Impact:

Ratings varied by year; 'Acceptable' or 'Good' was common for vehicles of this era.

Active Features

Active Safety Features:

Standard Symmetrical AWD, Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD).

Passive Features

Passive Safety Features:

Dual front airbags, front side-impact airbags (optional on some trims), three-point seatbelts with pretensioners, crumple zones, reinforced passenger cage.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player, with optional premium sound systems. Manual will cover speaker replacement, head unit removal, and wiring.

Driver Assistance

Driver Assistance Features:

Limited by modern standards. Primarily ABS and AWD. Cruise control is standard on most models.

Connectivity

Connectivity Options:

None from the factory in terms of Bluetooth or USB. Manual will detail basic wiring for aftermarket installations.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 3,750 miles (6,000 km) or 3.75 months, or 7,500 miles (12,000 km) or 7.5 months under severe driving conditions (consult manual for specifics).

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 15 months.

Spark Plug Replacement:

Every 30,000 miles (48,000 km) for platinum plugs.

Timing Belt Replacement:

Every 60,000 miles (96,000 km) or 60 months is a critical interval for EJ series engines to prevent catastrophic failure.

Coolant Replacement:

Initial replacement at 60,000 miles (96,000 km), then every 30,000 miles (48,000 km) or 30 months thereafter.

Fluid Specifications

Coolant Type:

Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant.

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid:

ATF (Automatic Transmission Fluid)Dexron II/III

Known Issues

Head Gasket Leaks:

While more prevalent in EJ25 DOHC engines of later generations, some earlier EJ25 SOHC engines could experience head gasket issues, particularly external coolant leaks. This manual would detail diagnostic procedures.

Timing Belt Wear:

Critical to adhere to the timing belt replacement interval to prevent interference engine damage. Manual will provide correct component part numbers and procedures.

Automatic Transmission Behavior:

Some reports of rough shifting or delayed engagement may occur over time; manual covers diagnostic procedures for the valve body and solenoids.

📚 Vehicle History

Brand Heritage

Subaru Heritage:

Subaru, a division of Subaru Corporation, has a long history of producing vehicles with horizontally opposed engines and all-wheel-drive systems, often associated with rally racing and rugged capability.

Model Evolution

First Generation Launch:

The Subaru Forester debuted in 1997 (as a 1998 model in North America) and this manual covers the entire first generation (SF chassis) from its introduction through its facelift in 2003.

Facelift Details:

A significant facelift occurred for the 2003 model year, which included revised exterior styling (headlights, grille, bumpers) and interior updates. This manual covers the pre-facelift and early facelift models within its specified years.

Production

Manufacturing Locations:

Primarily manufactured in Japan (Gunma Prefecture) and later in Lafayette, Indiana, USA for the North American market.

🏆 Awards & Recognition

Recognitions

Automotive Press Awards:

The Subaru Forester has consistently received praise for its practicality, safety, and AWD capability. Specific awards may include 'Best Small SUV' or similar from automotive publications of the era.