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Subaru Forester Service Repair Manual 1999-2002

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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation: SF Model Years Covered: 1999, 2000, 2001, 2002 Codes Chassis Code: SF5, SF9 👋 Introduction Market Position Segment: Compact Crossover SUV Key Selling Points: Symmetrical All-Wheel Drive, practicality, wagon-like utility, good visibility Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute Key Features Body Styles: 5-door SUV/Crossover Standard Drivetrain: Symmetrical All-Wheel Drive (AWD) 📋 Manual Details Coverage Areas Regions Covered: Global (primarily North American specifications unless otherwise noted) Page Count Estimated Page Count: 1500-2000+ (typical for comprehensive workshop manuals of this era, exact count not specified) Manual Type Manual Type: Service and Repair Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder heads, pistons, crankshaft, camshafts, timing belt, lubrication system, cooling system Engine Management: Fuel injection (MPI), ignition system, emissions control, engine control unit (ECU) diagnostics, sensor identification and testing Transmission Manual: Clutch system, gearbox disassembly and assembly, gear shift linkage, transmission fluid specifications Transmission Automatic: Automatic transmission (4EAT) operation, torque converter, valve body, transmission control unit (TCU) diagnostics, fluid specifications Drivetrain AWD: All-Wheel Drive (AWD) system, viscous coupling center differential, rear differential, drive shafts, CV joints Brakes: Front disc brakes, rear disc brakes (or drums on some early models), ABS system (if equipped), brake fluid specifications, bleeding procedures Suspension: Front struts and springs, rear multi-link suspension, shock absorbers, bushings, alignment specifications Steering: Power steering system, steering rack, tie rods, steering column, wheel alignment Electrical System: Battery, charging system (alternator), starting system (starter), lighting systems, fuses, relays, wiring diagrams Body And Interior: Body panel removal/installation, door mechanisms, interior trim, seats, HVAC system, glass replacement Diagnostics Troubleshooting: OBD-II diagnostic codes, symptom-based troubleshooting charts, diagnostic tool usage Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid level checks, tire rotation, brake pad inspection Engine Repairs: Head gasket replacement, timing belt service, piston ring replacement, valve adjustment Transmission Service: Automatic transmission fluid and filter change, clutch replacement, manual transmission rebuild Brake Service: Brake pad and rotor replacement, brake caliper servicing, ABS sensor replacement Suspension Repairs: Strut and spring replacement, ball joint replacement, control arm bushing replacement Electrical Diagnostics: Circuit testing, component testing, wiring harness repair, starter and alternator testing Air Conditioning Service: Refrigerant handling, component replacement (compressor, condenser, evaporator), leak testing Body Repair: Dent repair, panel replacement, rust prevention and repair, glass installation Technical Depth Depth Of Coverage: Comprehensive (from basic maintenance to complete engine and transmission overhauls) Diagnostic Capabilities: Advanced diagnostic procedures, wiring diagrams, pinout data, sensor voltage charts Torque Specifications: Detailed torque specifications for all critical fasteners Special Tools: Identification and use of Subaru-specific or recommended special tools 📊 Manual Specifications File Format PDF Quality: Likely scanned from original print, quality can vary but generally readable with searchable text features often present Print Quality Original Print Quality: Professional factory publication standards Binding Type Original Binding: Spiral-bound or perfect-bound (original print) Paper Type Original Paper Type: Durable, semi-gloss paper stock ⚙️ Engine Specifications Primary Engine Engine Code And Type: EJ253 (2.5L SOHC Naturally Aspirated) Displacement: 2457 cc (2.5 Liters) Bore X Stroke: 99.5 mm x 79.0 mm Compression Ratio: 9.7:1 Horsepower: 165 hp @ 5,500 rpm (approx.) Torque: 166 lb-ft @ 4,000 rpm (approx.) Valvetrain: SOHC (Single Overhead Camshaft) 16-valve Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Engine Options Turbocharged Engine Availability: Yes, Forester S/TB and STI models (GT) featured the EJ205 2.0L Turbocharged engine, not covered by this general manual unless specified. Performance 0 60 Mph Time: Approx. 8.5 - 9.5 seconds (depending on transmission and conditions) 🔧 Transmission Standard Standard Transmission: 4-speed Automatic Transmission (4EAT) Optional Optional Transmission: 5-speed Manual Transmission Features AWD System Type: Symmetrical All-Wheel Drive with viscous coupling center differential (Active AWD on automatic, viscous LSD on manual) Automatic Transmission Modes: Normal, Sport (with "Grade Logic Control" for downhill engine braking) 📐 Dimensions Exterior Length: 4405 mm (173.4 in) Width: 1735 mm (68.3 in) Height: 1590 mm (62.6 in) Wheelbase: 2530 mm (99.6 in) Ground Clearance: 195 mm (7.7 in) Weights Curb Weight Approx: 1450 - 1550 kg (3197 - 3417 lbs) Cargo Cargo Volume Behind Rear Seat: Approx. 31.5 cu ft (expandable) 🛡️ Safety Features Ratings NHTSA Rollover Rating: 4/5 Stars (for vehicles equipped with AWD) Active Features ABS: Standard on most models (4-wheel disc brakes with ABS) Traction Control: Not typically standard on this generation, but may have been optional or specific to certain markets/trims. Passive Features Airbags: Driver and front passenger airbags standard. Side airbags were optional or not available on all models. Seatbelts: 3-point height-adjustable front seatbelts with pretensioners and load limiters, rear 3-point seatbelts. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with optional premium sound system. Basic digital display for clock/radio. Climate Control: Manual HVAC controls with standard A/C. Automatic climate control was not common...
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Subaru Forester Service Repair Manual 1999-2002
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Generation:
SF
Model Years Covered:
1999, 2000, 2001, 2002
Codes
Chassis Code:
SF5, SF9
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Key Selling Points:
Symmetrical All-Wheel Drive, practicality, wagon-like utility, good visibility
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute
Key Features
Body Styles:
5-door SUV/Crossover
Standard Drivetrain:
Symmetrical All-Wheel Drive (AWD)
📋 Manual Details
Coverage Areas
Regions Covered:
Global (primarily North American specifications unless otherwise noted)
Page Count
Estimated Page Count:
1500-2000+ (typical for comprehensive workshop manuals of this era, exact count not specified)
Manual Type
Manual Type:
Service and Repair Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder heads, pistons, crankshaft, camshafts, timing belt, lubrication system, cooling system
Engine Management:
Fuel injection (MPI), ignition system, emissions control, engine control unit (ECU) diagnostics, sensor identification and testing
Transmission Manual:
Clutch system, gearbox disassembly and assembly, gear shift linkage, transmission fluid specifications
Transmission Automatic:
Automatic transmission (4EAT) operation, torque converter, valve body, transmission control unit (TCU) diagnostics, fluid specifications
Drivetrain AWD:
All-Wheel Drive (AWD) system, viscous coupling center differential, rear differential, drive shafts, CV joints
Brakes:
Front disc brakes, rear disc brakes (or drums on some early models), ABS system (if equipped), brake fluid specifications, bleeding procedures
Suspension:
Front struts and springs, rear multi-link suspension, shock absorbers, bushings, alignment specifications
Steering:
Power steering system, steering rack, tie rods, steering column, wheel alignment
Electrical System:
Battery, charging system (alternator), starting system (starter), lighting systems, fuses, relays, wiring diagrams
Body And Interior:
Body panel removal/installation, door mechanisms, interior trim, seats, HVAC system, glass replacement
Diagnostics Troubleshooting:
OBD-II diagnostic codes, symptom-based troubleshooting charts, diagnostic tool usage
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid level checks, tire rotation, brake pad inspection
Engine Repairs:
Head gasket replacement, timing belt service, piston ring replacement, valve adjustment
Transmission Service:
Automatic transmission fluid and filter change, clutch replacement, manual transmission rebuild
Brake Service:
Brake pad and rotor replacement, brake caliper servicing, ABS sensor replacement
Suspension Repairs:
Strut and spring replacement, ball joint replacement, control arm bushing replacement
Electrical Diagnostics:
Circuit testing, component testing, wiring harness repair, starter and alternator testing
Air Conditioning Service:
Refrigerant handling, component replacement (compressor, condenser, evaporator), leak testing
Body Repair:
Dent repair, panel replacement, rust prevention and repair, glass installation
Technical Depth
Depth Of Coverage:
Comprehensive (from basic maintenance to complete engine and transmission overhauls)
Diagnostic Capabilities:
Advanced diagnostic procedures, wiring diagrams, pinout data, sensor voltage charts
Torque Specifications:
Detailed torque specifications for all critical fasteners
Special Tools:
Identification and use of Subaru-specific or recommended special tools
📊 Manual Specifications
File Format
PDF Quality:
Likely scanned from original print, quality can vary but generally readable with searchable text features often present
Print Quality
Original Print Quality:
Professional factory publication standards
Binding Type
Original Binding:
Spiral-bound or perfect-bound (original print)
Paper Type
Original Paper Type:
Durable, semi-gloss paper stock
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
EJ253 (2.5L SOHC Naturally Aspirated)
Displacement:
2457 cc (2.5 Liters)
Bore X Stroke:
99.5 mm x 79.0 mm
Compression Ratio:
9.7:1
Horsepower:
165 hp @ 5,500 rpm (approx.)
Torque:
166 lb-ft @ 4,000 rpm (approx.)
Valvetrain:
SOHC (Single Overhead Camshaft) 16-valve
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Options
Turbocharged Engine Availability:
Yes, Forester S/TB and STI models (GT) featured the EJ205 2.0L Turbocharged engine, not covered by this general manual unless specified.
Performance
0 60 Mph Time:
Approx. 8.5 - 9.5 seconds (depending on transmission and conditions)
🔧 Transmission
Standard
Standard Transmission:
4-speed Automatic Transmission (4EAT)
Optional
Optional Transmission:
5-speed Manual Transmission
Features
AWD System Type:
Symmetrical All-Wheel Drive with viscous coupling center differential (Active AWD on automatic, viscous LSD on manual)
Automatic Transmission Modes:
Normal, Sport (with "Grade Logic Control" for downhill engine braking)
📐 Dimensions
Exterior
Length:
4405 mm (173.4 in)
Width:
1735 mm (68.3 in)
Height:
1590 mm (62.6 in)
Wheelbase:
2530 mm (99.6 in)
Ground Clearance:
195 mm (7.7 in)
Weights
Curb Weight Approx:
1450 - 1550 kg (3197 - 3417 lbs)
Cargo
Cargo Volume Behind Rear Seat:
Approx. 31.5 cu ft (expandable)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
4/5 Stars (for vehicles equipped with AWD)
Active Features
ABS:
Standard on most models (4-wheel disc brakes with ABS)
Traction Control:
Not typically standard on this generation, but may have been optional or specific to certain markets/trims.
Passive Features
Airbags:
Driver and front passenger airbags standard. Side airbags were optional or not available on all models.
Seatbelts:
3-point height-adjustable front seatbelts with pretensioners and load limiters, rear 3-point seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional premium sound system. Basic digital display for clock/radio.
Climate Control:
Manual HVAC controls with standard A/C. Automatic climate control was not common on this generation.
Driver Assistance
Cruise Control:
Standard on most trim levels.
All Wheel Drive:
The core technology and primary driver assistance feature, providing enhanced traction and stability.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Every 3,750 miles or 3 months (severe driving conditions) or 7,500 miles or 6 months (normal driving conditions).
Timing Belt Replacement:
Every 105,000 miles or 7 years, whichever comes first (CRITICAL maintenance item for EJ engines).
Coolant Flush:
Every 30,000 miles or 2 years.
Fluid Specifications
Engine Oil:
SAE 5W-30 API SG or SH certified oil. Check dipstick for accurate capacity.
Automatic Transmission Fluid:
Subaru ATF HP (or equivalent Dexron III/Mercon compatible fluid). Capacity approx. 3.5-4 quarts for change.
Manual Transmission Fluid:
SAE 75W-90 GL-5 gear oil. Capacity approx. 2.5 quarts.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
ATF (Automatic Transmission Fluid).
Known Issues
Head Gaskets:
Premature head gasket failure is a common concern on EJ series engines, especially on naturally aspirated models. The manual will detail diagnostic and replacement procedures.
Oil Leaks:
Oil leaks from valve cover gaskets, oil pan gaskets, and rear main seals can occur.
Wheel Bearings:
Front wheel bearings can be prone to premature wear.
ABS Sensors:
ABS wheel speed sensors can fail, leading to ABS warning lights.
📚 Vehicle History
Brand Heritage
Subaru Specialty:
Known for horizontally-opposed (Boxer) engines and Symmetrical All-Wheel Drive.
Model Evolution
First Generation Introduction:
Introduced in 1997 in Japan, 1998 in North America.
Sf Generation Updates:
Minor styling refreshes and feature updates occurred during this period, including the introduction of optional turbocharged models (GT/S/TB).
Production
Manufacturing Location:
Gunma Plant, Japan
🏆 Awards & Recognition
Recognitions
Motor Trend SUV Of The Year:
Not directly awarded 'SUV of the Year' by MotorTrend in this generation, but consistently praised for its AWD and utility.
IIHS Crash Test Ratings:
Generally performed well in IIHS crash tests for its era, earning 'Good' ratings in frontal and side impacts where tested.
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