Subaru Forester 2002 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2002 Generation Chassis Code: SF Series (Second Generation) Codes Subaru Model Code: SF5 (for naturally aspirated models), SF9 (for turbocharged models) 👋 Introduction Market Position Segment: Compact Crossover SUV Key Selling Points: Symmetrical All-Wheel Drive (standard), practicality, Subaru boxer engine, good visibility, reputation for reliability. Competitive Analysis Key Competitors 2002: Toyota RAV4, Honda CR-V, Ford Escape, Mazda Tribute, Nissan Xterra. Key Features Standard AWD: Subaru's signature Symmetrical All-Wheel Drive system was standard across all trims, a significant differentiator. Boxer Engine Layout: Flat-four 'boxer' engine provides a lower center of gravity for improved handling and stability. Practicality: Spacious interior for its class, versatile cargo area, and good ground clearance for light off-road use. 📋 Manual Details Coverage Areas Main Coverage: Complete repair and service procedures, maintenance schedules, troubleshooting guides Page Count Estimated Pages: 1500-2000 (typical for comprehensive factory service manuals of this era) Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: Likely available as a physical book or a searchable PDF 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication system, cooling system, fuel system, ignition system, emission control system, engine electrical, engine management (ECU) Transmission: Manual transmission (MT) and automatic transmission (AT) diagnosis, repair, overhaul, fluid specifications Drivetrain: All-Wheel Drive (AWD) system, differentials, driveshafts, axles, wheel bearings Suspension: Front and rear suspension components, springs, shock absorbers, control arms, sway bars, alignment specifications Steering: Power steering system, steering gear, tie rods, steering column, alignment Brakes: Front and rear brake systems (disc/drum configurations), ABS system, hydraulic lines, calipers, rotors, pads, parking brake Electrical: Wiring diagrams, fuses, relays, lighting system, power windows, power locks, mirrors, wipers, horn, battery, charging system, starting system Body: Body panels, doors, hood, tailgate, bumpers, glass, interior trim, weatherstripping HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, blower motor, controls Safety Systems: Airbag system, seat belts Procedures Included Maintenance: Oil change, filter replacement, fluid checks and top-offs, spark plug replacement, air filter replacement, belt inspection and replacement, brake fluid flush, coolant flush Repair: Engine overhaul, transmission rebuild, suspension component replacement, brake caliper overhaul, starter motor replacement, alternator replacement, radiator replacement, fuel pump replacement Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting for common issues, DTC (Diagnostic Trouble Code) explanations and correction Specifications: Torque specifications for all fasteners, engine clearances, alignment angles, fluid capacities, tire pressures Technical Depth Depth: Comprehensive; covers basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and body repairs 📊 Manual Specifications File Format Digital Format Details: If PDF, typically high-resolution scans of original factory documents, often searchable text with hyperlinked sections for easy navigation. Print Quality Print Quality Details: For physical copies, expect professional printing on durable paper, clear diagrams, and legible text. Binding Type Binding Type Details: Physical manuals are typically coil-bound or perfect-bound for durability and ease of use on a workbench. Paper Type Paper Type Details: Heavy-duty paper stock designed to withstand grease and workshop environments. ⚙️ Engine Specifications Primary Engine Engine Code Na: EJ253 Engine Type Na: 2.5L SOHC naturally aspirated flat-four (Boxer) Displacement Na: 2457 cc (2.5 Liters) Horsepower Na Approx: 165 hp @ 5,600 rpm Torque Na Approx: 166 lb-ft @ 4,000 rpm Optional Engine Engine Code Turbo: EJ205 Engine Type Turbo: 2.0L DOHC turbocharged flat-four (Boxer) - Forester XT models Displacement Turbo: 1994 cc (2.0 Liters) Horsepower Turbo Approx: 210-220 hp @ 5,600 rpm Torque Turbo Approx: 235-240 lb-ft @ 3,200 rpm Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded gasoline Recommended Octane: 87 AKI (for NA), 91 AKI (for Turbocharged XT models) 🔧 Transmission Standard Transmission Type Na: 4-Speed Automatic Transmission (4EAT) Transmission Type Manual: 5-Speed Manual Transmission (5MT) - Often standard on base models or optional Optional Transmission Type Turbo Auto: 4-Speed Automatic Transmission (4EAT) on XT models Features AWD Integration Auto: Variable torque distribution based on conditions (electronically controlled) AWD Integration Manual: Viscous coupling center differential with limited-slip rear differential 📐 Dimensions Exterior Length Approx: 175.0 inches Width Approx: 69.1 inches Height Approx: 63.0 inches Wheelbase Approx: 103.0 inches Ground Clearance Approx: 7.7 inches Weights Curb Weight Approx: 3100-3300 lbs (depending on trim and transmission) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (for 2002 models) NHTSA Front Impact Passenger: Good (for 2002 models) IIHS Front Offset Crash Rating: Acceptable (for models tested) Active Features ABS: Anti-lock Braking System (standard) Passive Features Airbags: Front driver and passenger airbags Seatbelts: Three-point seatbelts for all seating positions, pretensioners for front seats 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM/CD stereo, often with 4 or 6 speakers. Premium options might include Nakamichi or similar. Driver Assistance Cruise Control: Standard on most trims Traction Control: Not widely available on 2002 models. Some AWD benefits provide inherent traction stability. 🔧 Maintenance Service Intervals Oil Change Interval:...
87 AKI (for NA), 91 AKI (for Turbocharged XT models)
🔧 Transmission
Standard
Transmission Type Na:
4-Speed Automatic Transmission (4EAT)
Transmission Type Manual:
5-Speed Manual Transmission (5MT) - Often standard on base models or optional
Optional
Transmission Type Turbo Auto:
4-Speed Automatic Transmission (4EAT) on XT models
Features
AWD Integration Auto:
Variable torque distribution based on conditions (electronically controlled)
AWD Integration Manual:
Viscous coupling center differential with limited-slip rear differential
📐 Dimensions
Exterior
Length Approx:
175.0 inches
Width Approx:
69.1 inches
Height Approx:
63.0 inches
Wheelbase Approx:
103.0 inches
Ground Clearance Approx:
7.7 inches
Weights
Curb Weight Approx:
3100-3300 lbs (depending on trim and transmission)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for 2002 models)
NHTSA Front Impact Passenger:
Good (for 2002 models)
IIHS Front Offset Crash Rating:
Acceptable (for models tested)
Active Features
ABS:
Anti-lock Braking System (standard)
Passive Features
Airbags:
Front driver and passenger airbags
Seatbelts:
Three-point seatbelts for all seating positions, pretensioners for front seats
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM/CD stereo, often with 4 or 6 speakers. Premium options might include Nakamichi or similar.
Driver Assistance
Cruise Control:
Standard on most trims
Traction Control:
Not widely available on 2002 models. Some AWD benefits provide inherent traction stability.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-7,500 miles or 6-12 months, depending on driving conditions and oil type used (consult manual for exact recommendation).
Timing Belt Replacement:
Crucial for EJ-series engines. Interval typically 60,000-105,000 miles or 5-7 years. Failure results in catastrophic engine damage.
Transmission Fluid Change:
Automatic: Every 30,000-60,000 miles. Manual: Check and replace as needed, often at higher mileage (e.g., 60,000+ miles).
Fluid Specifications
Engine Oil Type Na:
API SG/SH/SJ, ILSAC GF-2/GF-3, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temperature).
Engine Oil Type Turbo:
API SG/SH/SJ, ILSAC GF-2/GF-3, SAE 5W-30 or 10W-30 (synthetic recommended for turbocharged engines).
Coolant Type:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant with Subaru additive. Never use plain water or mixed coolants.
Automatic Transmission Fluid Type:
Subaru ATF-HP (High Performance) or equivalent Dexron-III compatible fluid. Incorrect fluid can damage the transmission.
Manual Transmission Fluid Type:
API GL-5, SAE 75W-90 Gear Oil (Subaru Extra-S or equivalent).
Known Issues
Head Gaskets:
While not as prevalent as on some EJ25 DOHC engines, SOHC EJ253 engines can still experience head gasket leaks, particularly externally.
Rear Main Seal:
Common leak point on many Subarus of this era, often requiring transmission removal to replace.
Cv Axle Boots:
Front and rear CV axle boots are prone to tearing, leading to grease loss and eventual CV joint failure.
Exhaust Flange Gaskets:
Cracked exhaust manifold or downpipe gaskets can cause ticking noises and exhaust leaks.
Mass Airflow Sensor Dirty:
Can lead to rough idle, stalling, and poor performance. Cleaning is often a temporary fix before replacement.
📚 Vehicle History
Brand Heritage
Subaru AWD Legacy:
Subaru has been synonymous with All-Wheel Drive since the introduction of the Subaru Leone 4WD in 1972. The Forester built on this reputation.
Model Evolution
Generation Introduction:
The second generation Forester (SF series) was introduced for the 1998 model year and received a significant refresh for 2001, with the 2002 model year reflecting this updated design.
Production
Manufacturing Plant:
Ota City, Gunma Prefecture, Japan
🏆 Awards & Recognition
Recognitions
Motor Trend SUV Of The Year:
The Subaru Forester was not named MotorTrend SUV of the Year for 2002, but often ranked highly among its peers.
Edmunds Long Term Test:
Subarus generally received positive marks for reliability and capability in long-term tests from publications like Edmunds.
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