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1999 Subaru Forester Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 1999 Chassis Code: SF Series Codes Engine Code Primary: EJ25D (2.5L SOHC Naturally Aspirated) 👋 Introduction Market Position Vehicle Segment: Compact...
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1999 Subaru Forester Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Year:
1999
Chassis Code:
SF Series
Codes
Engine Code Primary:
EJ25D (2.5L SOHC Naturally Aspirated)
👋 Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV
Key Selling Points:
Symmetrical All-Wheel Drive (standard on most trims), practicality, go-anywhere capability, Subaru's reputation for durability and safety.
Competitive Analysis
Primary Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra.
Key Features
All Wheel Drive:
Standard Symmetrical All-Wheel Drive system, enhancing traction and stability in various driving conditions.
Ground Clearance:
Higher ground clearance compared to typical sedans, aiding in light off-road use and adverse weather.
Boxer Engine:
Subaru's signature horizontally opposed Boxer engine, providing a lower center of gravity for improved handling.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine Mechanical, Engine Performance, Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Clutch, Manual Transmission, Automatic Transmission, Transfer Case, Driveshafts, Axles, Suspension (Front & Rear), Steering System, Brakes (Front & Rear), ABS, Power Steering, Body & Chassis, Interior Trim, Exterior Trim, HVAC System, Electrical System, Wiring Diagrams, SRS (Airbag) System, Diagnostic Trouble Codes (DTCs), Maintenance Schedules, Troubleshooting Guides.
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed procedures for engine overhaul, cylinder head removal/installation, piston and connecting rod service, crankshaft and bearing inspection, timing belt replacement, valve train adjustment.
Engine Performance:
Diagnosis and repair of engine performance issues, fuel injection system operation, emissions control systems, sensor testing and replacement.
Transmission:
Covers both manual (e.g., 5MT) and automatic (e.g., 4EAT) transmissions, including removal, disassembly, inspection, repair, and installation. Includes fluid types and capacities.
Suspension Steering:
Front and rear suspension component inspection and replacement (struts, control arms, bushings), steering system diagnosis, power steering pump and rack repair.
Brakes ABS:
Brake system service including pad and rotor replacement, caliper overhaul, brake fluid bleeding, ABS system component testing and troubleshooting.
Electrical Wiring:
Comprehensive wiring diagrams for all vehicle systems, component locations, connector pinouts, diagnostic procedures for electrical faults, starter, alternator, battery service.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, differential fluid changes.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon problems, symptom-based troubleshooting trees.
Rebuild Procedures:
Detailed instructions for rebuilding major components such as engines, transmissions, and differentials.
Specification Data:
Torque specifications, clearances, fluid capacities, electrical specifications, and other critical data for proper repair.
Technical Depth
Depth:
Factory-level detail, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission overhauls, including diagnostics and wiring.
📊 Manual Specifications
File Format
File Type:
Likely PDF, optimized for digital viewing and printing.
Searchability:
Typically text-searchable, allowing for quick navigation to specific topics.
Print Quality
Image Resolution:
High-resolution illustrations, diagrams, and photographs.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Quality:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated, Horizontally Opposed (Boxer) 4-Cylinder
Engine Displacement:
2.5 Liters (2498 cc)
Engine Code:
EJ25D
Valvetrain:
16 Valves, Single Overhead Camshaft (SOHC) per bank
Bore X Stroke:
99.5 mm x 80.0 mm
Compression Ratio:
9.0:1
Performance
Horsepower Peak:
165 hp @ 5,500 rpm
Torque Peak:
166 lb-ft @ 4,000 rpm
Fuel System
Fuel Delivery:
Electronic Port Fuel Injection (MPI)
Fuel Type:
Unleaded Regular, 87 Octane
Ignition System:
Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Coil-Near-Plug configurations.
Lubrication
Oil Capacity With Filter:
4.5 US Quarts (4.3 Liters)
Oil Type:
API SJ or SL classification, SAE 5W-30 recommended
Cooling
Coolant Capacity:
7.5 US Quarts (7.1 Liters)
Coolant Type:
Ethylene Glycol based, Subaru genuine coolant or equivalent (blue color)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission (5MT)
Optional
Transmission Type Optional:
4-Speed Automatic Transmission with Electronic Control (4EAT)
Features
All Wheel Drive Integration:
Both transmissions are paired with Subaru's Symmetrical All-Wheel Drive system.
Automatic Transmission Modes:
May include 'Power' and 'Economy' modes on 4EAT models.
Fluid Specs
Manual Transmission Fluid:
API GL-5, SAE 75W-90 synthetic gear oil recommended.
Automatic Transmission Fluid:
Subaru Genuine ATF HP or equivalent.
Fluid Capacity
Manual Transmission Fluid Capacity:
Approx. 2.3 US Quarts (2.2 Liters)
Automatic Transmission Fluid Capacity:
Approx. 3.5 US Quarts (3.3 Liters) for pan drop and fill.
📐 Dimensions
Exterior
Length:
Approx. 177.0 inches (4496 mm)
Width:
Approx. 67.9 inches (1725 mm)
Height:
Approx. 63.2 inches (1605 mm)
Wheelbase:
Approx. 103.0 inches (2616 mm)
Ground Clearance:
Approx. 7.5 inches (190 mm)
Weights
Curb Weight Min:
Approx. 3130 lbs (1420 kg)
Curb Weight Max:
Approx. 3260 lbs (1480 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 4500 lbs (2041 kg)
Cargo
Cargo Volume Behind Rear Seat:
Approx. 30.0 cu ft (850 Liters)
Cargo Volume With Rear Seat Folded:
Approx. 68.0 cu ft (1925 Liters)
Wheels Tires
Standard Wheel Size:
15x6.0 inches
Optional Wheel Size:
16x6.5 inches (on higher trims)
Standard Tire Size:
P205/70R15
Optional Tire Size:
P215/60R16
Bolt Pattern:
5 x 100 mm
Center Bore:
56.1 mm
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test Driver:
4-star (with potential for 5-star depending on specific configuration and testing nuances for the era).
NHTSA Frontal Crash Test Passenger:
4-star (with potential for 5-star).
NHTSA Side Impact Crash Test Front Driver:
4-star
NHTSA Side Impact Crash Test Front Passenger:
4-star
IIHS Frontal Offset:
Good (for its class and time)
Active Features
All Wheel Drive:
Standard Symmetrical AWD enhances stability and traction.
Anti Lock Brakes ABS:
Standard on most trims, providing steering control during hard braking.
Passive Features
Airbags Front:
Driver and front passenger airbags.
Seatbelts:
Three-point seatbelts for all seating positions, front pretensioners.
Child Seat Anchors:
LATCH system (Lower Anchors and Tethers for CHildren) may be present on some models/trims.
💡 Technology Features
Infotainment
Audio System:
Base models typically featured a 4-speaker AM/FM/CD or Cassette player. Higher trims might have offered a 6-speaker system with a separate amplifier.
Climate Control:
Manual climate control with rotary knobs for fan speed, temperature, and air direction. Some higher trims may have offered automatic climate control.
Driver Assistance
Cruise Control:
Standard on most trims, offering convenience on longer journeys.
Connectivity
Power Windows Locks:
Available on most trims, power windows and door locks were common features.
Remote Keyless Entry:
Optional on some higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3-4 months, whichever comes first (under normal driving conditions). Severe driving conditions may require more frequent changes (e.g., every 3,000 miles).
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Engine Oil Filter:
Replace with every oil change.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for platinum-tipped spark plugs. Check manual for specific type.
Timing Belt Replacement:
Crucial: Every 105,000 miles (168,000 km) or 7 years, whichever comes first. Failure can cause catastrophic engine damage.
Coolant Replacement:
First replacement at 30,000 miles (48,000 km) or 2 years, then every 15,000 miles (24,000 km) or 1 year thereafter.
Brake Fluid Replacement:
Every 30,000 miles (48,000 km) or 2 years.
Fluid Specifications
Engine Oil Type Spec:
API SJ or SL, SAE 5W-30
Transmission Fluid Type Spec Manual:
API GL-5, SAE 75W-90 synthetic gear oil
Transmission Fluid Type Spec Automatic:
Subaru Genuine ATF HP or equivalent
Power Steering Fluid:
ATF Dexron III (check manual for specific recommendation, use high-quality fluid).
Brake Fluid Type:
DOT 3
Known Issues
Head Gaskets:
While the EJ25D engine in this generation is not as prone to catastrophic head gasket failure as some later EJ variants, it's still a common area of concern. Look for coolant leaks externally or internal coolant contamination (milky oil, white exhaust smoke).
Timing Belt:
As mentioned, the timing belt is a critical maintenance item. A broken belt can cause piston-to-valve contact, leading to expensive engine damage. Regular replacement is paramount.
Automatic Transmission Problems:
Some 4EAT transmissions can experience wear in the valve body or torque converter, leading to delayed shifts or slipping. Regular fluid changes are crucial for longevity.
Cv Axle Boots:
Front CV axle boots are susceptible to tearing, especially with age and exposure to road debris. Damaged boots can lead to CV joint failure.
Rear Main Seal Leaks:
Rear main engine seals can develop leaks over time, requiring transmission removal for replacement.
📚 Vehicle History
Brand Heritage
Subaru Identity:
Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), is renowned for its pioneering use of All-Wheel Drive in passenger vehicles and its signature Boxer engine layout.
Model Evolution
First Generation Forester:
The first generation Subaru Forester (SF series) debuted in 1997, essentially a raised version of the Subaru Impreza platform, designed to offer the versatility of an SUV with the driving dynamics of a car. The 1999 model year represents the mid-cycle of this initial generation.
Generation Designation:
First Generation (SF Series): 1997-2002
Production
Manufacturing Location:
Ota, Gunma, Japan
Production Years:
1997-2002
🏆 Awards & Recognition
Recognitions
Icam Award:
The 1998-2002 Subaru Forester was recognized by magazines like Motor Trend as a Top Sport/Utility Vehicle.
Value Perception:
Consistently praised for its value proposition, combining AWD capability with SUV practicality at a competitive price point.
Certifications
Safety Certifications:
Earned good safety ratings from organizations like the IIHS and NHTSA for its time, highlighting its robust construction and standard safety features.
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