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Subaru Forester 1999-2000 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Model Generation: First Generation (SF Series) Years Covered: 1999, 2000 Codes Chassis Code: SF5, SF9 👋 Introduction Market Position Segment: Compact SUV...
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Subaru Forester 1999-2000 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Model Generation:
First Generation (SF Series)
Years Covered:
1999, 2000
Codes
Chassis Code:
SF5, SF9
👋 Introduction
Market Position
Segment:
Compact SUV / Crossover
Target Audience:
Outdoor enthusiasts, families, individuals seeking a capable all-wheel-drive vehicle.
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra
Key Features
Drivetrain:
Standard Symmetrical All-Wheel Drive (AWD) across most trims, a defining feature for Subaru.
Engine Layout:
Horizontally-opposed (Boxer) engine, contributing to a lower center of gravity and improved handling.
Practicality:
Spacious interior for its class, good cargo capacity, raised ground clearance for light off-road capability.
📋 Manual Details
Coverage Areas
Systems:
Engine, Transmission (Automatic & Manual), Drivetrain, Suspension, Steering, Brakes, Fuel System, Cooling System, Exhaust System, Electrical System, HVAC, Body, Interior, Emissions Control
Page Count
Estimated Pages:
1500-2000 (typical for a full factory service manual)
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair of all engine components including cylinder heads, blocks, pistons, connecting rods, crankshafts, camshafts, valve train. Includes timing belt replacement procedures and specifications.
Engine Management And Emissions:
ECU diagnosis, sensor testing (MAP, TPS, O2, Crank/Cam position), actuator control, fuel injection system, ignition system, emission control systems (catalytic converter, EGR, PCV), EVAP system.
Transmission And Drivetrain:
Complete service and repair for both 4-speed automatic (4EAT) and 5-speed manual transmissions. Includes differential service, axle shaft inspection and replacement, viscous coupling unit (VCU) and center differential (where applicable) service for AWD models.
Suspension And Steering:
Front and rear suspension component diagnosis, repair, and replacement (struts, shocks, control arms, bushings, ball joints). Steering system diagnosis and repair (rack and pinion, power steering pump, hoses). Wheel alignment specifications.
Brakes:
Front and rear brake system service including disc brake pad and rotor replacement, caliper service, hydraulic system bleeding, parking brake adjustment, ABS system diagnosis and component testing.
Electrical System:
Detailed wiring diagrams, fuse box layouts, component testing procedures, starting and charging system service, lighting systems, instrument cluster, power accessories (windows, locks, mirrors), alarm system.
Body And Interior:
Body panel repair, door and tailgate mechanisms, glass replacement, interior trim removal and installation, seat adjustment, HVAC system service (blower motor, evaporator, heater core, refrigerant handling).
Procedures Included
Preventative Maintenance:
Scheduled maintenance tasks, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements, spark plug replacement, tire rotation, brake inspection, timing belt service.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon drivability issues, electrical faults, and mechanical problems. Includes symptom-based troubleshooting charts and diagnostic trouble codes (DTCs).
Repair And Rebuild:
Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, reassembly, and installation. Covers major component overhauls and replacements.
Diagnostics:
Detailed guidance on using diagnostic tools, reading scan data, testing sensors and actuators, and interpreting trouble codes for all major vehicle systems.
Specifications And Tolerances:
Provides torque specifications for all fasteners, critical clearances, fluid capacities, wear limits, and other essential technical data for accurate repairs and adjustments.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and body repair.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable (allows quick lookup of keywords and topics)
Print Quality
Quality:
High-resolution scans of original factory documentation, ensuring clear text and legible illustrations.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
EJ253
Engine Type 1:
2.5L SOHC 16-valve Flat-4 (Boxer)
Horsepower 1:
165 hp @ 5,600 rpm
Torque 1:
166 lb-ft @ 4,000 rpm
Engine Variants
Engine Code 2:
EJ20 (Japan Market)
Engine Type 2:
2.0L DOHC Turbocharged Flat-4 (Boxer) - GT models
Horsepower 2:
217 hp (approx.)
Performance
Acceleration 0 60:
Approximately 9.5 - 10.5 seconds (varies by transmission and configuration)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
Unleaded Gasoline, 87 Octane (91 Octane recommended for Turbocharged models)
Cooling System
Coolant Type:
Subaru Super Coolant (Blue) or equivalent Subaru Long Life Coolant (Blue) - typically 50/50 mix with distilled water.
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (4EAT) with AWD
Optional
Transmission Type:
5-Speed Manual with AWD
Features
Automatic Modes:
Includes Snow/Hold mode for improved traction in slippery conditions.
Fluid Specifications
Automatic Fluid Type:
Subaru ATF HP or equivalent DEXRON III/MERCON
Manual Fluid Type:
Subaru Manual Transmission Lubricant API GL-5 75W-90
📐 Dimensions
Exterior
Length:
177.0 inches (4496 mm)
Width:
67.9 inches (1725 mm)
Height:
63.0 inches (1600 mm)
Wheelbase:
103.0 inches (2616 mm)
Ground Clearance:
7.7 inches (196 mm)
Interior
Passenger Volume:
Approx. 95.0 cu ft
Cargo
Cargo Volume Behind Rear Seat:
Approx. 30.0 cu ft
Cargo Volume With Rear Seat Folded:
Approx. 65.0 cu ft
Weights
Curb Weight:
Approx. 3100 - 3300 lbs (1406 - 1500 kg) depending on trim and transmission
Towing Capacity:
2000 lbs (907 kg) (when properly equipped)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash:
4-star driver, 4-star passenger (for the 1999 model year)
IIHS Frontal Offset:
Good (for models equipped with airbags)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most models.
AWD:
Symmetrical All-Wheel Drive enhances traction and stability.
Passive Features
Airbags:
Driver and front passenger airbags standard.
Seatbelts:
3-point front and rear seatbelts, pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM stereo with CD player or cassette tape. Optional premium sound systems were available.
Climate Control:
Manual or optional automatic climate control systems. Manual details HVAC component diagnostics and refrigerant handling.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Auxiliary Input:
Not standard; aftermarket solutions were common.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles or 3.75 months (whichever comes first) under normal driving conditions; 3,000 miles or 3.75 months under severe driving conditions.
Timing Belt:
Replace every 90,000 miles or 7 years (crucial for EJ engines to prevent catastrophic failure).
Coolant Flush:
Every 30,000 miles or 3 years.
Transmission Fluid Change:
Automatic: Every 30,000 miles or 3 years. Manual: Check for leaks, typically serviced if symptoms arise or during clutch replacement.
Fluid Specifications
Engine Oil:
SAE 5W-30 API SG or SH rated oil. Capacity: 4.5 US quarts (4.3 L) with filter.
Power Steering Fluid:
Subaru Genuine Power Steering Fluid or DEXRON II/III
Brake Fluid:
DOT 3
Known Issues
Head Gaskets:
While less prevalent than on later EJ25 SOHC engines in other models, internal coolant leaks from head gaskets can occur. The manual provides procedures for inspection and replacement.
Oil Leaks:
Valve cover gaskets and oil pan gaskets are common sources of minor oil leaks on older Subarus. Manual details replacement procedures.
Evaporative Emissions System:
Issues with the EVAP system (e.g., charcoal canister, vent valve) can lead to 'check engine' lights. The manual covers diagnosis and repair.
Cvt Issues:
Not applicable to this model year; 1999-2000 Foresters exclusively used traditional automatic or manual transmissions.
📚 Vehicle History
Brand Heritage
Subaru Identity:
Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history of manufacturing aircraft and later diversified into automobiles known for their Boxer engines and All-Wheel Drive systems.
Model Evolution
Forester Introduction:
The Subaru Forester was introduced globally in 1997 as a 'sport utility wagon' or crossover, bridging the gap between a traditional station wagon and an SUV. The 1999-2000 models represent the initial iteration of this successful formula.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Consumer Guide Review:
Often received positive reviews from publications like Consumer Guide for its AWD system and practicality, though sometimes criticized for engine noise and refinement.
Ratings
Kbb Value:
As a used vehicle, its value is determined by condition, mileage, and market demand, but its reputation for durability contributes positively.
Certifications
Factory Documentation:
This manual is derived from original Subaru factory service documentation, ensuring accuracy and completeness for technicians and owners.
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