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2001-2002 SUBARU FORESTER Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2001-2002 Codes Chassis Code: SF5/SG5 (for applicable variants) 👋 Introduction Market Position Segment: Compact Crossover SUV Usp: Standard Symmetrical All-Wheel Drive,...
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2001-2002 SUBARU FORESTER Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Year:
2001-2002
Codes
Chassis Code:
SF5/SG5 (for applicable variants)
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Usp:
Standard Symmetrical All-Wheel Drive, Boxer Engine, Practicality, Off-Road Capability (relative to segment)
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra (older generations)
Key Features
Engine Layout:
Horizontally Opposed (Boxer)
Drivetrain Type:
Full-Time All-Wheel Drive
Body Style:
5-Door SUV/Crossover
Purpose Of Manual
Target Audience:
Subaru Service Personnel, Dealership Technicians, Independent Repair Shops, and knowledgeable DIY Enthusiasts.
📋 Manual Details
Coverage Areas
Region:
Global (Primarily North American market focus implied by description, but service data is generally universal)
Page Count
Estimated Page Count:
500-800+ (typical for a comprehensive factory service manual of this era)
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (Likely PDF, based on common sales practices for older manuals)
📖 Manual Coverage
Systems Covered
Engine:
2.5L Naturally Aspirated (EJ253), 2.5L Turbocharged (EJ255/EJ257 - depending on specific market trims)
Transmission:
4-Speed Automatic (4EAT), 5-Speed Manual (TY754VB)
Drivetrain:
Symmetrical All-Wheel Drive (AWD) System, Front & Rear Differentials, Transfer Case
Suspension:
Front MacPherson Strut, Rear Multi-link Independent Suspension
Brakes:
Front Ventilated Discs, Rear Solid Discs (ABS equipped variants)
Steering:
Power Assisted Rack and Pinion
Electrical:
Full Electrical Schematics, Lighting, Ignition, Starting, Charging System, ECU Pinouts, Body Control Modules
HVAC:
Heating, Ventilation, Air Conditioning System Diagnosis and Repair
Body:
Body Panel Repair, Door Mechanisms, Glass Replacement, Interior Trim, Exterior Trim
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Spark Plug Service, Coolant Flush, Brake Fluid Flush, Differential Fluid Change, Transmission Fluid Change, Air Filter Replacement
Diagnostics:
Troubleshooting Guides based on symptoms, DTC Code Interpretation, On-Board Diagnostics (OBD-II) Procedures
Repair:
Engine Component Overhaul (pistons, rods, crank, heads), Transmission Rebuilds, Suspension Component Replacement (struts, control arms, bushings), Brake System Repair (calipers, rotors, lines), Power Steering System Repair, Cooling System Repair, Fuel System Repair, Electrical Component Replacement (alternator, starter, sensors), Body Panel Repair and Replacement
Disassembly Assembly:
Detailed step-by-step instructions for removal and installation of all major components and sub-assemblies.
Specifications Data:
Torque Specifications for all fasteners, Fluid Capacities and Types, Electrical System Data, Emission Control Information
Technical Depth
Depth:
Comprehensive. Covers routine maintenance, detailed diagnostics, component-level repair, and complete system overhauls. Suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Readability:
High Resolution, Clear Diagrams and Text for easy reading and printing.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format - Printable on standard paper)
Searchability
Text Search:
Searchable text content for quick access to specific information.
Illustrations
Diagrams Photos:
Includes detailed diagrams, exploded views, and photographic illustrations to aid in understanding procedures.
⚙️ Engine Specifications
Primary Engine
Engine Code Na:
EJ253
Engine Code Turbo:
EJ255 (GT) / EJ257 (STI-derived, less common in Forester of this era)
Displacement Na:
2.5 Liters (2498 cc)
Bore Na:
99.5 mm
Stroke Na:
79.0 mm
Performance
Horsepower Na:
Approx. 165-170 hp @ 5600-6000 rpm (market dependent)
Torque Na:
Approx. 162-166 lb-ft @ 3600-4000 rpm (market dependent)
Horsepower Turbo:
Approx. 210-230 hp (for XT/GT models)
Torque Turbo:
Approx. 235-250 lb-ft (for XT/GT models)
Fuel System
Injection Type:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (Premium required for Turbocharged models)
Engine Design
Configuration:
Horizontally Opposed 4-Cylinder Boxer
Valvetrain:
Dual Overhead Camshafts (DOHC), 4 Valves per Cylinder
Compression Ratio Na:
9.7:1 (Typical)
Compression Ratio Turbo:
8.2:1 - 8.5:1 (Typical for XT/GT)
🔧 Transmission
Standard
Transmission Type Std:
5-Speed Manual Transmission (TY754VB)
Optional
Transmission Type Opt:
4-Speed Electronically Controlled Automatic Transmission (4EAT)
Features
AWD Coupling Manual:
Viscous Center Differential (typically)
AWD Coupling Auto:
Variable Torque Distribution AWD (VTD) or electronically controlled coupling depending on exact year/model. Often features a planetary gear center differential.
Fluid Specifications
Manual Transmission Fluid:
API GL-5, SAE 75W-90 (Check manual for specific Subaru specification)
Automatic Transmission Fluid:
Subaru ATF-HP (or equivalent specified by Subaru)
📐 Dimensions
Exterior
Length:
Approx. 175.5 - 177.0 inches (4455 - 4495 mm)
Width:
Approx. 69.9 inches (1775 mm)
Height:
Approx. 63.0 - 63.5 inches (1600 - 1615 mm)
Wheelbase:
Approx. 103.1 inches (2620 mm)
Ground Clearance:
Approx. 7.5 - 8.0 inches (190 - 203 mm)
Weights
Curb Weight:
Approx. 3100 - 3500 lbs (1406 - 1588 kg), varies by trim and transmission
Towing Capacity:
Typically rated around 2000 lbs (907 kg) with proper towing package.
Cargo
Cargo Volume Behind Rear Seats:
Approx. 30-32 cubic feet
Cargo Volume With Rear Seats Folded:
Approx. 65-68 cubic feet
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
Typically received 4-star ratings for driver and passenger in frontal impact.
IIHS Crash Test:
Generally rated 'Good' in frontal offset tests, but side impact ratings varied.
Active Features
ABS:
Standard on most models, especially XT/GT trims. 4-wheel Anti-lock Braking System.
Traction Control:
Available on some higher trims or as an option.
Passive Features
Airbags:
Frontal airbags standard, optional side airbags on some models.
Seatbelts:
3-point height-adjustable front seat belts with pretensioners, rear 3-point seat belts.
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium audio systems may be present on higher trims.
Navigation:
Rarely offered, not a common feature for this model year.
Driver Assistance
Cruise Control:
Standard on most trims.
Stability Control:
Vehicle Stability Control (VSC) and Traction Control System (TCS) were becoming available/optional on higher trims, but not ubiquitous.
Connectivity
Aux Input:
Not typically factory standard; aftermarket solutions are common.
Bluetooth:
Not factory standard for this model year.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3.75 months for severe driving, 7,500 miles (12,000 km) or 7.5 months for normal driving (refer to manual for specific details).
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed. Typically around 30,000 miles (48,000 km).
Spark Plug Replacement:
Typically 60,000-100,000 miles (96,000-160,000 km) for iridium or platinum plugs (check manual for type).
Coolant Flush Interval:
Initial 7,500 miles (12,000 km) or 7.5 months, then every 30,000 miles (48,000 km) or 30 months thereafter (refer to manual for specific coolant type).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic (check manual for specific viscosity and API classification, e.g., API SM/SN or ILSAC GF-4/GF-5)
Engine Oil Capacity:
Approx. 4.5 US quarts (4.3 Liters) with filter change (EJ25 engine)
Coolant Type:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based antifreeze, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 (refer to manual for specific recommendation)
Power Steering Fluid:
Subaru Genuine Power Steering Fluid (or Dexron III/Mercon equivalent, check manual)
Known Issues
Head Gaskets:
While less prevalent than in earlier EJ25 engines, Subaru head gasket leaks were a known concern for some EJ25 engines of this era. The manual will detail diagnostic procedures and replacement steps.
Crankshaft Position Sensor:
Can fail, leading to no-start or stalling conditions. Manual will cover location and replacement.
Oxygen Sensors:
Can degrade over time, affecting fuel economy and emissions. Manual covers testing and replacement.
Automatic Transmission Issues:
Some reports of wear in automatic transmissions, especially with aggressive use or lack of maintenance. The manual's diagnostic section is crucial here.
Cv Axle Boots:
Rubber boots can tear, leading to grease loss and potential CV joint damage. Manual details replacement.
📚 Vehicle History
Brand Heritage
Brand Origin:
Japan
Brand Focus:
Known for horizontally opposed engines and all-wheel-drive systems.
Model Evolution
Generation 1 Start Year:
1997
Generation 1 End Year:
2002
Generation 2 Start Year:
2003
Production
Manufacturing Location:
Gunma Plant, Japan
Sales Performance Era:
Gained popularity as a practical and capable compact SUV, carving a niche for AWD capability.
🏆 Awards & Recognition
Recognitions
Car And Driver Component:
Often featured on Car and Driver's '10Best Trucks' list in its early years.
Consumer Reports Rating:
Generally received average to good reliability ratings, with some noted issues as per maintenance section.
Certifications
Epa Fuel Economy:
EPA estimated MPG ranges from approximately 19-21 MPG city and 24-27 MPG highway, depending on engine and transmission configuration.
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