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Subaru Forester 2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2002 Codes Chassis Code: SF Generation Generation Name: Second Generation (SG) 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Target...
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Subaru Forester 2002 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Year:
2002
Codes
Chassis Code:
SF
Generation
Generation Name:
Second Generation (SG)
👋 Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV
Target Audience:
Owners seeking to perform their own maintenance, repairs, and modifications, as well as professional automotive technicians
Competitive Analysis
Key Competitors 2002:
Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute
Key Features
Vehicle Distinguishing Features:
Standard All-Wheel Drive (Symmetrical AWD), comfortable ride, practical cargo space, reliable Boxer engines
Manual Value Proposition
Manual Benefit Statement:
Empowers owners with the knowledge and procedures to maintain their Subaru Forester's performance, longevity, and safety, saving time and money on dealership services.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service, repair, maintenance, and restoration
Page Count
Estimated Page Count:
1500+
Manual Type
Manual Format Type:
Full Service & Repair Manual
Language
Language Type:
English
Format
Manual Delivery Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine System Coverage:
Engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions, performance tuning, turbocharger systems
Transmission System Coverage:
Manual and automatic transmission repair, rebuilding, diagnostics, fluid specifications
Drivetrain System Coverage:
All-Wheel Drive (AWD) system, differentials, driveshafts, CV joints, transfer case
Suspension System Coverage:
Front and rear suspension components, struts, shocks, springs, control arms, bushings, alignment procedures
Braking System Coverage:
Disc brakes, ABS system, parking brake, hydraulic system, component replacement, bleeding procedures
Steering System Coverage:
Power steering system, steering rack, tie rods, steering column
Electrical System Coverage:
Wiring diagrams, charging system, starting system, lighting, instruments, body control modules, sensors, ECUs
Body And Chassis Coverage:
Body panels, doors, glass, interior trim, chassis frame, rust prevention and repair
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake pad replacement
Repair Procedures:
Engine overhauls, transmission rebuilds, suspension component replacement, brake system repair, electrical diagnostics and repair, bodywork
Troubleshooting Guides:
Diagnostic charts, symptom-based troubleshooting, error code interpretation
Diagnostic Procedures:
OBD-II diagnostics, sensor testing, component testing, circuit tracing
Rebuilding Procedures:
Detailed steps for rebuilding engines, transmissions, differentials, and other major components
Technical Depth
Diagnostic Capability:
Advanced diagnostics and troubleshooting for all major systems
Repair Complexity:
Suitable for DIY enthusiasts and professional mechanics, covering basic to in-depth repairs
Component Rebuild Detail:
Explicit instructions for complete component disassembly, inspection, repair, and reassembly
📊 Manual Specifications
File Format
Digital File Quality:
High-resolution, searchable PDF with clear text and legible diagrams
Print Quality
Diagram Clarity:
Detailed schematics, wiring diagrams, and exploded views with high clarity
Binding Type
Digital Format Accessibility:
Accessible on any device capable of viewing PDF files (computers, tablets, smartphones)
Paper Type
Digital Content Type:
Fully text-searchable content for quick information retrieval
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
EJ253 (2.5L Naturally Aspirated SOHC Boxer-4) and EJ255 (2.5L Turbocharged DOHC Boxer-4 - optional for XT trims)
Displacement Na:
2457 cc (150 cubic inches)
Displacement Turbo:
2457 cc (150 cubic inches)
Performance
Horsepower Na:
165 hp @ 5600 rpm
Torque Na:
170 lb-ft @ 4000 rpm
Horsepower Turbo:
210 hp @ 5600 rpm (approximate for XT)
Torque Turbo:
235 lb-ft @ 3500 rpm (approximate for XT)
Fuel System
Fuel Delivery System:
Multi-point Fuel Injection (MPI)
Recommended Fuel Octane:
87 Octane (91 Octane recommended for Turbocharged models)
Engine Management
Engine Control Unit:
ECU with OBD-II diagnostic capabilities
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission Type:
4-speed Automatic Transmission (with electronically controlled AWD)
Features
AWD System Type:
Symmetrical All-Wheel Drive (Center Differential with viscous coupling for manual, electronically controlled for automatic)
Fluid Specifications
Manual Transmission Fluid:
API GL-5, SAE 75W-90 gear oil (e.g., Subaru Extra-S or equivalent)
Automatic Transmission Fluid:
Subaru ATF-HP (Highly Recommended) or Dexron III/Mercon equivalent (check specific VIN)
📐 Dimensions
Exterior
Length:
176.0 inches (4470 mm)
Width:
69.9 inches (1775 mm)
Height:
63.0 inches (1600 mm)
Wheelbase:
103.0 inches (2615 mm)
Ground Clearance:
7.5 inches (190 mm)
Interior
Passenger Volume:
Approx. 96.4 cubic feet
Cargo
Cargo Volume Behind Rear Seats:
Approx. 32.0 cubic feet
Cargo Volume With Rear Seats Folded:
Approx. 63.0 cubic feet
Weights
Curb Weight Na Manual:
Approx. 3265 lbs (1481 kg)
Curb Weight Na Auto:
Approx. 3330 lbs (1510 kg)
Curb Weight Turbo Xt Auto:
Approx. 3460 lbs (1569 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
4-Star (Driver & Passenger) for 2002 Model Year
IIHS Front Offset Crash Rating:
Good (for similar models tested in the generation)
Active Features
Active Safety Systems Available:
Anti-lock Braking System (ABS), Traction Control System (TCS - often standard)
Passive Features
Passive Safety Features:
Dual front airbags, front side-impact airbags (optional on some trims), crumple zones, reinforced safety cage
💡 Technology Features
Infotainment
Infotainment System Base:
Base models typically featured a Subaru ETR/AM/FM stereo with CD player. Higher trims might have a premium audio system.
Driver Assistance
Driver Assistance Features Available:
Limited for 2002; primary focus was on ABS and AWD. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.
Connectivity
Connectivity Options:
No integrated Bluetooth or USB ports. Auxiliary input may be present on some aftermarket or upgraded head units.
Chassis Technology
AWD System Description:
Symmetrical All-Wheel Drive provides consistent power distribution to all four wheels for enhanced traction and stability in various conditions.
🔧 Maintenance
Service Intervals
Oil And Filter Change Interval:
Every 3,750 miles or 3.75 months (severe service) / 7,500 miles or 7.5 months (normal service), check owner's manual for specifics.
Engine Coolant Replacement Interval:
Initial: 105,000 miles (7.5 years). Subsequent: every 52,500 miles (3.75 years).
Timing Belt Replacement Interval:
105,000 miles or 105 months (for vehicles equipped with timing belts; many EJ engines use timing chains, verify specific engine model)
Spark Plug Replacement Interval:
105,000 miles (for Iridium type spark plugs)
Fluid Specifications
Engine Oil Specification:
5W-30 API SG or SH (check owner's manual for specific API rating and viscosity)
Engine Coolant Specification:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based antifreeze mixed 50/50 with distilled water
Brake Fluid Specification:
DOT 3
Power Steering Fluid Specification:
Subaru Genuine Power Steering Fluid or Dexron III/Mercon compatible fluid
Known Issues
Common Forester 2002 Issues:
Head gasket leaks (especially on early EJ25 engines), catalytic converter failure, front strut bearing wear, rear differential pinion seal leaks, A/C system failures, exhaust manifold cracks.
Manual Coverage Of Known Issues:
Provides diagnostic procedures and repair instructions for common issues like head gasket replacement, clutch system diagnostics, and suspension wear.
📚 Vehicle History
Brand Heritage
Subaru Brand Focus:
Known for its horizontally-opposed Boxer engines and Symmetrical All-Wheel Drive systems, emphasizing capability and durability.
Model Evolution
Forester Development Goal:
To combine the utility of a station wagon with the ride height and traction of an SUV, creating a versatile CUV.
Second Generation Launch:
Introduced for the 2003 model year, but the 2002 model is the final year of the first generation (SF). The manual likely covers the end of the SF and potentially early SG transition details.
Production
Manufacturing Location:
Japan (Gunma Prefecture)
🏆 Awards & Recognition
Recognitions
Vehicle Awards General:
While specific awards for the 2002 model year are scarce, Subaru Foresters consistently received praise for their practicality, safety, and all-weather capability from automotive journalists and consumer reports during this era.
Ratings
Consumer Reports Reliability:
Variable; some model years and specific components (e.g., head gaskets) were noted for potential issues, while overall reliability was generally considered decent to good.
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