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SUBARU FORESTER Service Repair Manual 1998-2002

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🏷️ Basic Information Identification Make: Subaru Model: Forester Generation: SF Series (First Generation) Codes Chassis Code: SF5, SF9 👋 Introduction Market Position Segment: Compact Crossover SUV Usp: Standard Symmetrical All-Wheel...
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SUBARU FORESTER Service Repair Manual 1998-2002
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Generation:
SF Series (First Generation)
Codes
Chassis Code:
SF5, SF9
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Usp:
Standard Symmetrical All-Wheel Drive (AWD), practicality, safety, and Subaru's renowned boxer engine reliability.
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Mazda Tribute, Nissan Xterra, Ford Escape.
Key Features
Vehicle Attributes:
High ground clearance, comfortable ride, spacious interior for its class, good visibility, durable build quality.
Manual Value
Benefit To Owner:
Empowers owners and independent mechanics with factory-level knowledge to perform maintenance, diagnose issues, and complete repairs, saving time and money.
📋 Manual Details
Coverage Areas
Years Covered:
1998, 1999, 2000, 2001, 2002
Page Count
Estimated Pages:
2000+
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, engine management (ECU), cooling system, lubrication system, engine overhaul, emissions control.
Transmission:
Manual transmission (M/T) and Automatic transmission (A/T) repair, overhaul, removal/installation, clutch system, torque converter, transmission control module (TCM).
Drivetrain:
All-Wheel Drive (AWD) system, front and rear differentials, driveshafts, CV joints, transfer case, viscous coupling unit (VCU).
Suspension Steering:
Front and rear suspension components (struts, springs, control arms, bushings), steering system (rack and pinion, power steering pump, steering column), wheel alignment specifications.
Brakes:
Front and rear brake systems (disc brakes, drum brakes), ABS (Anti-lock Braking System) diagnostics and repair, brake fluid specifications, parking brake system.
Electrical:
Complete wiring diagrams, fuse box layouts, starter, alternator, battery, lighting system, power windows, power locks, wipers, horn, instrument cluster, audio system, climate control electronics, ECU pinouts.
Body Chassis:
Body panels, doors, hood, tailgate, bumpers, interior trim, glass, seals, chassis lubrication points, frame specifications.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair, refrigerant types, AC compressor, condenser, evaporator, blower motor, controls.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tire rotation, brake pad replacement, tune-ups.
Diagnostics:
Troubleshooting guides for common problems, diagnostic trouble codes (DTCs), component testing procedures, electrical circuit analysis.
Repair Rebuild:
Engine rebuilding, transmission overhaul, suspension component replacement, brake caliper service, exhaust system repair, body panel repair.
Installation Replacement:
Removal and installation procedures for all major components (engine, transmission, suspension parts, body panels, interior components, electrical modules).
Technical Depth
Depth:
Comprehensive: Covers everything from basic preventative maintenance and fluid checks to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable PDF for quick information retrieval.
Print Quality
Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
EJ251/EJ252 (2.5L SOHC Boxer-4) and EJ205 (2.0L DOHC Turbocharged Boxer-4 for GT/STi variants).
Performance
Horsepower Ej25:
165 hp @ 5,600 rpm (Naturally Aspirated)
Torque Ej25:
175 lb-ft @ 4,000 rpm (Naturally Aspirated)
Horsepower Ej205:
217 hp @ 5,600 rpm (Turbocharged - for specific JDM/EDM models)
Torque Ej205:
251 lb-ft @ 3,200 rpm (Turbocharged - for specific JDM/EDM models)
Fuel System
System Type:
Multi-point Fuel Injection (MPI)
Fuel Type
Fuel Recommendation:
Unleaded gasoline, 87 octane minimum (91 octane recommended for turbocharged models).
Engine Management
ECU Type:
Subaru Engine Control Unit (ECU) with OBD-II diagnostics.
🔧 Transmission
Standard
Transmission Type Na:
5-speed Manual Transmission (M/T)
Optional
Transmission Type Auto:
4-speed Automatic Transmission (A/T) with Sportshift
Features
AWD System:
Symmetrical All-Wheel Drive (AWD) with viscous coupling limited-slip center differential for M/T, or electronically controlled multi-plate transfer clutch for A/T.
📐 Dimensions
Exterior
Length:
Approx. 4,510 mm (177.6 in)
Width:
Approx. 1,770 mm (69.7 in)
Height:
Approx. 1,590 mm (62.6 in)
Wheelbase:
Approx. 2,635 mm (103.7 in)
Ground Clearance:
Approx. 7.7 inches (196 mm)
Cargo
Cargo Volume:
Approx. 31.0 cu ft (rear seats up)
Weights
Curb Weight Est:
3,100 - 3,400 lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4-star driver, 4-star passenger (for models equipped with airbags)
IIHS Side Impact:
Good (for models with side airbags, availability varied by year/trim)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most trims.
AWD:
Standard Symmetrical All-Wheel Drive for enhanced traction and stability.
Passive Features
Airbags:
Driver and front passenger airbags standard; optional side airbags available on later models/trims.
Seatbelts:
3-point front and rear seatbelts, pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium sound system. Basic analog controls for climate and audio.
Driver Assistance
Features:
ABS, AWD. No advanced electronic driver-assistance systems (ADAS) were standard or commonly available.
Connectivity
Ports:
No USB or Bluetooth connectivity; aftermarket solutions would be required.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe conditions), 7,500 miles or 12 months (normal conditions), refer to manual for specifics.
Coolant Change Interval:
Initial 100,000 miles, then every 50,000 miles.
Transmission Fluid Change Interval At:
Every 30,000 miles (severe use) or 60,000 miles (normal use) for automatic; 60,000 miles for manual. Consult manual for exact schedule.
Fluid Specifications
Engine Oil Spec:
API SG or higher, SAE 5W-30 (viscosity may vary based on climate; consult owner's manual).
Coolant Spec:
Subaru Super Coolant (blue) or equivalent silicate-free, ethylene glycol-based coolant.
Brake Fluid Spec:
DOT 3 or DOT 4 Brake Fluid.
Atf Spec:
Subaru ATF (Dexron III compatible) or equivalent.
Mtf Spec:
API GL-4 SAE 75W-90 Gear Oil.
Known Issues
Head Gaskets:
While less common than in later generations, early EJ25 engines could be prone to head gasket failure due to coolant leaks. The manual details inspection and replacement procedures.
Viscous Coupling Unit:
The VCU in the AWD system can wear out, particularly if mismatched tire sizes are used. Manual covers VCU inspection and potential replacement.
O2 Sensors:
Oxygen sensors can fail, leading to check engine lights and poor fuel economy. Manual provides diagnostic and replacement steps.
Catalytic Converter:
Can become clogged or fail over time, impacting performance. Manual offers diagnostic advice.
📚 Vehicle History
Brand Heritage
Subaru Identity:
Subaru, part of Fuji Heavy Industries, known for its horizontally opposed (boxer) engines and All-Wheel Drive systems since the 1970s.
Model Evolution
Forester Debut:
The Forester debuted in Japan in 1997 and internationally in 1998 as Subaru's first crossover SUV, blending car-like handling with SUV utility.
Production
Manufacturing Location:
Gunma, Japan
Production Years
Generation Span:
1997-2002 (SF Series)
🏆 Awards & Recognition
Recognitions
Consumer Guide:
Named a 'Best Buy' by Consumer Guide in 2000 and 2001, praised for its AWD system and utility.
IIHS Ratings:
Achieved good ratings in IIHS frontal and side crash tests, highlighting its safety engineering.
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