Subaru Forester 2002 Digital Factory Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2002 Generation: Second Generation (SG) Codes Chassis Code: SG5, SG9 👋 Introduction Market Position Segment: Compact Crossover SUV Key Selling Points:...

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Sku: 358561

Tags: 2002 Car Cars Forester Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Year:

Generation:

Second Generation (SG)

Codes

Chassis Code:

SG5, SG9

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Key Selling Points:

Symmetrical All-Wheel Drive, practicality, affordability, Subaru's reputation for durability

Competitive Analysis

Direct Competitors:

Honda CR-V, Toyota RAV4, Nissan Xterra, Ford Escape

Key Features

Standard AWD:

Subaru's signature Symmetrical All-Wheel Drive system is standard on all models

Ground Clearance:

Higher-than-average ground clearance for its class, enhancing off-road capability

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete workshop service and repair

Page Count

Estimated Page Count:

Over 2000 pages (typical for factory service manuals of this era)

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, timing belt, pistons, rings, connecting rods, crankshaft, camshafts, cylinder heads, valve train

Engine Management:

Fuel injection system, ignition system, emission control systems, sensors (MAF, O2, TPS, etc.), ECU diagnostics and testing

Transmission Manual:

Clutch system, gearbox assembly, internal components, shift mechanism, torque specifications

Transmission Automatic:

ATF system, valve body, torque converter, planetary gear sets, electronic control unit (TCU), diagnostic procedures

Drivetrain:

All-Wheel Drive (AWD) system, center differential, rear differential, driveshafts, CV joints, wheel bearings

Suspension:

Front suspension (MacPherson struts), rear multi-link suspension, springs, shock absorbers, control arms, bushings, alignment specifications

Brakes:

Brake system components (master cylinder, calipers, rotors, pads), ABS system, hydraulic circuits, bleeding procedures, parking brake

Steering:

Power steering system, steering rack, tie rods, steering column, alignment specifications

Electrical System:

12V battery, charging system (alternator), starting system (starter motor), lighting system, horn, wipers, power accessories

Body And Interior:

Body panels, doors, windows, locks, seats, dashboard, trim panels, HVAC system, body sealing, rust prevention

HVAC:

Air conditioning system (refrigerant, compressor, evaporator, condenser), heater core, blower motor, climate control system

Safety Systems:

Airbag system, SRS module, seat belt pre-tensioners, SRS wiring diagrams

Procedures Included

Routine Maintenance:

Oil and filter change, air filter replacement, spark plug replacement, coolant flush, brake fluid flush, differential fluid change

Diagnostic Troubleshooting:

Step-by-step troubleshooting flowcharts, symptom-based diagnostics, OBD-II code interpretation and resolution

Component Replacement:

Removal and installation procedures for all major and minor components

Engine Rebuild:

Detailed instructions for complete engine overhaul, including torques and clearances

Transmission Overhaul:

Procedures for complete transmission disassembly and reassembly

Electrical Diagnostics:

Wiring diagrams, component testing, troubleshooting shorts, opens, and high resistance

Bodywork Repair:

Panel replacement, dent repair, welding procedures, seam sealing

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete rebuilds and advanced diagnostics)

Diagrams And Illustrations:

Detailed step-by-step diagrams, exploded views, and schematics

Specifications And Tolerances:

Precise torque values, clearances, fluid capacities, electrical resistance values, and diagnostic parameters

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable if properly created OCR'd digital copy

Print Quality

Print Recommendation:

High-quality print for clarity of diagrams and text

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code Usdm:

EJ253 (2.5L SOHC)

Engine Type:

Naturally Aspirated Boxer-4

Displacement:

2457 cc (2.5 Liters)

Bore X Stroke:

99.5 mm x 79.0 mm

Compression Ratio:

9.7:1

Performance

Horsepower Usdm:

165 hp @ 5600 rpm

Torque Usdm:

166 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Recommended Octane:

87 Octane (USA)

Engine Codes Non Usdm

Engine Code Ej251:

2.5L SOHC (pre-facelift, some markets)

Engine Code Ej255:

2.5L Turbocharged DOHC (Forester XT)

Performance Xt Hp:

210-230 hp (depending on market/tune)

Performance Xt Torque:

235-250 lb-ft (depending on market/tune)

🔧 Transmission

Standard

Type:

5-Speed Manual

Optional

Type:

4-Speed Automatic (with Electronic Control)

Features

AWD System Manual:

Viscous coupling limited-slip center differential

AWD System Automatic:

Active All-Wheel Drive (electronically controlled multi-plate transfer clutch)

📐 Dimensions

Exterior

Length:

4485 mm (176.6 in)

Width:

1735 mm (68.3 in)

Height:

1590 mm (62.6 in) (without roof rails)

Wheelbase:

2630 mm (103.5 in)

Ground Clearance:

200 mm (7.9 in)

Weights

Curb Weight Manual:

Approx. 1450 kg (3197 lbs)

Curb Weight Automatic:

Approx. 1485 kg (3274 lbs)

Cargo

Cargo Volume Seats Up:

Approx. 88.0 cu ft (2490 liters) with rear seats folded

🛡️ Safety Features

Ratings

NHTSA Front Driver Side Impact:

5 Stars

NHTSA Front Passenger Side Impact:

5 Stars

NHTSA Side Driver Front Seat:

5 Stars

NHTSA Side Passenger Front Seat:

5 Stars

NHTSA Side Driver Rear Seat:

5 Stars

NHTSA Side Passenger Rear Seat:

5 Stars

IIHS Moderate Overlap Frontal Offset:

IIHS Side Impact:

Active Features

Standard Anti-lock Braking System

Traction Control:

Available (often with automatic transmission models)

Passive Features

Airbags Front:

Standard dual front airbags

Airbags Side:

Optional front side-impact airbags

Seatbelts:

Front pretensioner seatbelts, three-point rear seatbelts

💡 Technology Features

Infotainment

Audio System:

Base models typically feature a 4-speaker AM/FM/CD player. Higher trims may offer a 6-speaker system and an in-dash CD changer.

Navigation:

Optional factory navigation system available on select higher trim levels.

Driver Assistance

Cruise Control:

Standard cruise control on most trims.

Standard Anti-lock Braking System.

Connectivity

Auxiliary Input:

No standard auxiliary input or USB ports. Bluetooth was not a factory option.

Climate Control

Manual Ac:

Manual climate control with air conditioning.

Automatic Climate Control:

Optional automatic climate control on higher trim levels.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles or 3 months (severe conditions), 7,500 miles or 6 months (normal conditions) - refer to specific market manual

Engine Oil Type:

SAE 5W-30 (API SG or higher)

Engine Oil Capacity:

4.5 US quarts (4.2 liters) with filter change

Timing Belt Replacement Interval:

Approximately 105,000 miles or 105 months (critical maintenance item)

Fluid Specifications

Transmission Fluid Manual:

Gear oil API GL-5 SAE 75W-90 (check manual for specific PN)

Transmission Fluid Automatic:

Subaru ATF-HP (Genuine Subaru or equivalent)

Coolant Type:

Subaru Super Coolant (blue) or equivalent silicate-free long-life coolant

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Head Gaskets:

While less prevalent than in earlier EJ engines, some EJ253 engines may still experience coolant leaks from head gaskets over time. The manual will detail inspection and replacement.

Wheel Bearings:

Front and rear wheel bearings can wear out, leading to noise. Manual covers diagnosis and replacement.

Cv Boots:

Torn CV boots can lead to joint failure. Manual provides replacement procedures.

Automatic Transmission Control:

Early 4-speed automatics can sometimes exhibit delayed engagement or shifting issues, often related to fluid quality or solenoid issues. Manual offers diagnostic steps.

Exhaust Flange Gaskets:

Cracked exhaust manifold or up-pipe gaskets can cause exhaust leaks and ticking noises, particularly on turbocharged models, but also can occur on naturally aspirated ones. Manual covers replacement.

📚 Vehicle History

Brand Heritage

Subaru AWD Legacy:

Subaru's pioneering history with All-Wheel Drive technology dating back to the Subaru Leone in the 1970s.

Model Evolution

First Generation:

First generation Subaru Forester (SF chassis) introduced in 1997.

Second Generation Launch:

The 2002 model year marked the introduction of the second generation (SG chassis) Forester, with a significantly revised platform and styling.

Facelift:

A minor facelift occurred for the 2005 model year, primarily affecting the front fascia and interior trim.

Production

Manufacturing Location:

Ota, Gunma Prefecture, Japan (Subaru's primary manufacturing facility)

🏆 Awards & Recognition

Recognitions

Car And Driver Щения:

Car and Driver's 10Best Trucks and SUVs multiple times during its early generations.

Ratings

Edmunds Review:

Generally praised for its standard AWD, comfortable ride, and practicality, though criticized for interior materials and engine power on non-turbo models.

Certifications

Safety Certifications:

Consistently received high safety ratings from IIHS and NHTSA for its class during this period.