Subaru Forester 1999-2002 Factory Service Repair Manual Pdf

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 1999-2002 Chassis Codes: SF Series Codes Product Name: Subaru Forester 1999-2002 Factory Service Repair Manual PDF 👋 Introduction Market Position Vehicle...

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Tags: 1999 2000 2001 2002 Car Cars Forester Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Year:

1999-2002

Chassis Codes:

SF Series

Codes

Product Name:

Subaru Forester 1999-2002 Factory Service Repair Manual PDF

👋 Introduction

Market Position

Vehicle Segment:

Compact Crossover SUV

Target Audience:

Families, outdoor enthusiasts, individuals seeking a practical and capable AWD vehicle.

Competitive Analysis

Key Competitors:

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

Key Features

All Wheel Drive:

Standard Symmetrical All-Wheel Drive system, a key differentiator.

Ground Clearance:

Higher ground clearance than many competitors, enhancing off-road capability.

Practicality:

Spacious interior, good cargo volume, and a reputation for durability.

Safety:

Strong emphasis on safety features and crashworthiness.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Coverage Years:

1999, 2000, 2001, 2002

Intended User:

Dealership Technicians, Professional Mechanics, Experienced DIYers

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive coverage for all gasoline engine variants, including diagnostics, repair, overhaul, and specifications.

Transmission:

Detailed information for both automatic (4EAT) and manual (5-speed) transmissions, including operation, diagnostics, and repair procedures.

Drivetrain:

Includes coverage of the Subaru Symmetrical All-Wheel Drive system, viscous coupling center differential, and front/rear differentials.

Suspension:

Complete repair and diagnostic procedures for front and rear suspension components, including struts, springs, control arms, and bushings.

Steering:

Coverage of the power steering system, steering rack, tie rods, and alignment procedures.

Brakes:

Detailed specifications and repair instructions for front and rear disc brakes, including ABS system diagnostics and components.

Electrical System:

Extensive wiring diagrams, component locations, diagnostic procedures, and repair instructions for all electrical systems.

HVAC:

Diagnosing and repairing the heating, ventilation, and air conditioning system, including refrigerant handling and component replacement.

Body And Interior:

Repair procedures for body panels, doors, trim, glass, and interior components.

Body Electrical:

Focus on body control modules, lighting systems, power windows, door locks, and other body-related electrical functions.

Chassis:

Includes information on the unibody construction, frame components, and mounting points.

Procedures Included

Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, belt inspections, and general upkeep procedures.

Diagnostics:

Comprehensive diagnostic flowcharts, symptom-based troubleshooting guides, and OBD-II diagnostic trouble codes (DTCs) with explanations.

Repair:

Step-by-step repair instructions for virtually every component of the vehicle, from minor adjustments to major component overhauls.

Overhaul And Rebuild:

Detailed procedures for engine and transmission rebuilds, including clearances, torque specifications, and assembly sequences.

Troubleshooting:

Systematic approaches to diagnosing and resolving common and uncommon vehicle problems.

Calibration And Adjustment:

Procedures for setting idle speed, ignition timing (where applicable), and other critical adjustments.

Torque Specifications:

Essential torque values for all fasteners and critical engine/chassis components.

Technical Depth

Depth:

Extremely high. Covers everything from basic fluid checks to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic strategies.

Detail Level:

Factory-level detail, mirroring the information used by Subaru dealerships.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text content for quick information retrieval.

Print Quality

Image Resolution:

High-resolution for clear viewing of diagrams, illustrations, and text.

Printable:

Fully printable pages for convenient on-site reference.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

Completeness

Completeness:

Complete, factory-authorized service manual covering all aspects of the vehicle.

⚙️ Engine Specifications

Primary Engine

Engine Code:

EJ253 (SOHC)

Engine Type:

2.5L Naturally Aspirated SOHC EJ-Series Boxer-4

Displacement:

2457 cc (149.9 cubic inches)

Bore X Stroke:

99.5 mm x 79.0 mm

Compression Ratio:

9.7:1

Horsepower:

165 hp @ 5,600 rpm (approximate, may vary slightly by year)

Torque:

166 lb-ft @ 4,000 rpm (approximate, may vary slightly by year)

Performance

0-60 Mph:

Approx. 9.5-10.5 seconds (depending on transmission and driver)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Fuel Tank Capacity:

60 liters (15.9 US gallons)

Emissions Controls:

Catalytic converter, oxygen sensors, EGR system.

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic Transmission (4EAT)

Optional

Transmission Type:

5-speed Manual Transmission

Features

AWD System Integration:

Integrated with Subaru's Symmetrical All-Wheel Drive system, featuring a viscous coupling center differential.

Automatic Transmission Modes:

Includes a selectable low-gear range for enhanced traction and engine braking.

Fluid Specifications

Automatic Transmission Fluid Type:

Subaru ATF HP (Genuine Subaru part no. K08161-99070 or equivalent Dexron III/Mercon)

Manual Transmission Fluid Type:

GL-5 75W-90 Gear Oil (API classification)

📐 Dimensions

Exterior

Length:

4410 mm (173.6 inches)

Width:

1770 mm (69.7 inches)

Height:

1605 mm (63.2 inches) (unloaded)

Wheelbase:

2530 mm (99.6 inches)

Ground Clearance:

Approx. 195 mm (7.7 inches)

Approach Angle:

Approx. 30 degrees

Departure Angle:

Approx. 31 degrees

Cargo

Cargo Volume:

Approx. 35.7 cubic feet (with rear seats up)

Max Cargo Volume:

Approx. 67.7 cubic feet (with rear seats folded)

Weights

Curb Weight:

Approx. 1450-1550 kg (3197-3417 lbs) depending on transmission and trim

Gross Vehicle Weight Rating:

Approx. 1950 kg (4299 lbs)

Towing Capacity:

Up to 2000 lbs (907 kg) with trailer brakes, 1000 lbs (454 kg) without trailer brakes (check local regulations and specific model year).

Wheels And Tires

Wheel Bolt Pattern:

5x100 mm

Wheel Size:

15-inch or 16-inch alloy or steel wheels

Tire Size:

205/70R15 or 215/60R16 (depending on trim and year)

🛡️ Safety Features

Ratings

NHTSA Frontal Impact:

4-star driver and passenger (for 1999-2002 models)

NHTSA Side Impact:

4-star front and rear passengers (for 1999-2002 models)

Active Features

Standard Anti-lock Braking System (ABS) on most models.

Symmetrical All-Wheel Drive enhances stability and traction in various conditions.

Passive Features

Airbags:

Front driver and passenger airbags. Some models may have optional side airbags.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system compatibility.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with available cassette. Speaker configurations vary by trim level.

Display:

Basic dashboard display for audio and climate controls. No central infotainment screen.

Driver Assistance

Cruise Control:

Standard on most trim levels.

Connectivity

Connectivity Options:

Limited to analog systems. No Bluetooth or USB connectivity from the factory.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 3,750 miles or 3.75 months, or every 7,500 miles or 7.5 months for synthetic oil (refer to owner's manual for specific recommendations).

Air Filter Replacement:

Inspect every 15,000 miles, replace as needed or approximately every 30,000 miles.

Spark Plug Replacement:

Approximately every 60,000-100,000 miles depending on spark plug type (copper, platinum, iridium).

Coolant Replacement:

Initial replacement at 30,000 miles or 30 months, then every 30,000 miles or 30 months thereafter. Use Subaru Super Coolant.

Timing Belt Replacement:

Critical: 105,000 miles or 105 months. Failure can cause severe engine damage.

Fluid Specifications

Engine Oil Type:

5W-30 API SG or SH certified (Synthetic recommended for extended intervals)

Engine Oil Capacity:

Approx. 4.5 quarts (4.3 liters) with filter change

Brake Fluid Type:

DOT 3

Power Steering Fluid Type:

Subaru Genuine Power Steering Fluid or equivalent DEXRON-III ATF

Coolant Type:

Subaru Super Coolant (Blue, Ethylene Glycol based, 50/50 mix with distilled water)

Known Issues

Head Gaskets:

While less common on the 2.5 SOHC EJ253 compared to earlier DOHC variants, head gasket leaks can still occur. The manual provides diagnostic and repair procedures.

Timing Belt Tensioner:

The timing belt tensioner can fail over time; timely replacement as per schedule is crucial. The manual details the replacement process.

Automatic Transmission Issues:

Some early 4EAT transmissions could develop issues if fluid is not maintained. The manual covers diagnostic steps.

Rust And Corrosion:

Subarus of this era can be susceptible to rust, particularly in areas with heavy road salt use. The manual can guide on body panel repair.

Suspension Wear:

Control arm bushings, sway bar links, and strut mounts can wear out, impacting ride quality. The manual provides replacement and alignment procedures.

📚 Vehicle History

Brand Heritage

Subaru Philosophy:

Subaru has a long-standing reputation for building reliable vehicles with a focus on safety, durability, and all-wheel-drive capability.

Model Evolution

First Generation Launch:

The first generation Subaru Forester (SF series) was introduced in 1997 in Japan and later in North America for the 1998 model year. This manual covers the latter half of the first generation.

Facelift:

The 1999 model year saw a significant facelift with updated styling, improved interior, and a larger engine for North American models.

Second Generation Introduction:

The second generation Forester (SG series) was introduced for the 2003 model year, marking the end of the production covered by this manual.

Production

Manufacturing Location:

Japan (Gunma Plant)

Production Period:

1997-2002 (SF Series)

🏆 Awards & Recognition

Recognitions

Car And Driver Best SUV:

Car and Driver recognized the Subaru Forester in its '10Best' lists multiple times during its production run for its blend of practicality and capability.

Ratings

IIHS Top Safety Pick:

While IIHS ratings are less comprehensive for this era, the Forester consistently performed well in crash tests relative to its class.