Subaru Forester 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2002 Generation Chassis Code: SF Series (Second Generation) Codes Subaru Model Code: SF5 (for naturally aspirated models), SF9 (for turbocharged models)...

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Type: Car

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Sku: 321546

Tags: 2002 Car Cars Forester Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Year:

Generation

Chassis Code:

SF Series (Second Generation)

Codes

Subaru Model Code:

SF5 (for naturally aspirated models), SF9 (for turbocharged models)

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Key Selling Points:

Symmetrical All-Wheel Drive (standard), practicality, Subaru boxer engine, good visibility, reputation for reliability.

Competitive Analysis

Key Competitors 2002:

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

Key Features

Standard AWD:

Subaru's signature Symmetrical All-Wheel Drive system was standard across all trims, a significant differentiator.

Boxer Engine Layout:

Flat-four 'boxer' engine provides a lower center of gravity for improved handling and stability.

Practicality:

Spacious interior for its class, versatile cargo area, and good ground clearance for light off-road use.

📋 Manual Details

Coverage Areas

Main Coverage:

Complete repair and service procedures, maintenance schedules, troubleshooting guides

Page Count

Estimated Pages:

1500-2000 (typical for comprehensive factory service manuals of this era)

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

Likely available as a physical book or a searchable PDF

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, lubrication system, cooling system, fuel system, ignition system, emission control system, engine electrical, engine management (ECU)

Transmission:

Manual transmission (MT) and automatic transmission (AT) diagnosis, repair, overhaul, fluid specifications

Drivetrain:

All-Wheel Drive (AWD) system, differentials, driveshafts, axles, wheel bearings

Suspension:

Front and rear suspension components, springs, shock absorbers, control arms, sway bars, alignment specifications

Steering:

Power steering system, steering gear, tie rods, steering column, alignment

Brakes:

Front and rear brake systems (disc/drum configurations), ABS system, hydraulic lines, calipers, rotors, pads, parking brake

Electrical:

Wiring diagrams, fuses, relays, lighting system, power windows, power locks, mirrors, wipers, horn, battery, charging system, starting system

Body:

Body panels, doors, hood, tailgate, bumpers, glass, interior trim, weatherstripping

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, blower motor, controls

Safety Systems:

Airbag system, seat belts

Procedures Included

Maintenance:

Oil change, filter replacement, fluid checks and top-offs, spark plug replacement, air filter replacement, belt inspection and replacement, brake fluid flush, coolant flush

Repair:

Engine overhaul, transmission rebuild, suspension component replacement, brake caliper overhaul, starter motor replacement, alternator replacement, radiator replacement, fuel pump replacement

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting for common issues, DTC (Diagnostic Trouble Code) explanations and correction

Specifications:

Torque specifications for all fasteners, engine clearances, alignment angles, fluid capacities, tire pressures

Technical Depth

Depth:

Comprehensive; covers basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and body repairs

📊 Manual Specifications

File Format

Digital Format Details:

If PDF, typically high-resolution scans of original factory documents, often searchable text with hyperlinked sections for easy navigation.

Print Quality

Print Quality Details:

For physical copies, expect professional printing on durable paper, clear diagrams, and legible text.

Binding Type

Binding Type Details:

Physical manuals are typically coil-bound or perfect-bound for durability and ease of use on a workbench.

Paper Type

Paper Type Details:

Heavy-duty paper stock designed to withstand grease and workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Code Na:

EJ253

Engine Type Na:

2.5L SOHC naturally aspirated flat-four (Boxer)

Displacement Na:

2457 cc (2.5 Liters)

Horsepower Na Approx:

165 hp @ 5,600 rpm

Torque Na Approx:

166 lb-ft @ 4,000 rpm

Optional Engine

Engine Code Turbo:

EJ205

Engine Type Turbo:

2.0L DOHC turbocharged flat-four (Boxer) - Forester XT models

Displacement Turbo:

1994 cc (2.0 Liters)

Horsepower Turbo Approx:

210-220 hp @ 5,600 rpm

Torque Turbo Approx:

235-240 lb-ft @ 3,200 rpm

Fuel System

Fuel Delivery:

Multi-port Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline

Recommended Octane:

87 AKI (for NA), 91 AKI (for Turbocharged XT models)

🔧 Transmission

Standard

Transmission Type Na:

4-Speed Automatic Transmission (4EAT)

Transmission Type Manual:

5-Speed Manual Transmission (5MT) - Often standard on base models or optional

Optional

Transmission Type Turbo Auto:

4-Speed Automatic Transmission (4EAT) on XT models

Features

AWD Integration Auto:

Variable torque distribution based on conditions (electronically controlled)

AWD Integration Manual:

Viscous coupling center differential with limited-slip rear differential

📐 Dimensions

Exterior

Length Approx:

175.0 inches

Width Approx:

69.1 inches

Height Approx:

63.0 inches

Wheelbase Approx:

103.0 inches

Ground Clearance Approx:

7.7 inches

Weights

Curb Weight Approx:

3100-3300 lbs (depending on trim and transmission)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Good (for 2002 models)

NHTSA Front Impact Passenger:

Good (for 2002 models)

IIHS Front Offset Crash Rating:

Acceptable (for models tested)

Active Features

Anti-lock Braking System (standard)

Passive Features

Airbags:

Front driver and passenger airbags

Seatbelts:

Three-point seatbelts for all seating positions, pretensioners for front seats

💡 Technology Features

Infotainment

Audio System:

Factory fitted AM/FM/CD stereo, often with 4 or 6 speakers. Premium options might include Nakamichi or similar.

Driver Assistance

Cruise Control:

Standard on most trims

Traction Control:

Not widely available on 2002 models. Some AWD benefits provide inherent traction stability.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-7,500 miles or 6-12 months, depending on driving conditions and oil type used (consult manual for exact recommendation).

Timing Belt Replacement:

Crucial for EJ-series engines. Interval typically 60,000-105,000 miles or 5-7 years. Failure results in catastrophic engine damage.

Transmission Fluid Change:

Automatic: Every 30,000-60,000 miles. Manual: Check and replace as needed, often at higher mileage (e.g., 60,000+ miles).

Fluid Specifications

Engine Oil Type Na:

API SG/SH/SJ, ILSAC GF-2/GF-3, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temperature).

Engine Oil Type Turbo:

API SG/SH/SJ, ILSAC GF-2/GF-3, SAE 5W-30 or 10W-30 (synthetic recommended for turbocharged engines).

Coolant Type:

Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant with Subaru additive. Never use plain water or mixed coolants.

Automatic Transmission Fluid Type:

Subaru ATF-HP (High Performance) or equivalent Dexron-III compatible fluid. Incorrect fluid can damage the transmission.

Manual Transmission Fluid Type:

API GL-5, SAE 75W-90 Gear Oil (Subaru Extra-S or equivalent).

Known Issues

Head Gaskets:

While not as prevalent as on some EJ25 DOHC engines, SOHC EJ253 engines can still experience head gasket leaks, particularly externally.

Rear Main Seal:

Common leak point on many Subarus of this era, often requiring transmission removal to replace.

Cv Axle Boots:

Front and rear CV axle boots are prone to tearing, leading to grease loss and eventual CV joint failure.

Exhaust Flange Gaskets:

Cracked exhaust manifold or downpipe gaskets can cause ticking noises and exhaust leaks.

Mass Airflow Sensor Dirty:

Can lead to rough idle, stalling, and poor performance. Cleaning is often a temporary fix before replacement.

📚 Vehicle History

Brand Heritage

Subaru AWD Legacy:

Subaru has been synonymous with All-Wheel Drive since the introduction of the Subaru Leone 4WD in 1972. The Forester built on this reputation.

Model Evolution

Generation Introduction:

The second generation Forester (SF series) was introduced for the 1998 model year and received a significant refresh for 2001, with the 2002 model year reflecting this updated design.

Production

Manufacturing Plant:

Ota City, Gunma Prefecture, Japan

🏆 Awards & Recognition

Recognitions

Motor Trend SUV Of The Year:

The Subaru Forester was not named MotorTrend SUV of the Year for 2002, but often ranked highly among its peers.

Edmunds Long Term Test:

Subarus generally received positive marks for reliability and capability in long-term tests from publications like Edmunds.