🏷️ Basic Information

Make:

Subaru

Model:

Forester

Model Years:

1998-2006

Product Name:

1998-2006 Subaru Forester Master Workshop Service & Parts Manual

Chassis Codes Covered:

SF5, SF9, SG5, SG9

👋 Introduction

Vehicle Segment:

Compact SUV / Crossover

Key Selling Points:

Standard Symmetrical All-Wheel Drive, practicality, SUV-like versatility in a car-like package.

Direct Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra (early years).

Standard AWD:

Subaru's signature Symmetrical All-Wheel Drive system, providing enhanced traction and stability.

Horizontally Opposed Engine:

Subaru's boxer engine design contributes to a lower center of gravity for improved handling.

Versatility:

Offers good cargo space and a comfortable ride for its class.

📋 Manual Details

Diagnostic Procedures:

Comprehensive diagnostic flowcharts and troubleshooting guides for all major systems.

Repair Procedures:

Detailed step-by-step repair instructions for engine, transmission, suspension, brakes, electrical, and body components.

Maintenance Schedules:

Factory-recommended maintenance intervals for various mileage and time-based services.

Parts Information:

Identification and sometimes diagrams for factory replacement parts.

Estimated Page Count:

Extensive (exact number not specified, but typical for master workshop manuals covering multiple years/engines).

Manual Type:

Master Workshop Service & Parts Manual

Language:

English

Format:

Likely digital format (PDF) given the description of being 'complete and intact' and targeted at 'do-it-yourself' users, often distributed digitally.

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, component specifications, timing belt/chain, valve adjustments, cooling system, lubrication.

Engine Management:

Fuel injection, ignition system, emissions control, sensors, actuators, ECU diagnostics.

Transmission Manual:

Clutch operation, gear shift mechanism, transmission disassembly and assembly, fluid specifications.

Transmission Automatic:

Automatic transmission operation, internal components, torque converter, hydraulic control, fluid specifications, diagnostics.

Drivetrain:

All-Wheel Drive (AWD) system operation, differentials (front, rear, center), driveshafts, CV joints, axle shafts.

Suspension:

Front and rear suspension components, shock absorbers, struts, springs, control arms, alignment specifications.

Steering:

Power steering system, steering rack, tie rods, steering column, steering angle sensor.

Brakes:

Front and rear brake systems (disc/drum), ABS (Anti-lock Braking System) operation and diagnostics, brake fluid specifications, rotor/pad replacement.

Electrical System:

Battery, charging system (alternator), starting system (starter), lighting, wiring diagrams, fuses, relays.

Body And Chassis:

Body panel removal and installation, interior trim, exterior trim, glass replacement, chassis components.

Climate Control:

HVAC (Heating, Ventilation, and Air Conditioning) system, A/C compressor, condenser, evaporator, refrigerant, blower motor.

Safety Systems:

Airbag system operation and diagnostics, seat belt mechanisms.

Basic Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), fluid checks and top-offs, tire rotations.

Scheduled Maintenance:

Timing belt replacement (critical for EJ25/EJ20 engines), spark plug replacement, coolant flushes, brake fluid flushes.

Troubleshooting:

Diagnosing common drivability issues, electrical faults, and mechanical noises.

Engine Rebuilding:

Detailed instructions for engine disassembly, inspection, repair, and reassembly, including torque specifications and clearances.

Transmission Repair:

Overhaul procedures for both manual and automatic transmissions.

Brake System Repair:

Replacement of brake pads, rotors, calipers, and hydraulic lines.

Electrical Component Replacement:

Alternator, starter, battery, sensors, control modules.

Suspension Component Replacement:

Struts, shocks, ball joints, control arms, bushings.

Body Panel Repair:

Removal and installation of fenders, hoods, doors, bumpers.

Depth Of Information:

Comprehensive, covering from basic maintenance to full engine and transmission rebuilds.

Diagnostic Capabilities:

Includes information on On-Board Diagnostics (OBD-II) system, fault codes, and diagnostic procedures.

Wiring Diagrams:

Detailed electrical wiring diagrams for various vehicle systems, essential for electrical troubleshooting.

Special Tools:

Lists and descriptions of specialized tools required for specific procedures.

📊 Manual Specifications

File Format Details:

If digital, typically PDF. Searchable text is highly desirable. High-resolution scans ensure clarity of diagrams and illustrations.

Illustration Quality:

Factory-quality illustrations, diagrams, and exploded views are expected for clarity.

Binding Type Physical:

If printed, typically a robust binding (e.g., spiral-bound, perfect-bound) to withstand shop use.

Paper Type Physical:

If printed, durable, high-quality paper suitable for a workshop environment.

⚙️ Engine Specifications

Engine Code 1:

EJ251 / EJ253 (2.5L SOHC/DOHC Naturally Aspirated)

Engine Displacement 1:

2457 cc (2.5 Liters)

Engine Configuration 1:

Horizontally Opposed (Boxer), 4-Cylinder

Horsepower 1:

Approx. 165-175 hp (depending on specific year and SOHC/DOHC)

Torque 1:

Approx. 166-177 lb-ft (depending on specific year and SOHC/DOHC)

Fuel System 1:

Multi-point Fuel Injection (MPI)

Engine Code 2:

EJ205 (2.0L DOHC Turbocharged - JDM/Certain Exports)

Engine Displacement 2:

1994 cc (2.0 Liters)

Engine Configuration 2:

Horizontally Opposed (Boxer), 4-Cylinder, Turbocharged

Horsepower 2:

Approx. 210-220 hp (for turbocharged models like GT/STi variants)

Torque 2:

Approx. 236-250 lb-ft (for turbocharged models)

Fuel System 2:

Multi-point Fuel Injection (MPI), Turbocharged

Engine Aspirated Types:

Naturally Aspirated and Turbocharged

Fuel Type Requirement:

Unleaded gasoline (Octane rating varies by engine and market, check specific vehicle recommendations).

🔧 Transmission

Standard Transmission Type:

5-speed Manual Transmission (5MT)

Optional Transmission Type:

4-speed Automatic Transmission (4EAT/4AT)

AWD Engagement Manual:

Driver-controlled center differential with viscous coupling (manual transmission models).

AWD Engagement Automatic:

Active All-Wheel Drive system with electronically controlled multi-plate transfer clutch (automatic transmission models).

📐 Dimensions

Wheelbase 1:

Approx. 2500 mm (98.4 in) for SF chassis

Wheelbase 2:

Approx. 2515 mm (99.0 in) for SG chassis

Length 1:

Approx. 4410 mm (173.6 in) for SF chassis

Length 2:

Approx. 4485 mm (176.6 in) for SG chassis

Width:

Approx. 1735 mm (68.3 in)

Height:

Approx. 1590 mm (62.6 in) to 1670 mm (65.7 in) depending on roof rails

Cargo Volume Behind Rear Seats:

Approx. 33.5 cu ft (varies slightly by generation)

Cargo Volume With Rear Seats Folded:

Approx. 67.5 cu ft (varies slightly by generation)

Curb Weight:

Approx. 1400-1600 kg (3086-3527 lbs) depending on configuration

🛡️ Safety Features

NHTSA Frontal Crash Rating Driver:

4/5 Stars (for models tested)

NHTSA Frontal Crash Rating Passenger:

4/5 Stars (for models tested)

IIHS Frontal Offset Score:

Good (for models tested that qualified)

ABS:

Standard Anti-lock Braking System

Traction Control:

Available (market/trim dependent)

Airbags:

Front airbags (driver and passenger) standard. Side airbags were optional or standard on later models/trims.

Seat Belts:

3-point seat belts with pretensioners for front occupants.

💡 Technology Features

Audio System:

Factory-installed AM/FM stereo with CD player, optional premium audio with subwoofer.

Instrument Cluster:

Includes tachometer, speedometer, fuel gauge, temperature gauge, and various warning lights. Some models may have trip computers.

Cruise Control:

Standard on most trims.

Remote Keyless Entry:

Available on higher trims or as an option.

Power Windows Locks:

Standard on most trims.

🔧 Maintenance

Oil Change Interval:

Every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6 months, depending on driving conditions and oil type used.

Timing Belt Replacement Interval:

Every 105,000 miles (168,000 km) or 7 years (whichever comes first) for EJ25/EJ20 engines. This is a critical maintenance item.

Spark Plug Replacement Interval:

Approx. 60,000 - 100,000 miles (96,000 - 160,000 km) depending on plug type (copper, platinum, iridium).

Engine Oil Type 1:

SAE 5W-30 API SG, SH, SJ, or higher (check owner's manual for specific viscosity and API rating).

Engine Oil Capacity 1:

Approx. 4.7 US quarts (4.4 Liters) with filter change for 2.5L engine.

Coolant Type:

Subaru Super Coolant (blue) or equivalent ethylene glycol based antifreeze/coolant.

Transmission Fluid Manual:

API GL-5, SAE 75W-90 Gear Oil (for 5MT).

Transmission Fluid Automatic:

Subaru ATF HP orDexron III/Mercon equivalent (check manual for specific grade for 4EAT).

Brake Fluid Type:

DOT 3 or DOT 4.

Head Gasket Failure:

A common concern on EJ series engines, particularly earlier DOHC naturally aspirated versions, though less prevalent on 2.5 SOHC (EJ251/EJ253) in later years of this generation. The manual would detail inspection and replacement procedures.

Timing Belt Wear:

Crucial to adhere to replacement intervals to prevent catastrophic engine damage due to interference design.

Cv Joint Boots:

Can wear and tear, leading to lubrication loss and potential joint failure if not addressed.

Rear Differential Leaks:

Occasionally reported, often due to aging seals.

📚 Vehicle History

Subaru Identity:

Known for its Symmetrical All-Wheel Drive and horizontally opposed boxer engines, emphasizing capability and safety.

First Generation Sf:

Launched in 1997 for the 1998 model year, based on the Impreza platform. Introduced the concept of a compact, lifted wagon/SUV.

Second Generation Sg:

Introduced for the 2003 model year. Featured a more rounded styling, larger dimensions, and updated powertrains. Offered the turbocharged GT model.

Production Location:

Japan (Gunma Plant)

Production Years:

1998-2006 (covering two generations: 1998-2002 SF, 2003-2006 SG)

🏆 Awards & Recognition

Consumer Reports Reliability:

Generally rated as average to above average, with some years showing higher reliability than others. The manual would help diagnose and address specific issues that impact reliability.

Vehicle Type Classification:

Considered one of the pioneering compact crossover SUVs, blending car-like handling with SUV utility.