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Subaru Forester 1998-2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Years: 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Chassis Codes: SF, SG 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV...
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Type: Car
Vendor:
Sku: 467558
Subaru Forester 1998-2004 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Years:
1998, 1999, 2000, 2001, 2002, 2003, 2004
Codes
Chassis Codes:
SF, SG
👋 Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV
Key Selling Points:
Symmetrical All-Wheel Drive, practicality, reliability, boxer engine character
Competitive Analysis
Competitors:
Honda CR-V, Toyota RAV4, Mazda Tribute, Ford Escape
Key Features
AWD Standard:
Standard Symmetrical All-Wheel Drive across most trims and powertrains
Ground Clearance:
Higher ground clearance compared to many segment rivals, aiding off-road capability
Boxer Engine:
Horizontally opposed (boxer) engine configuration contributing to a lower center of gravity
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Workshop Manual
Language:
English
Format:
PDF Download
Delivery:
Instant Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, cylinder head, block, pistons, crankshaft, timing belt/chain replacement, lubrication system, cooling system
Engine Performance:
Fuel injection system, ignition system, emissions control, exhaust system, turbocharger (if applicable)
Transmission Manual:
Clutch, gearbox overhaul, gear selection, driveshafts, differentials
Transmission Automatic:
Torque converter, valve body, planetary gear sets, transmission control module (TCM), fluid and filter service
Drivetrain:
All-Wheel Drive (AWD) system, differentials, transfer case, driveshafts, CV joints
Brakes:
Hydraulic system, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake pads, rotors, calipers, lines, master cylinder
Suspension:
Front and rear suspension components, struts, shocks, springs, control arms, bushings, sway bars
Steering:
Power steering system, steering column, rack and pinion, tie rods
Electrical:
Battery, charging system, starting system, lighting, wipers, horn, power windows, mirrors, door locks
Electronics:
ECU (Engine Control Unit), sensors, actuators, instrument cluster, audio system, climate control, immobilizer
Body And Chassis:
Body panels, doors, hood, trunk, interior trim, glass, bumpers, frame, structural components
HVAC:
Air conditioning system, heater, ventilation, blower motor, refrigerant, control panel
Procedures Included
Scheduled Maintenance:
Oil change intervals, filter replacement, fluid checks and top-offs, spark plug replacement, timing belt replacement schedule
Troubleshooting:
Diagnostic procedures, fault codes (DTCs), symptom-based troubleshooting guides, electrical schematics for diagnostics
Repair Procedures:
Step-by-step repair instructions for all major systems, torque specifications, disassembly and reassembly guidance
Diagnostics:
OBD-II (On-Board Diagnostics II) procedures, sensor testing, electrical component testing
Replacement:
Component replacement procedures (e.g., alternator, starter, water pump, fuel pump)
Adjustment:
Valve adjustments, parking brake adjustments, belt tension adjustments
Technical Depth
Depth:
Comprehensive factory-level repair and diagnostic information
Detail Level:
Includes detailed diagrams, exploded views, specifications, and procedures for complete vehicle overhaul
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval
Printability:
Printable pages for workshop use
Print Quality
Image Resolution:
High-resolution diagrams and illustrations
Binding Type
Format Type:
Digital Download
Paper Type
Digital Format:
Optimized for viewing on computers, tablets, and smartphones
⚙️ Engine Specifications
Primary Engine
Engine Code Sf:
EJ251, EJ253
Engine Code Sg:
EJ251, EJ253, EJ255 (turbocharged)
Displacement Na:
2.5 Liters (2498cc)
Configuration Na:
Naturally Aspirated SOHC/DOHC Flat-4 (Boxer)
Horsepower Na Early:
165 hp @ 5600 rpm
Torque Na Early:
162 lb-ft @ 4000 rpm
Horsepower Na Late:
173 hp @ 5600 rpm
Torque Na Late:
166 lb-ft @ 4000 rpm
Horsepower Turbo:
210 hp @ 5600 rpm (Forester XT)
Torque Turbo:
235 lb-ft @ 3500 rpm (Forester XT)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (MPI)
Recommended Fuel:
87 Octane Unleaded (91 Octane for Turbo models)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic
Optional
Transmission Type:
5-Speed Manual
Features
AWD System Auto:
Active All-Wheel Drive (electronically controlled multi-plate clutch)
AWD System Manual:
Continuous All-Wheel Drive (viscous coupling center differential)
Fluid Specifications
Automatic Fluid Type:
Subaru ATF-HP (or equivalent Dexron III/Mercon compatible fluid for earlier models, consult manual for specifics)
📐 Dimensions
Exterior
Length:
175.2 - 178.2 inches (4450 - 4525 mm)
Width:
69.7 inches (1770 mm)
Height:
63.2 - 65.0 inches (1605 - 1650 mm)
Wheelbase:
103.0 inches (2615 mm)
Ground Clearance:
7.7 - 8.1 inches (195 - 205 mm)
Weights
Curb Weight:
3150 - 3550 lbs (1430 - 1610 kg) approx.
Cargo
Cargo Volume Rear Seats Up:
31.5 - 37.7 cu ft (892 - 1068 L) depending on year/trim
Cargo Volume Rear Seats Down:
65.7 - 72.1 cu ft (1859 - 2042 L) depending on year/trim
🛡️ Safety Features
Ratings
NHTSA Front Driver:
Good (for SF generation, specific ratings vary by year)
NHTSA Front Passenger:
Good (for SF generation, specific ratings vary by year)
IIHS Side Impact:
Acceptable/Good (depending on year and equipment, consult specific IIHS reports)
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brake-force Distribution
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Optional front side-impact airbags (available on higher trims/later years)
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Audio System:
Factory CD/Cassette/AM/FM stereo systems. Higher trims may feature premium audio or CD changer.
Driver Assistance
Cruise Control:
Standard cruise control on most models.
Connectivity
Auxiliary Input:
Rarely found on factory systems; aftermarket solutions common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-7,500 miles (5,000-12,000 km) or 6-12 months, depending on driving conditions and oil type used (refer to manual for specific recommendations)
Timing Belt Replacement:
Every 105,000 miles (168,000 km) or 7 years, whichever comes first (crucial interval to prevent catastrophic engine damage)
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for platinum-tipped plugs (consult manual for exact interval and plug type)
Fluid Specifications
Engine Oil Type:
5W-30 or 10W-30 Synthetic Blend or Full Synthetic (check owner's manual for specific viscosity based on climate)
Engine Oil Capacity:
4.5 - 5.0 US quarts (4.3 - 4.7 Liters) with filter change (confirm with manual)
Coolant Type:
Subaru Super Coolant (Blue) or equivalent ethylene glycol-based coolant with Subaru anti-corrosion additives
Coolant Capacity:
Approx. 6.0 - 6.5 US quarts (5.7 - 6.2 Liters) (check manual)
Known Issues
Head Gaskets:
Premature head gasket failure (especially on earlier EJ25 engines) is a common concern; manual provides inspection and replacement procedures.
Suspension Wear:
Front strut mounts and rear bushings can wear over time, affecting ride quality and alignment.
Oil Leaks:
Rear main seal and oil pan gasket leaks can occur with age.
Catalytic Converter:
Can become clogged, leading to performance issues.
📚 Vehicle History
Brand Heritage
Subaru Focus:
Known for its Symmetrical All-Wheel Drive system and horizontally opposed boxer engines
Model Evolution
Generation 1 Sf:
First generation (SF) produced from 1997-2002, introduced as a compact SUV blending car-like handling with off-road capability
Generation 2 Sg:
Second generation (SG) produced from 2003-2008, featuring a larger platform, updated styling, and improved safety features, including the turbocharged Forester XT variants
Production
Manufacturing Location:
Gunma Plant, Japan
🏆 Awards & Recognition
Recognitions
Model Reputation:
Consistently ranked highly for reliability and all-weather capability by automotive publications.
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