🏷️ Basic Information

Make:

Subaru

Model:

Forester

Product Name:

SUBARU FORESTER Service Repair Manual 1999 2000 2001 2002 2003 2004

👋 Introduction

Segment:

Compact Crossover SUV (SAC - Sport Activity Coupe designation by Subaru)

Target Audience:

Active individuals and families seeking a versatile, all-wheel-drive vehicle with utility and off-road capability.

Key Competitors:

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

Subaru Advantage:

Standard Symmetrical All-Wheel Drive, horizontally-opposed 'Boxer' engine for a lower center of gravity, reputation for reliability and safety.

All Wheel Drive:

Standard Symmetrical All-Wheel Drive system across all trims, providing enhanced traction and stability.

Engine Layout:

Horizontally-opposed Boxer engine, contributing to a lower center of gravity and smoother operation.

Ground Clearance:

Class-leading ground clearance for its segment, enhancing off-road capability.

Practicality:

Spacious interior, versatile cargo area, and SUV-like utility in a more car-like package.

📋 Manual Details

Coverage Years:

1999, 2000, 2001, 2002, 2003, 2004

Included Models:

All Forester models and trim levels for the specified production years.

Included Engines:

All engine variants offered for the 1999-2004 Subaru Forester.

Estimated Page Count:

Detailed information suggests a comprehensive manual, likely exceeding 2,000 pages for all systems and variations.

Type:

Complete Service and Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, inspection, assembly, timing belt replacement, cylinder head service, piston and connecting rod service, crankshaft and bearing service, lubrication system, cooling system.

Engine Management:

Fuel injection system, ignition system, emissions control systems (EGR, PCV, EVAP), sensor diagnostics, ECU operation and troubleshooting.

Transmission:

Manual transmission (clutch, gearbox, drivetrain components) and automatic transmission (torque converter, valve body, gear sets, hydraulic control, cooler, shift control).

Drivetrain:

Front and rear differentials, driveshafts, CV joints, AWD system operation and maintenance.

Suspension:

Front and rear suspension components (struts, springs, control arms, bushings), alignment specifications, shock absorber replacement.

Brakes:

Brake system components (master cylinder, brake lines, calipers, pads, rotors), ABS system operation and diagnosis, parking brake.

Steering:

Power steering system (pump, rack and pinion, fluid), steering column, wheel alignment.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting, wipers, power windows, mirrors, horn, fuse box diagrams, relay locations.

Climate Control:

HVAC system (heater core, evaporator, blower motor, refrigerant system, A/C compressor).

Body And Chassis:

Body panel removal and installation, interior trim, door mechanisms, glass replacement, structural components.

Diagnostics:

OBD-II codes, diagnostic trouble codes (DTCs), troubleshooting charts, symptom-based diagnostics.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, brake pad replacement.

Major Repairs:

Engine overhaul, transmission rebuild, suspension component replacement, brake system overhauls, electrical component repair.

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon issues.

Component Removal Installation:

Detailed instructions for removing and installing virtually every component of the vehicle.

Depth:

Comprehensive, covering everything from basic fluid checks and filter changes to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

Format:

PDF

Searchability:

Searchable text for quick access to specific information.

Printability:

Printable pages for in-garage reference.

Quality:

High-resolution scans of original factory service manuals, ensuring clarity of diagrams and text.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code 1:

EJ253 (Naturally Aspirated)

Engine Type 1:

2.5-liter SOHC 16-valve Flat-4 (Boxer)

Displacement 1:

2457 cc

Bore X Stroke 1:

99.5 mm x 80.0 mm

Compression Ratio 1:

9.7:1

Horsepower 1:

165 hp @ 5,600 rpm (approx.)

Torque 1:

166 lb-ft @ 4,000 rpm (approx.)

Engine Code 2:

EJ255 (Turbocharged - for XT models)

Engine Type 2:

2.5-liter DOHC 16-valve Turbocharged Flat-4 (Boxer)

Horsepower 2:

210-230 hp (depending on trim/year)

Torque 2:

235-250 lb-ft (depending on trim/year)

Fuel Delivery:

Electronic Fuel Injection (MPI - Multi-Point Injection)

Fuel Type:

Unleaded gasoline (87 octane recommended for NA, 91+ octane for Turbo)

ECU Type:

Subaru Engine Control Unit (ECU)

🔧 Transmission

Type 1:

5-Speed Manual Transmission

Type 2:

4-Speed Automatic Transmission (with Electronically Controlled Transfer Clutch)

AWD System:

Symmetrical All-Wheel Drive (Active on Automatic Transmission models, Full-Time on Manual Transmission models).

📐 Dimensions

Length:

Approx. 175.0 - 176.0 inches

Width:

Approx. 69.7 inches

Height:

Approx. 63.0 - 63.6 inches

Wheelbase:

Approx. 103.1 inches

Ground Clearance:

Approx. 8.0 - 8.1 inches

Cargo Volume Seats Up:

Approx. 38.0 - 41.0 cu ft

Cargo Volume Seats Down:

Approx. 65.0 - 70.0 cu ft

Curb Weight:

Approx. 3,200 - 3,550 lbs

Towing Capacity:

Up to 2,400 lbs (with proper equipment, consult manual for specifics)

🛡️ Safety Features

NHTSA Front Impact:

5-star rating (for driver and passenger side, where applicable)

IIHS Side Impact:

Good rating (for applicable models and years)

ABS:

Standard Anti-lock Braking System (ABS)

E Brake:

Standard parking brake system.

Airbags:

Front airbags, available front-side airbags and side-curtain airbags (depending on trim and year).

Seat Belts:

3-point seat belts with pretensioners for all occupants.

Child Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Head Unit:

Base models featured a single-CD or cassette player with AM/FM radio. Higher trims offered optional CD changers and premium audio systems.

Display:

Simple digital displays for clock, odometer, and climate control. No advanced touchscreens or navigation in standard configurations for this era.

Cruise Control:

Standard cruise control on most trims.

ABS:

Standard Anti-lock Braking System (ABS) across all models.

Aux Input:

Not standard. Aftermarket solutions or specific factory options might exist.

Bluetooth:

Not available from the factory for these model years.

🔧 Maintenance

Oil Change Interval:

Every 3,750 miles or 3 months, or 7,500 miles/6 months with synthetic oil (consult owner's manual for precise recommendations and severe driving conditions).

Timing Belt Replacement:

Every 90,000 - 105,000 miles or 7-10 years, whichever comes first. Critical maintenance item on these EJ series engines.

Spark Plug Replacement:

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

Engine Oil:

SAE 5W-30, API SJ or higher (refer to manual for exact specifications and synthetic recommendations).

Coolant:

Subaru Genuine Coolant or equivalent (50/50 mix of ethylene glycol and distilled water).

Transmission Fluid Auto:

Subaru Genuine ATF HP or Dexron III compatible fluid.

Transmission Fluid Manual:

GL-5 gear oil, SAE 75W-90 (consult manual for specific type).

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Subaru Genuine Power Steering Fluid or Dexron III compatible fluid.

Head Gaskets:

While less common in this generation compared to earlier models, some EJ series engines can experience head gasket leaks over time, especially if overheated or improperly maintained. The manual will detail diagnosis and replacement procedures.

Oil Consumption:

Some EJ engines, particularly at higher mileage, may exhibit increased oil consumption. The manual will cover checks and potential causes.

Cv Axle Boots:

Torn CV axle boots are a common wear item that can lead to joint damage if not addressed promptly. The manual will guide replacement.

Automatic Transmission Line Leaks:

Early automatic transmission cooler lines could be prone to leaks. The manual details the system for inspection and repair.

📚 Vehicle History

Subaru Origins:

Subaru, a division of Subaru Corporation (formerly Fuji Heavy Industries), has a long history of producing innovative vehicles, particularly known for their pioneering use of all-wheel-drive technology and horizontally-opposed engines.

First Generation Start:

The Subaru Forester was introduced in 1997 (as a 1998 model year in North America), marking Subaru's entry into the compact SUV/crossover segment.

Second Generation Start:

The second generation Forester, covering the provided manual's years (1999-2004), saw significant styling and engineering updates. The 2003 model year brought a more substantial redesign with a bolder exterior, improved interior, and enhanced safety features.

Manufacturing Locations:

Primary manufacturing occurred at Subaru's plant in Gunma, Japan. Some assembly may have occurred in other locations depending on market.

🏆 Awards & Recognition

Car And Driver Best SUV:

Subaru Forester was frequently recognized by publications like Car and Driver for its value, practicality, and all-wheel-drive capability in the compact SUV segment during its production run.

Consumer Reports Reliability:

Generally received average to above-average reliability ratings from sources like Consumer Reports for this period, with specific model years having their own nuances detailed in the manual.

Safety Certifications:

Achieved good safety ratings from government agencies (NHTSA) and insurance industry (IIHS) for its crashworthiness.