Subaru Forester 2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2002 Codes Chassis Code: SF/SG Generation (Second Generation) Engine Code Primary: EJ253 (2.5L SOHC) Engine Code Optional: EJ255 (2.5L DOHC Turbo...

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类型: Car

斯库: 317164

标签: 2002 Car Cars Forester Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Year:

Codes

Chassis Code:

SF/SG Generation (Second Generation)

Engine Code Primary:

EJ253 (2.5L SOHC)

Engine Code Optional:

EJ255 (2.5L DOHC Turbo - XT models)

👋 Introduction

Market Position

Segment:

Compact SUV / Crossover

Target Audience:

Families, outdoor enthusiasts, individuals seeking AWD capability

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan X-Trail (Rogue)

Key Features

Drivetrain:

Standard Symmetrical All-Wheel Drive (AWD)

Body Style:

Wagon/SUV crossover

Ground Clearance:

Elevated for light off-road capability

📋 Manual Details

Coverage Areas

Diagnostic Troubleshooting:

Comprehensive

Maintenance Procedures:

Detailed

Repair Operations:

Step-by-step

Component Overhaul:

Complete

Wiring Diagrams:

Included

Page Count

Estimated Pages:

~1500-2000

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, pistons, crankshaft, valve train, lubrication system, cooling system

Engine Fuel System:

Fuel injection, fuel pump, injectors, pressure regulator, EVAP system

Engine Ignition System:

Ignition coils, spark plugs, timing, ECU control

Engine Emissions Control:

Catalytic converter, O2 sensors, EGR system

Transmission Manual:

Clutch, gearbox, shift linkages, internal components, fluid specifications

Transmission Automatic:

Torque converter, valve body, planetary gears, hydraulic system, electronic control unit (ECU), fluid specifications

Drivetrain AWD:

Center differential, viscous coupling, driveshafts, rear differential, fluid specifications

Suspension Front:

MacPherson struts, control arms, sway bar, bushings, alignment specifications

Suspension Rear:

Multi-link independent suspension, trailing arms, springs, dampers, alignment specifications

Brakes Front:

Disc brakes, calipers, rotors, brake pads, ABS components

Brakes Rear:

Disc brakes (standard), calipers, rotors, brake pads, parking brake mechanism, ABS components

Steering System:

Power steering rack and pinion, pump, fluid specifications, tie rods, steering column

Electrical System:

Battery, alternator, starter, fuses, relays, wiring harness routing

Lighting System:

Headlights, taillights, interior lights, bulb types, wiring

HVAC System:

Air conditioning, heater core, blower motor, climate control panel, refrigerant type

Body Exterior:

Body panels, doors, hood, tailgate, bumpers, glass, seals

Body Interior:

Seats, dashboard, trim panels, headliner, carpet, safety belts

Chassis Frame:

Frame structure, body mounting points, rust prevention

Wheels Tires:

Tire sizes, wheel specifications, bolt patterns, pressure recommendations

Procedures Included

Oil Change Interval:

Every 3,750 miles or 6 months

Air Filter Replacement:

Every 15,000 miles or 12 months

Spark Plug Replacement:

Every 30,000 miles

Coolant Flush Interval:

Every 30,000 miles or 24 months

Transmission Fluid Change Interval:

Manual: 60,000 miles; Automatic: 30,000 miles (severe use) / 60,000 miles (normal use)

Brake Fluid Change Interval:

Every 30,000 miles or 24 months

Timing Belt Replacement:

70,000-105,000 miles (refer to specific engine variant)

Diagnostics:

OBD-II scan, DTC (Diagnostic Trouble Code) interpretation, sensor testing, component testing

Troubleshooting Guides:

System-specific symptom-based troubleshooting charts

Engine Rebuild:

Torque specifications, clearances, assembly procedures

Transmission Overhaul:

Component replacement, seal installation, calibration

Suspension Alignment:

Front and rear alignment angles, caster, camber, toe

Brake Service:

Pad replacement, rotor resurfacing/replacement, caliper service, bleeding procedures

Electrical Component Replacement:

Alternator, starter, power steering pump, HVAC blower motor

Body Panel Replacement:

Door replacement, fender replacement, tailgate repair

Interior Trim Removal:

Dashboard removal, door panel removal, center console removal

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds)

📊 Manual Specifications

File Format

PDF Searchability:

High (text-searchable)

Resolution:

High (clear diagrams and text)

Print Quality

Printability:

Printable (allows users to print specific sections or the entire manual)

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Displacement Primary:

2.5 Liters (2498 cc)

Engine Configuration Primary:

Horizontally-opposed (Boxer) SOHC 4-cylinder

Horsepower Primary:

165 hp @ 5,600 rpm

Torque Primary:

166 lb-ft @ 4,000 rpm

Optional Engine

Engine Displacement Optional:

2.5 Liters (2457 cc)

Engine Configuration Optional:

Horizontally-opposed (Boxer) DOHC 4-cylinder Turbocharged (EJ255)

Horsepower Optional:

210 hp @ 5,600 rpm (XT model)

Torque Optional:

235 lb-ft @ 3,000 rpm (XT model)

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Delivery:

Multi-point fuel injection (MPI)

Recommended Octane:

87 octane (91 for XT model)

🔧 Transmission

Standard

Type Standard:

5-speed Manual Transmission

Optional

Type Optional:

4-speed Automatic Transmission (with overdrive)

Features

AWD Integration:

Integrated with Symmetrical AWD system

Fluid Type Manual:

Subaru Extra-S Synthetic Gear Oil API GL-5 75W-90 or equivalent

Fluid Type Automatic:

Subaru ATF-HP (High Performance) or equivalent

📐 Dimensions

Exterior

Length:

179.5 inches

Width:

69.7 inches

Height:

63.0 inches

Wheelbase:

103.0 inches

Ground Clearance:

8.0 inches

Cargo

Cargo Volume Behind Rear Seat:

32.1 cubic feet

Cargo Volume With Rear Seat Folded:

63.0 cubic feet

Weights

Curb Weight Manual:

~3,250 lbs

Curb Weight Automatic:

~3,350 lbs

Towing Capacity:

2,400 lbs

🛡️ Safety Features

Ratings

NHTSA Frontal Impact Driver:

5-star

NHTSA Frontal Impact Passenger:

5-star

NHTSA Side Impact Front Driver:

4-star

NHTSA Side Impact Front Passenger:

4-star

IIHS Frontal Offset Score:

Active Features

Standard Anti-lock Braking System

Traction Control:

Available (on some models/trims)

Passive Features

Airbags Front:

Dual front airbags

Airbags Side:

Available front side-impact airbags (on some models/trims)

Seatbelts:

3-point front and rear seatbelts, pre-tensioners

💡 Technology Features

Infotainment

Head Unit:

Factory AM/FM/CD player with optional premium audio system

Display:

Basic LCD display for clock and radio information

Driver Assistance

Cruise Control:

Standard

Anti Lock Brakes:

Standard

Connectivity

Auxiliary Input:

Not standard, aftermarket options available

Bluetooth:

Not standard, aftermarket options available

🔧 Maintenance

Service Intervals

Oil Change Frequency:

3,750 miles / 6 months

Tire Rotation Frequency:

7,500 miles / 6 months

Brake Inspection Frequency:

Every 15,000 miles

Fluid Specifications

Engine Oil Type:

SAE 5W-30 (Synthetic recommended)

Engine Oil Capacity:

4.5 US quarts (4.3 liters) with filter

Coolant Type:

Subaru Super Coolant (Blue) or equivalent silicate-free, long-life coolant

Coolant Capacity:

6.7 US quarts (6.3 liters)

Power Steering Fluid:

ATF Dexron III or equivalent

Known Issues

Head Gaskets:

While less common on the EJ253 compared to earlier generations, head gasket leaks can still occur over time. Look for coolant loss or white smoke from the exhaust.

Wheel Bearings:

Front wheel bearings can be a wear item, especially with AWD and mileage. Listen for humming or grinding noises.

Cv Axles:

Front CV boots can tear, leading to grease loss and potential CV joint damage. Inspect for cracking or torn boots.

Exhaust Manifold Cracks:

Some EJ engines can develop cracks in the exhaust manifolds due to thermal cycling. Listen for exhaust leaks or ticking sounds.

Rear Differential Clunking:

Sometimes associated with worn bushings or minor play in the differential. Proper fluid changes are important.

📚 Vehicle History

Brand Heritage

Manufacturer:

Subaru Corporation (Japan)

Specialty:

Known for Symmetrical AWD and Boxer engines

Model Evolution

Generation Start Year:

Second Generation Launch Year:

Design Changes 2002:

All-new platform, larger dimensions, improved styling, updated powertrains, increased interior space

Production

Manufacturing Location:

Gunma Prefecture, Japan

🏆 Awards & Recognition

Recognitions

Car And Driver All Wheel Drive SUV Comparison:

Often praised for its standard AWD and utility in comparisons

Iiihs Top Safety Pick Legacy:

While not directly for the 2002 Forester, Subaru's consistent safety performance built brand reputation.