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SUBARU FORESTER Service Repair Manual 99-02

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🏷️ Basic Information Identification Make: Subaru Model: Forester Years Covered: 1999-2002 Generation: SF Series (Second Generation) Codes Chassis Codes: SF5, SF9 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV...
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SUBARU FORESTER Service Repair Manual 99-02
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Years Covered:
1999-2002
Generation:
SF Series (Second Generation)
Codes
Chassis Codes:
SF5, SF9
👋 Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV / Station Wagon
Key Selling Points:
Standard Symmetrical All-Wheel Drive, practicality, cargo space, good visibility, robust build quality.
Competitive Analysis
Competitors 1999-2002:
Honda CR-V, Toyota RAV4, Ford Escape, Mazda Tribute, Nissan Xterra.
Key Features
Powertrain Emphasis:
Subaru's signature Boxer engine and Symmetrical AWD system.
Utility Focus:
Designed for active lifestyles, offering versatility and capability beyond typical sedans.
📋 Manual Details
Coverage Areas
Engine Variants Covered:
2.5L EJ25 SOHC & DOHC Naturally Aspirated & Turbocharged (EJ251, EJ253, EJ255, EJ205)
Transmission Variants Covered:
4-speed Automatic (4EAT), 5-speed Manual
Drivetrain Variants Covered:
Symmetrical All-Wheel Drive (AWD)
Page Count
Estimated Pages:
Hundreds (specific count not provided, but indicative of comprehensive coverage)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, lubrication, cooling, fuel injection, ignition, emissions, diagnostics, timing belt replacement, piston/ring/valve service, cylinder head overhaul
Transmission:
Automatic Transmission (4EAT) overhaul, maintenance, diagnostics, valve body repair, torque converter; Manual Transmission overhaul, maintenance, diagnostics, clutch service
Drivetrain:
Front axle, rear axle, driveshafts, differentials, propeller shaft, AWD system components
Suspension:
Front struts/coil springs, rear struts/coil springs, control arms, ball joints, bushings, sway bars, wheel bearings
Brakes:
Front disc brakes, rear disc/drum brakes (depending on model/trim), ABS system (if equipped), brake fluid specifications, caliper, rotor, pad service, bleeding procedures
Steering:
Power steering system, steering rack, tie rod ends, steering column
Electrical:
Battery, charging system (alternator), starting system (starter), lighting, instrumentation, power accessories, wiring diagrams, fuse box locations, ECU/ECM diagnostics
HVAC:
Air conditioning system, heater core, blower motor, refrigerant handling, cabin air filter replacement
Body:
Exterior panels, interior trim, doors, glass, sunroof, body sealing, paint repair guidance
Chassis And Frame:
Frame construction, unibody structure, corrosion protection
Procedures Included
Maintenance:
Oil change, filter replacement, fluid checks and changes (coolant, brake, power steering, transmission), spark plug replacement, air filter replacement, timing belt inspection/replacement, tune-up procedures
Diagnostics:
Troubleshooting guides for common problems, diagnostic trouble codes (DTCs), on-board diagnostics (OBD-I/OBD-II), symptom-based troubleshooting
Repair:
Component removal, installation, overhaul, and replacement for all major systems
Rebuild:
Engine rebuilding, transmission rebuilding, differential rebuilds
Adjustment:
Valve clearance adjustment, parking brake adjustment
Troubleshooting Specifics:
Detailed steps for diagnosing and repairing issues related to starting, running rough, overheating, transmission slippage, electrical faults, etc.
Technical Depth
Level:
Comprehensive Professional Level: Covers everything from basic routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.
Diagrams Included:
Detailed schematics, wiring diagrams, exploded views, torque specifications, and step-by-step illustrated repair procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (standard for high-quality PDF manuals)
Print Quality
Clarity:
High-resolution digital scans, ensuring clarity of text and diagrams.
Binding Type
Binding:
N/A (Digital PDF Format)
Paper Type
Paper Quality:
N/A (Digital PDF Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Base:
EJ25
Engine Displacement Base:
2.5 Liters (2457 cc)
Engine Configuration Base:
Horizontally-opposed (Boxer), 4-cylinder, SOHC
Performance
Horsepower Base Na:
Approx. 165 hp @ 5,500-6,000 rpm (EJ251/EJ253)
Torque Base Na:
Approx. 162 lb-ft @ 4,000 rpm (EJ251/EJ253)
Horsepower Turbocharged:
Approx. 210-220 hp @ 5,600-6,000 rpm (EJ205/EJ255 - WRX/GT models, often included in performance manuals)
Torque Turbocharged:
Approx. 236-250 lb-ft @ 3,000-4,000 rpm (EJ205/EJ255)
Fuel System
Fuel Delivery:
Electronic Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane recommended for NA, 91+ for Turbocharged)
Engine Components
Timing System:
Timing Belt (requiring periodic replacement)
Engine Management:
ECU (Engine Control Unit) / ECM (Engine Control Module)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission (4EAT) with Lock-up Torque Converter
Features
AWD Integration:
Integrated with Subaru's Symmetrical All-Wheel Drive system. Manual transmissions typically featured a viscous coupling center differential, while automatics used an electronically controlled multi-plate clutch AWD system.
Fluid Specifications
Manual Transmission Fluid:
Subaru Extra-S Gear Oil (or equivalent API GL-5, SAE 75W-90)
Automatic Transmission Fluid:
Subaru ATF HP (or equivalent Dexron-III/Mercon)
📐 Dimensions
Exterior
Length:
Approx. 175.6 inches (4460 mm)
Width:
Approx. 66.7 inches (1695 mm)
Height:
Approx. 63.0 inches (1600 mm)
Wheelbase:
Approx. 103.0 inches (2615 mm)
Weights
Curb Weight Base:
Approx. 3,100 - 3,300 lbs (1400 - 1500 kg) depending on trim and transmission
Cargo
Cargo Volume Rear Seats Up:
Approx. 30.0 cu ft (850 L)
Cargo Volume Rear Seats Folded:
Approx. 67.0 cu ft (1900 L)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4-star (for models equipped with airbags)
NHTSA Front Impact Passenger:
4-star (for models equipped with airbags)
Active Features
Braking System:
Standard 4-wheel disc brakes on most trims; some base models may have rear drums. Optional Anti-lock Braking System (ABS).
Traction Control:
Not commonly available on this generation, AWD is the primary traction enhancement.
Passive Features
Airbags:
Driver and front passenger airbags standard on most models.
Seatbelts:
3-point front and rear seat belts, driver's seat belt pretensioner.
💡 Technology Features
Infotainment
Audio System:
Typically a 1-DIN or 2-DIN AM/FM stereo with CD player. Some models offered premium audio systems.
Navigation:
Rarely offered, if at all, on this generation. Aftermarket solutions were more common.
Driver Assistance
Cruise Control:
Standard on most trims.
Power Features:
Power windows, power door locks, power mirrors were common options or standard on higher trims.
Connectivity
Auxiliary Input:
Not standard; often required aftermarket modification for audio device connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months, whichever comes first (under normal driving conditions).
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 60 months (critical maintenance item to prevent catastrophic engine damage).
Engine Coolant Change:
Initially at 30,000 miles (48,000 km) or 24 months, then every 15,000 miles (24,000 km) or 12 months thereafter.
Transmission Fluid Change Auto:
Every 30,000 miles (48,000 km) or 24 months.
Transmission Fluid Change Manual:
Every 60,000 miles (96,000 km) or 48 months.
Fluid Specifications
Engine Oil Spec:
API SJ or higher, ILSAC GF-2, SAE 5W-30 (preferred) or 10W-30.
Engine Oil Capacity:
Approx. 4.8 US quarts (4.5 L) with filter change.
Coolant Type:
Subaru Super Coolant (Blue) or equivalent silicate-free, long-life ethylene glycol based coolant.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Head Gaskets:
While less prevalent than in later generations with the EJ25, some early EJ25 engines can experience head gasket leaks. The manual will detail inspection and replacement procedures.
Automatic Transmission:
The 4EAT can sometimes develop issues with solenoids or valve bodies, particularly with delayed engagement or rough shifts. The manual's diagnostic section is crucial here.
Suspension Wear:
Worn bushings, ball joints, and wheel bearings are common wear items on higher mileage vehicles of this era. The manual provides specs for replacement.
📚 Vehicle History
Brand Heritage
Subaru Legacy Connection:
Based on the Subaru Impreza/Legacy platform, sharing many components and engineering principles.
Model Evolution
Generation Launch:
The second generation (SF Series facelift) was introduced for the 1998 model year in Japan and globally for 1999.
Design Changes Vs First Gen:
Updated exterior styling, revised interior, improved NVH (Noise, Vibration, Harshness), and some powertrain enhancements.
Production
Manufacturing Location:
Gunma Plant, Japan
🏆 Awards & Recognition
Recognitions
Car And Driver Щения:
Often featured in '10Best' lists for SUVs or all-around vehicles during its production run, praised for its AWD system and utility.
Ratings
Ieda Safety Awards:
Subaru vehicles of this era were generally well-regarded for their build quality and safety, though specific awards might vary by year and region.
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