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Subaru Forester 2002 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Subaru Model: Forester Year: 2002 Body Style: Compact SUV/Crossover Generation Generation Code: SF/SG (Transition Year) Generation Description: The 2002 model year marks a significant transition...
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Subaru Forester 2002 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Subaru
Model:
Forester
Year:
2002
Body Style:
Compact SUV/Crossover
Generation
Generation Code:
SF/SG (Transition Year)
Generation Description:
The 2002 model year marks a significant transition from the first generation (SF) to the second generation (SG) Subaru Forester. While many elements might carry over from the SF, the SG generation introduced styling updates and powertrain refinements.
Codes
Chassis Code:
Likely SG5 for Naturally Aspirated, SG9 for Turbocharged models (common for this generation transition)
👋 Introduction
Market Position
Market Position:
The Subaru Forester has historically positioned itself as a capable and practical compact SUV with a strong emphasis on all-wheel-drive performance and utility. The 2002 model continued this trend, appealing to buyers seeking versatility for outdoor activities and everyday driving in various weather conditions.
Competitive Analysis
Competitive Analysis:
Competed against vehicles like the Toyota RAV4, Honda CR-V, Ford Escape, and Nissan Xterra. Its Symmetrical All-Wheel Drive system and boxer engine provided a distinct advantage in handling and stability, particularly in adverse weather.
Key Features
Key Features:
Standard Symmetrical All-Wheel Drive, distinctive wagon-like SUV styling, robust boxer engine, good visibility, practical interior space, and Subaru's reputation for durability.
📋 Manual Details
Coverage Areas
Coverage Areas General:
Comprehensive repair, maintenance, diagnostics, and troubleshooting for the 2002 Subaru Forester.
Page Count
Page Count:
Estimated 1000+ pages (typical for a full workshop manual)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF) - Likely searchable and printable
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanicals (including EJ25 SOHC, EJ25 DOHC, and potentially EJ20 Turbo), Engine control systems (ECU, sensors, actuators), Fuel system, Ignition system, Cooling system, Lubrication system, Exhaust system, Transmission (manual & automatic), Drivetrain (AWD system, differentials, drive shafts), Brakes (ABS, hydraulic, parking), Steering system, Suspension (front & rear), Electrical system (wiring diagrams, lighting, accessories, charging, starting), Bodywork and exterior, Interior trim and accessories, Climate control (HVAC), Safety systems (airbags, seatbelts), Diagnostic procedures and trouble codes (DTCs).
Procedures Included
Procedures Included:
Scheduled maintenance, routine servicing, disassembly and reassembly of all major components, diagnostic troubleshooting, repair procedures for common failures, component testing, electrical diagnostics, body panel replacement, interior trim removal, fluid changes and flushes, torque specifications, alignment procedures, engine tuning, clutch replacement, brake pad/rotor replacement, suspension component replacement, heating and cooling system servicing.
Technical Depth
Technical Depth:
In-depth technical information suitable for professional technicians and advanced DIY mechanics. Covers everything from basic fluid changes to complete engine and transmission rebuilds, including detailed diagnostic trees and component testing methods.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution, clear text and diagrams for easy reading and printing.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
2.5L Naturally Aspirated EJ25 SOHC/DOHC
Performance
Horsepower Na:
Approximately 165 hp (for SOHC EJ25) to 175 hp (for DOHC EJ25, depending on market and specific version)
Torque Na:
Approximately 166 lb-ft (for SOHC EJ25) to 177 lb-ft (for DOHC EJ25)
Engine Variant Turbo:
2.0L Turbocharged EJ20 (likely for specific markets, e.g., Japan, or performance trims like STI variants if applicable in this year's global lineup).
Horsepower Turbo:
Varies by turbo model; could range from 210 hp to 250 hp for the EJ20 Turbo.
Torque Turbo:
Varies by turbo model; could range from 235 lb-ft to 280 lb-ft for the EJ20 Turbo.
Fuel System
Fuel System Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline
Engine Layout
Engine Layout:
Horizontally-opposed (Boxer)
Engine Configuration:
4-cylinder
Engine Details
Compression Ratio:
Typical 9.5:1 to 10.7:1 depending on SOHC/DOHC and specific tune.
Bore X Stroke:
For EJ25: 99.5 mm x 79.0 mm
🔧 Transmission
Standard
Transmission Standard:
5-speed Manual Transmission (M/T)
Optional
Transmission Optional:
4-speed Automatic Transmission (A/T)
Features
AWD System:
Subaru Symmetrical All-Wheel Drive (standard on all models)
Manual Transmission AWD Coupling:
Viscous center coupling
Automatic Transmission AWD Coupling:
Active All-Wheel Drive with electronically controlled multi-plate transfer clutch
Fluid Specs
Manual Transmission Fluid:
API GL-5, SAE 75W-90 Gear Oil (Subaru Extra-S or equivalent)
Automatic Transmission Fluid:
Subaru ATF-HP (Genuine Subaru)
📐 Dimensions
Exterior
Length:
Approx. 177.0 - 177.4 inches (depending on trim/minor updates)
Width:
Approx. 69.7 inches
Height:
Approx. 63.0 - 63.2 inches
Wheelbase:
Approx. 103.0 inches
Weights
Curb Weight:
Approx. 3,100 - 3,400 lbs (depending on configuration)
Cargo
Cargo Volume Behind Rear Seats:
Approx. 30.1 - 32.0 cubic feet
Cargo Volume With Rear Seats Folded:
Approx. 67.7 - 71.9 cubic feet
Wheels
Wheel Bolt Pattern:
5x100
Wheel Size:
Typically 15-inch or 16-inch alloy wheels
Tires
Tire Size:
Commonly 215/60R16 or 215/70R15
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Likely 4/5 Stars (based on similar models from this era)
NHTSA Front Impact Passenger:
Likely 4/5 Stars
IIHS Front Offset Impact:
Good (for models tested in this generation)
Active Features
Active Features:
Symmetrical All-Wheel Drive, Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD)
Passive Features
Passive Features:
Front airbags, Side airbags (optional on some trims), 3-point seatbelts with pre-tensioners, Child safety seat anchors (LATCH).
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM/CD player. Cassette player might be present on some base models. Optional premium audio systems were available.
Display Type:
No central infotainment screen; basic climate and audio controls.
Driver Assistance
Driver Assistance Features:
Limited driver assistance features by modern standards. Primarily focused on the AWD system for traction and stability. Cruise control was common.
Connectivity
Connectivity Options:
No integrated Bluetooth or USB connectivity. Aftermarket head units are a common upgrade.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe conditions), or 7,500 miles/12 months (normal conditions), using synthetic oil.
Engine Air Filter Replacement:
Every 15,000 - 30,000 miles, or as needed based on driving conditions.
Cabin Air Filter Replacement:
Every 15,000 miles or 1 year.
Spark Plug Replacement:
Around 60,000 miles for standard plugs; Platinum/Iridium plugs can last longer (check manual for specific type).
Timing Belt Replacement:
Critical: Around 100,000 miles or 105 months for EJ25 engines. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (preferred) or 10W-30. Always check oil cap or manual for exact viscosity.
Engine Oil Capacity:
Approx. 4.8 US quarts (4.5 Liters) with filter change for EJ25.
Coolant Type:
Subaru Super Coolant (Blue) or equivalent for Subaru vehicles. Do NOT mix with other colors.
Coolant Capacity:
Approx. 7.0 - 7.4 US quarts (6.6 - 7.0 Liters)
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid:
Genuine Subaru Power Steering Fluid or DEXRON II/III ATF.
Known Issues
Known Issues:
Head gasket leaks (especially on earlier EJ25 engines), catalytic converter failure, wheel bearing wear, occasional transmission issues (especially with neglect), minor rust on common areas, possible sludge buildup if oil changes are neglected.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Subaru, a division of Fuji Heavy Industries, has a long history of producing reliable and capable vehicles, particularly known for its pioneering use of the boxer engine and Symmetrical All-Wheel Drive system. This heritage is deeply embedded in the Forester's design philosophy.
Model Evolution
Model Evolution:
Introduced in 1997 as the first generation (SF), the Forester combined the utility of an SUV with the driving dynamics of a car. The 2002 model year represents the cusp of the second generation (SG), which brought a more sculpted exterior, improved interior amenities, and updated powertrains. Key changes from the SF to SG include revised styling, a slightly longer wheelbase, and often more refined interior materials.
Production
Production Years:
First Generation (SF): 1997-2002; Second Generation (SG): 2003-2008. The 2002 model is the final year of the first generation or a transitional model leading into the second.
Manufacturing Locations:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Recognitions:
Subaru Forester models from this era often received positive reviews for their practicality, AWD capability, and value, though specific awards for the 2002 model year should be verified against automotive press archives.
Ratings
Ratings:
Consumer satisfaction ratings were generally good, with praise for reliability and AWD performance.
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