Subaru Forester 1999-2002 WSM Service Manual Repair

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🏷️ Basic Information Identification Make: Subaru Model: Forester Model Generation: First Generation (SF) Applicable Years: 1999, 2000, 2001, 2002 Codes Chassis Codes: SF5, SF9 👋 Introduction Market Position Vehicle Segment:...

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标签: 1999 2000 2001 2002 Car Cars Forester Misc Subaru

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Description

🏷️ Basic Information

Identification

Make:

Subaru

Model:

Forester

Model Generation:

First Generation (SF)

Applicable Years:

1999, 2000, 2001, 2002

Codes

Chassis Codes:

SF5, SF9

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Crossover

Unique Selling Proposition:

Standard Symmetrical All-Wheel Drive, practicality, go-anywhere capability

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Nissan Xterra, Ford Escape

Key Features

Powertrain Philosophy:

Horizontally-opposed 'Boxer' engines for a lower center of gravity

Drivetrain:

Symmetrical All-Wheel Drive (standard on most trims)

Suspension Design:

Independent strut front, multi-link rear for comfortable ride and handling

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Workshop Manual (WSM)

Language:

English

Format:

Digital Download (likely PDF)

Coverage Scope:

Comprehensive repair and service information

Page Count

Estimated Page Count:

Approximately 1500-2500 pages (typical for factory WSM)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, timing belt, lubrication, cooling system

Engine Management:

Fuel injection system, ignition system, emissions control, ECU diagnostics, sensor data

Transmission Manual:

Clutch, gearbox overhaul, gear ratios, shift mechanisms, fluid specifications

Transmission Automatic:

ATF specifications, torque converter, valve body, hydraulic control, transmission overhaul

Drivetrain:

All-Wheel Drive (AWD) system, front differential, rear differential, driveshafts, CV joints

Suspension:

Front and rear suspension components, springs, shock absorbers, control arms, wheel alignment specifications

Steering:

Power steering system, steering rack, tie rods, steering column

Brakes:

Brake system components (front and rear), hydraulic lines, ABS system, brake fluid specifications, rotor and pad replacement

Electrical System:

Battery, charging system, starter, lighting, ignition, power distribution, wiring diagrams

Body And Chassis:

Body panel removal and installation, interior trim, glass replacement, chassis lubrication

HVAC:

Heating, ventilation, and air conditioning system diagnosis and repair

Body Electronics:

Power windows, power locks, remote keyless entry, security system

Diagnostics:

OBD-II diagnostic trouble codes (DTCs), troubleshooting flowcharts, diagnostic procedures

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection

Major Repairs:

Engine rebuild, transmission overhaul, differential repair, suspension component replacement

Troubleshooting:

Step-by-step diagnostic guides for common and complex issues

Component Replacement:

Detailed instructions for replacing all major and minor vehicle components

Electrical Diagnostics:

Using multimeters, oscilloscopes, and diagnostic tools for electrical faults

Wiring Diagrams:

Complete and detailed wiring schematics for all vehicle systems

Technical Depth

Depth:

Factory-level detail, suitable for professional technicians and experienced DIY enthusiasts

Diagnostic Procedures:

Includes specific diagnostic routines and expected values

Torque Specifications:

All critical torque values for fasteners and assemblies

Clearances And Tolerances:

Specific measurement guidelines for engine and mechanical components

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Searchability:

Text-searchable for quick information retrieval

Printability:

Printable pages for on-the-job use

Print Quality

Image Resolution:

High-resolution images and diagrams

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

EJ251 (2.5L SOHC)

Engine Type 1:

2.5 Liter Flat-4 (Boxer), Naturally Aspirated, SOHC

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 @ 5600 rpm

Torque 1:

166 lb-ft @ 4000 rpm

Secondary Engine

Engine Code 2:

EJ25D (2.5L DOHC - early 99 models, rare)

Engine Type 2:

2.5 Liter Flat-4 (Boxer), Naturally Aspirated, DOHC

Horsepower 2:

165 hp @ 5600 rpm

Torque 2:

162 lb-ft @ 4000 rpm

Performance

0-60 Mph Approx:

8.0 - 9.5 seconds (depending on transmission and trim)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline, 87 octane recommended

Fuel Tank Capacity:

60 Liters (15.8 US gallons)

🔧 Transmission

Standard

Transmission Type Standard:

5-Speed Manual Transmission

Optional

Transmission Type Optional:

4-Speed Automatic Transmission (4EAT)

Features

AWD System Manual:

Continuous All-Wheel Drive (CAWD) with viscous coupling center differential

AWD System Automatic:

Active Automatic All-Wheel Drive (with electronically controlled clutch pack)

Fluid Specifications

Manual Transmission Fluid:

Subaru Gear Oil GL-5 75W-90 (or equivalent)

Automatic Transmission Fluid:

Subaru ATF-HP (or Dexron-III compatible)

📐 Dimensions

Exterior

Length:

4,410 mm (173.6 in)

Width:

1,735 mm (68.3 in)

Height:

1,620 mm (63.8 in) (without roof rails)

Wheelbase:

2,510 mm (98.8 in)

Ground Clearance:

200 mm (7.9 in)

Wheel Base Pattern:

5x100 mm

Interior

Seating Capacity:

5 passengers

Cargo

Cargo Volume Rear Seats Up:

Approximately 64.5 cubic feet (with rear seats folded)

Weights

Curb Weight Approx:

1400 - 1550 kg (3086 - 3417 lbs) (depending on configuration)

Towing Capacity Max:

1000 kg (2200 lbs) (with optional tow package)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4/5 Stars (1999-2002 models)

NHTSA Front Impact Passenger:

4/5 Stars (1999-2002 models)

IIHS Side Impact:

Acceptable (models with side airbags, not standard)

Active Features

Standard Anti-lock Braking System (ABS) on most trims

Standard Symmetrical All-Wheel Drive for enhanced traction

Passive Features

Airbags:

Dual front airbags standard; optional side airbags on select trims

Seatbelts:

3-point height-adjustable front seatbelts with pretensioners

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM stereo with CD player or cassette tape player, optional premium audio

Display:

Basic analog gauges, digital odometer

Driver Assistance

Cruise Control:

Standard on most trims

Traction Control:

Not typically available on this generation

Connectivity

Aux Input:

Not standard, requires aftermarket adapter

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 3 months (whichever comes first), or 7,500 miles (12,000 km) or 6 months with synthetic oil (check manual for specific recommendation)

Engine Oil Filter:

Replace at every oil change

Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed

Spark Plugs:

Replace every 60,000 miles (96,000 km) (NGK Platinum recommended)

Timing Belt:

Replace every 105,000 miles (168,000 km) or 105 months. Crucial item, failure can cause catastrophic engine damage.

Coolant Flush:

Every 30,000 miles (48,000 km) or 24 months

Fluid Specifications

Engine Oil Type Capacity:

API SG or SH, SAE 5W-30. Capacity: 4.5 Liters (4.8 US Quarts) with filter

Brake Fluid:

DOT 3 or DOT 4

Power Steering Fluid:

Subaru All-Season Synthetic Power Steering Fluid or equivalent (Dexron-III is sometimes used but check specific model recommendations)

Known Issues

Head Gaskets:

Potential for coolant leaks due to degrading head gasket seals, especially on higher mileage DOHC engines (less common on SOHC EJ251, but still possible).

Timing Belt Tensioner:

Tensioner bearing failure can occur, leading to belt slippage or failure. Replace with tensioner when changing belt.

Wheel Bearings:

Front wheel bearings can wear prematurely, causing humming or grinding noises.

Ac Compressor Clutch:

AC clutch failure can result in loss of cooling.

Exhaust Manifold Cracks:

Exhaust manifold can develop cracks, leading to exhaust leaks and ticking noises.

📚 Vehicle History

Brand Heritage

Subaru Identity:

Known for its commitment to All-Wheel Drive technology and reliable, practical vehicles

Model Evolution

First Generation Launch:

Introduced in 1997 in Japan, North American debut in 1998 for the 1999 model year

Sf Generation Design:

Characterized by its high beltline, rugged styling, and wagon-like profile

Updates During Generation:

Minor styling updates and equipment changes occurred throughout the 1999-2002 model years

Production

Manufacturing Location:

Gunma Plant, Japan

🏆 Awards & Recognition

Recognitions

Consumer Guide Best Buy:

Often cited as a 'Best Buy' in its segment for its AWD and utility by publications like Consumer Guide Automotive.

Icam Safety Award:

Subaru vehicles frequently recognized for safety by the Insurance Institute for Highway Safety (IIHS) in the early 2000s.

Certifications

Vehicle Type:

Certified as a compact SUV/Crossover with off-road capabilities due to AWD and ground clearance.