Subaru Forester 2002 User Manual

2002 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX SUPPLEMENT

This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUBARU vehicles. This manual includes the procedures for maintenance, disassembling, reassembling, inspection and adjustment of components and diagnostics for guidance of experienced mechanics. Please peruse and utilize this manual fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition. When replacement of parts during repair work is needed, be sure to use SUBARU genuine parts.

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD.

G8060GE

SPECIFICATIONS

1. Forester.......................................................................................................2

SPC

Page

Specifications

1. Forester SA08758

A: DIMENSIONS SA08758G28

Model 2.0 L Non-TURBO 2.0 L TURBO Overall length mm (in) 4,460 (175.6), 4,530 (178.3)*1 Overall width mm (in) 1,735 (68.3), 1,765 (69.5)*2 Overall height (at CW) mm (in) 1,595 (62.8) 1,585 (62.4) Compartment Length mm (in) 1,745 (68.7)

Width mm (in) 1,435 (56.5)

Height mm (in) 1,245 (49.0), 1,220 (48.0)*3 Wheelbase mm (in) 2,525 (99.4) Tread Front mm (in) 1,475 (58.1)

Rear mm (in) 1,465 (57.7) Minimum road clearance mm (in) 190 (7.5), 200 (7.9)*4

*1: With bushing bar *2: With fender flare *3: With sunroof *4: Australia spec. vehicles

B: ENGINE SA08758G29

FORESTER

Model 2.0 L Non-TURBO 2.0 L TURBO Engine type Horizontally opposed, liquid cooled, 4-cylinder, 4-stroke gasoline engine Valve arrangement Overhead camshaft type Bore × Stroke mm (in) 92 × 75 (3.62 × 2.95) Displacement cm Compression ratio 10.0 8.0 Firing order 1 — 3 — 2 — 4 Idle speed at Park/

Neutral position

Maximum output kW (HP)/rpm 92 (123)/5,600 130 (174)/5,600 Maximum torque N·m (kgf-m, ft-lb)/rpm 184 (18.8, 136)/3,600 245 (25, 181)/3,200

*1: Without OBD *2: Australia spec. vehicle

(cu in) 1,994 (121.67)

rpm 700±100

MT: 650±100*1

AT: 675±100*1

700±100

240 (24.5, 177)/3,200*2

C: ELECTRICAL SA08758G30

Model 2.0 L Non-TURBO 2.0 L TURBO Ignition timing at idling speed BTDC/rpm 10°±10°/700

MT: 10°±10°/650*1

AT: 10°±10°/675*1

Spark plug Type and manufacturer CHAMPION: RC10YC4 (with catalyst)

NGK: BKR6E (without catalyst)

NGK: BKR5E-11 (with catalyst) Generator 12 V — 75 A Battery Type and capacity

(5HR)

*1: Without OBD

For Europe 5MT: 12 V — 48AH

4AT: 12 V — 52AH For Australia 12 V — 40AH Others 12 V — 40AH

12°±10°/700

NGK: PFR6G

SPC-2

FORESTER

Specifications

D: TRANSMISSION SA08758G31

Model 2.0 L Non-TURBO 2.0 L TURBO

AWD Transmission type 5MT*1 4AT*2 5MT*3 4AT*2 Clutch type DSPD TCC DSPD TCC Gear ratio 1st 3.454 2.785 3.454 2.785

2nd 2.062 1.545 1.947 1.545 3rd 1.448 1.000 1.366 1.000 4th 1.088 0.694 0.972 0.694 5th 0.871 — 0.738 — Reverse 3.333 2.272 3.333 2.272

Auxiliary transmission gear ratio High 1.000 ———

Low 1.447 ———

Reduction gear (Front drive)

Reduction gear (Rear drive)

5MT*1: 5 × 2 forward speeds with synchromesh and 1-reverse — with center differential and viscous coupling 4AT*2: Electronically controlled fully-automatic, 4-forward speeds and 1-reverse — with hydraulically controlled transfer clutch 5MT*3: 5-forward speeds with synchromesh and 1-reverse — with center differential and viscous coupling DSPD: Dry Single Plate Diaphragm TCC: Torque Converter Clutch *4: For Europe *5: Others

1st reduction Type of gear — Helical — Helical

Gear ratio — 1.000 — 1.000

Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid

Gear ratio 4.111 4.444 4.444 4.111

Transfer reduction

Final reduction Type of gear Hypoid Hypoid Hypoid Hypoid

Type of gear Hypoid — Hypoid — Gear ratio 1.000 — 1.081*4, 1.000*5 —

Gear ratio 4.111 4.444 4.111*4, 4.444*5 4.111

E: STEERING SA08758G32

Model LHD RHD Type Rack and Pinion Turns, lock to lock 3.4 3.0 Minimum turning circle m (ft) Curb to curb: 10.8 (35.4)

F: SUSPENSION SA08758G33

Front MacPherson strut type, Independent, Coil spring Rear Dual link strut type, Independent, Coil spring

SPC-3

Specifications

G: BRAKE SA08758G34

FORESTER

Model Australia spec. vehicles and 2000

TURBO Service brake system Dual circuit hydraulic with vacuum suspended power unit Front Ventilated disc brake Rear Disc brake Drum brake Parking brake Mechanical on rear brakes

Others

H: TIRE SA08758G35

Rim size 15 × 6J 16 × 61/2JJ Tire size 205/70R15 215/60R16 Type Steel belted radial, Tubeless

I: CAPACITY SA08758G36

Model 2.0 L Non-TURBO 2.0 L TURBO

AWD AWD

5MT 4AT 5MT 4AT Fuel tank  (US gal, Imp gal) 60 (15.9, 13.2) 60 (15.9, 13.2) Engine oil Upper level  (US qt, Imp qt) 4.5 (4.8, 4.0) 5.0 (5.3, 4.4)

Lower level  (US qt, Imp qt) 3.5 (3.7, 3.1) 4.0 (4.2, 3.5) Transmission gear oil  (US qt, Imp qt) 4.0 (4.2, 3.5) — 3.5 (3.7, 3.1) — Automatic transmission fluid  (US qt, Imp qt) — 8.4 (8.9, 7.4) — 9.3 (9.8, 8.2) AT differential gear oil  (US qt, Imp qt) — 1.2 (1.3, 1.1) — 1.2 (1.3, 1.1) AWD rear differential gear oil  (US qt, Imp qt) 0.8 (0.8, 0.7) 0.8 (0.8, 0.7) Power steering fluid  (US qt, Imp qt) 0.7 (0.7, 0.6) 0.7 (0.7, 0.6) Engine coolant  (US qt, Imp qt) 6.4 (6.8, 5.6) 6.3 (6.7, 5.5) 7.2 (7.6, 6.3) 7.2 (7.6, 6.3)

SPC-4

FORESTER

Specifications

J: WEIGHT SA08758G37

1. EXCEPT AUSTRALIA SPEC. VEHICLE SA08758G3706

Model 2.0 L Non-TURBO

AWD

LHD RHD

5MT 4AT 5MT 4AT

Curb weight (CW) Front kg (lb) 730 (1,610) 745 (1,643) 745 (1,643) 760 (1,676)

Rear kg (lb) 615 (1,356) 615 (1,356) 620 (1,367) 620 (1,367) Total kg (lb) 1,345 (2,966) 1,360 (2,999) 1,365 (3,010) 1,380 (3,043)

Maximum permissible axle weight (MPAW)

Maximum permissible weight (MPW)

Model 2.0 L TURBO

Curb weight (CW) Front kg (lb) 795 (1,753) 815 (1,797) 790 (1,742) 810 (1,786)

Maximum permissible axle weight (MPAW)

Maximum permissible weight (MPW)

NOTE: When any of the following optional parts are installed, add the weight to the curb weight.

Front kg (lb) 920 (2,029) 930 (2,051) 920 (2,029) 930 (2,051) Rear kg (lb) 990 (2,183) 990 (2,183) 990 (2,183) 990 (2,183) Total kg (lb) 1,875 (4,134) 1,890 (4,163) 1,875 (4,134) 1,890 (4,167)

AWD

LHD RHD

5MT 4AT 5MT 4AT

Rear kg (lb) 635 (1,400) 630 (1,389) 630 (1,389) 630 (1,389) Total kg (lb) 1,430 (3,153) 1,445 (3,186) 1,420 (3,131) 1,440 (3,175) Front kg (lb) 975 (2,150) 995 (2,195) 975 (2,150) 995 (2,195) Rear kg (lb) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225) 1,010 (2,225) Total kg (lb) 1,950 (4,300) 1,970 (4,344) 1,950 (4,300) 1,970 (4,344)

Weight of

optional

parts

Frontkg (lb) 10 (22) 11 (24) 2 (4) −1 (−2) 3.6 (7.9) 17 (38) 9 (20) 3 (7) 2 (4.4) 2 (4) 2.6 (5.7) Rear kg (lb) −1 (−2) −1 (−2) 0 (0) 2 (4) −1 (−2) −3 (−7) 14 (31) 2 (4) 2 (4.4) −1 (−2) 4.4 (9.7) Total kg (lb) 9 (20) 10 (22) 2 (4) 1 (2) 2.6 (5.7) 14 (31) 23 (51) 5 (11) 4 (8.8) 1 (2) 7.0

ABS (Turbo model)

ABS (NonTurbo

model)

Cruise control

Self-

levelizer

Fog

lamp

Air con-

ditioner

Sunroof SRS

airbag

(Driver &

Passen-

ger)

SRS airbag (Side)

Cold

weather

pack

Cold

weather

pack

(Leather

seat)

(15.4)

SPC-5

Specifications

FORESTER

2. AUSTRALIA SPEC. VEHICLE SA08758G3704

Model 2.0 L Non-TURBO 2.0 L TURBO

AWD AWD RHD RHD

5MT 4AT 5MT 4AT

Unladen mass (UM) Front kg (lb) 740 (1,632) 755 (1,665) 810 (1,786) 835 (1,841)

Rear kg (lb) 625 (1,378) 625 (1,378) 630 (1,389) 625 (1,378) Total kg (lb) 1,365 (3,010) 1,380 (3,043) 1,440 (3,175) 1,460 (3,219)

Gross vehicle mass (GVM )

NOTE: When any of the following optional parts are installed, add the weight to the unladen mass.

Front kg (lb) 885 (1,951) 910 (2,007) 960 (2,117) 980 (2,161) Rear kg (lb) 990 (2,183) 980 (2,161) 990 (2,183) 990 (2,183) Total kg (lb) 1,875 (4,134) 1,890 (4,167) 1,950 (4,300) 1,970 (4,344)

Weight of

optional parts

Front kg (lb) 10 (22) 2 (4) −1(−2) 3.6 (7.9) 17 (38) 9 (20) 3 (7) 2 (4.4) 2.6 (5.7) Rear kg (lb) −1(−2) 0 (0) 2 (4) −1(−2) −3(−7) 14 (31) 2 (4) 2 (4.4) 4.4 (9.7) Total kg (lb) 9 (20) 2 (4) 1 (2) 2.6 (5.7) 14 (31) 23 (51) 5 (11) 4 (8.8) 7.0 ( 15.4)

ABS Cruise

control

Self-

levelizer

Fog lamp Air condi-

tioner

Sunroof SRS airbag

(Driver &

Passenger)

SRS airbag

(Side)

Cold

weather

pack

SPC-6

IDENTIFICATION

1. Identification ................................................................................................2

Page

Identification

1. Identification SA06679

A: IDENTIFICATION SA06679F70

2. MEANING OF V.I.N. SA06679F7002

The meaning of the VIN is as follows:

쐌 Europe, Australia and General (Except GCC)

]JF1SF5LJ32G002001[

The starting and ending brackets ( ][ ) are stop marks.

Digits Code Meaning Details

1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made

JF2: MPV, FHI made 4 S Car line Forester 5 F Body type F: Wagon 6 5 Displacement 5: 2.0 L AWD 7 L Steering position K: RHD (Right-hand drive)

L: LHD (Left-hand drive) 8 J Engine & transmission J: SOHC MPI Full-time AWD 5-speed MT

R: SOHC MPI 4-speed AT

D: DOHC Turbo Full-time AWD 5-speed MT

P: DOHC Turbo 4-speed AT 9 3 Drive type 3: Full-time AWD 5-speed MT single range

4: Full-time AWD 5-speed MT dual range

5: Full-time AWD 4-speed AT 10 2 Model year 2: 2002MY

3: 2003MY 11 G Factory location G: FHI (Gunma) 12 to 17 002001 Serial number

IDENTIFICATION

쐌 GCC countries (Saudi Arabia, etc.)

]JF1SF53MX2J002001[

The starting and ending brackets ( ][ ) are stop marks.

Digits Code Meaning Details 1 to 3 JF1 Manufacturer body area JF1: Passenger car, FHI made 4 S Car line Forester 5 F Body type E: Wagon 6 5 Displacement 5: 2.0 L AWD 7 3 Grade 3: BASE

5: NA SPRT 8 M Restraint M: Manual belts, dual airbag 9 X Check digit 10 2 Model year 2: 2002MY

3: 2003MY 11 J Transmission type H: Full-time AWD 4-speed AT

J: Full-time AWD 5-speed MT dual range 12 to 17 002001 Serial number

ID-2

IDENTIFICATION

Identification

3. MODEL NUMBER PLATE SA06679F7003

The model number plate indicates: the applied model, the option code, the trim code, the engine type, the transmission type, and the exterior color code. This information is helpful when placing orders for parts.

SF5EL7R

Digits Code Meaning Details 1 S Series Forester 2 F Body style F: Wagon 3 5 Engine displacement

Drive system

Suspension system 4 E Minor change 2002MY 5 L Destination K: Right-hand drive for general market

6 7 Grade 2: BASE

7 R Transmission, fuel feed

system

5: 2.0 L AWD

L: Left-hand drive for general market

3: HUNTER Ver. 4: NA SPORT 5: TYPE-S

P: DOHC MPI Turbo 4-speed AT D: DOHC MPI Turbo center differential MT J: SOHC MPI center differential MT R: SOHC MPI 4-speed AT

The engine and transmission type are as follows:

쐌 Engine

EJ202NXVBB

Digits Code Meaning Details 1 and 2 EJ Engine type EJ: 4 cylinders 3 and 4 20 Displacement 20: 2.0 L 5 2 Fuel feed system 1: D-MPI SOHC-A

2: D-MPI SOHC-B 4: MPI DOHC

5: MPI Turbo 6 N Detailed specifications Used when ordering parts. See the parts catalog for details. 7 X Transmission W: AWD MT

X: AWD AT 8 V Minor change V: Current model 9 to 10 BB Detailed specifications Used when ordering parts. See the parts catalog for details.

ID-3

Identification

IDENTIFICATION

쐌 Transmission

TZ1A3ZN3AA

Digits Code Meaning Details 1 T Transmission T: Transmission 2 Z Transmission type Y: Full-time AWD MT center differential

Z: Full-time AWD AT MPT

3 and 4 1A Classification 75: MT

1A: New AT

5 3 Series 3: AT

5: MT

6 Z Transmission specifica-

tions

7 to 10 N3AA Detailed specifications Used when ordering parts. See the parts catalog for details.

쐌 Rear differential 1

VA1RFF

V: Full-time AWD 5-speed MT with viscous coupling center differential single range X: Full-time AWD 5-speed MT with viscous coupling center differential dual range Z: Full-time AWD 4-speed AT with MPT

Digits Code Meaning Details 1 V For AWD V: AWD 2 A Type A: A type 3 1 Hypoid gear diameter 1: 152 dia.

2: 160 dia. 4 R Installation position R: Rear 5 F Reduction gear ratio F: 4.444 6 F Specification differences F: Case A

쐌 Rear differential 2

Code Reduction

gear ratio T1 3.900 No T2 4.111 No TP 4.444 No BK 4.111 No BP 4.111 Strengthened type BL 4.444 Strengthened type VB 3.700 No

LSD

쐌 Option code

ECPS

Digits Code Meaning Details

1 to 2 EC Destination EC: EC

3 to 4 PS Main options

KO: KO K4: K4 KS: KS EK: EK KA: KA K1: K1

–

on vehicle

ID-4

FUEL INJECTION (FUEL SYSTEMS)

FU(SOHC)

1. General Description

2. Throttle Body

3. Intake Manifold

4. Engine Coolant Temperature Sensor

5. Crankshaft Position Sensor

6. Camshaft Position Sensor

7. Knock Sensor

8. Throttle Position Sensor

9. Intake Air Temperature and Pressure Sensor

10. Atmospheric Pressure Sensor ....................................................................2

11. Idle Air Control Solenoid Valve

12. Air Assist Injector Solenoid Valve

13. Fuel Injector

14. Front Oxygen (A/F) Sensor

15. Rear Oxygen Sensor

16. Engine Control Module

17. Main Relay

18. Fuel Pump Relay

19. Fuel

20. Fuel Tank

21. Fuel Filler Pipe

22. Fuel Pump

23. Fuel Level Sensor

24. Fuel Sub Level Sensor

25. Fuel Filter

26. Fuel Cut Valve

27. Fuel Damper Valve

28. Fuel Delivery, Return and Evaporation Lines

29. Fuel System Trouble in General

Page

Fuel Injection (Fuel Systems)

ATMOSPHERIC PRESSURE SENSOR

10. Atmospheric Pressure Sensor

A: REMOVAL S155045A18

NOTE: Not applicable to vehicles with option code “KS”. <Ref. to ID-3, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

1) Disconnect battery ground cable.

2) Disconnect connector from atmospheric pressure sensor.

3) Remove atmospheric pressure sensor from bracket.

S155045

G6M0095

B: INSTALLATION S155045A11

NOTE: Not applicable to vehicles with option code “KS”. <Ref. to ID-3, MODEL NUMBER PLATE, IDENTIFICATION, Identification.>

Install in the reverse order of removal.

Tightening torque:

6.4 N·m (0.65 kgf-m, 4.7 ft-lb)

EN1001

FU(SOHC)-2

AUTOMATIC TRANSMISSION

1. General Description.....................................................................................2

2. Automatic Transmission Fluid

3. Differential Gear Oil

4. Road Test

5. Stall Test......................................................................................................3

6. Time Lag Test

7. Line Pressure Test

8. Transfer Clutch Pressure Test

9. Automatic Transmission Assembly

10. Transmission Mounting System

11. Extension Case Oil Seal

12. Inhibitor Switch

13. Front Vehicle Speed Sensor

14. Rear Vehicle Speed Sensor

15. Torque Converter Turbine Speed Sensor

16. Control Valve Body

17. Shift Solenoids, Duty Solenoids and ATF Temperature Sensor

18. ATF Filter

19. Transmission Control Module (TCM)

20. ATF Cooler Pipe and Hose

Page

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