Subaru Forester 2.5X 2003 Installation and operation manual

Technicians
Reference
Booklet
2003 New Model
Updates
Module 912
MSA5P0250C

3
© Copyright 2002
Subaru of America, Inc.
Allrightsreserved.Thisbookmaynotbereproduced
inwholeorinpartwithouttheexpresspermissionof
Subaru of America, Inc.
SubaruofAmerica,Inc.reservestherightatanytime
to make changes or modifications to systems,
procedures,descriptions,andillustrationscontained
in this book without necessarily updating this
document.Informationcontainedhereinisconsidered
current as of June 2002.
© Subaru of America, Inc. 2002

2003 New Model Update (912)
4

5June 2002
2003 New Model Update (912)
Table of Contents
Introduction........................................................................................................................6
2003Forester.....................................................................................................................6
Exterior..............................................................................................................................6
Interior .............................................................................................................................11
SupplementalRestraintSystem .......................................................................................14
Brakes .............................................................................................................................16
AutomaticAirConditioning ...............................................................................................19
Legacy .............................................................................................................................23
VCU/ VIU Remove ..........................................................................................................29
SPORTSHIFT ..................................................................................................................31
Baja .................................................................................................................................33
Newfor Pre-DeliveryInspection ......................................................................................39
SlideSequence ................................................................................................................41

6June 2002
2003 New Model Update (912) Forester
Introduction
This Technicians Reference Booklet introduces
the 2003 Forester 2.5X, 2.5XS, Baja and the
OnStar system. It covers the component
operation, trouble-shooting, diagnosis, and
service precautions and procedures. This
information is presented with special emphasis
on procedures, tools and materials unique to
Subaru vehicles. Subaru-specific servicing
procedures and precautions are also included
in this booklet.
The text and illustrations are derived from and
follow the classroom lectures and slide
presentations.Theyareintendedto supplement
andreinforce classroom instructionand to serve
as a home-study reference source.
2003 Forester
The New Forester for the 2003 model year is
available in three models. The 2.5X, 2.5XS and
the 2.5XS Premium Package.
The 2003 Forester is not only the consolidation
of recent enhancements and refinements to the
LegacyandImpreza ina newmoreaerodynamic
body style. The Forester is also the continuing
effortby Subarutoincrease safetyand drivability
by introducing to the new Forester such items
as the active head restraint, high pillow side
airbags and reduced turning radius.
Weighing in at 3,175 lbs. (Curb 4EAT) the new
Forester is equipped with either the 5-speed
manual or the 4 speed electronic automatic
transmission, coupled with the 165 horsepower
2.5-liter SOHC engine.
Exterior
The complete taillight assemble is housed on
body of the vehicle rather than splitting the light
as previous Forester Models.
6
7
9

7June 2002
2003 New Model Update (912) Forester
Servicing of the taillight bulbs is achieved by
opening the rear gate and removing two 6 mm
bolts and removing the taillight assemble from
the body. The bulbs are reached from the
backside of the taillight assembly.
An additional line in the rear defogger grid
located in the wiper park position provides
improved wiper deicing. The rear wiper now
parks on the left side of the rear window.
XS models have a larger side view mirror than
the X model and are equipped with heated side
view mirrors which are activated by the front
windshield deicer switch. (15 minute timer)
The side view mirror and the C pillar post trim
are metallic colored to improve appearance.
The driver door lock cylinder is the only key
position on the exterior of the vehicle. This
cylinderwill lock andunlock the driverdoor only.
(Keyless entry is standard)
10
11
12
13
14

8June 2002
2003 New Model Update (912) Forester
The new (aluminum) hood line is lower on the
new Forester. Sliding a thumb across the top of
the grill until the release lever is located and slid
to the passenger side of the vehicle best
activates the secondary release for the hood.
The new headlight assembly can be removed
by first removing the grill and the filler panel.
The lower hood line of the vehicle requires the
useofa remotelocatedpower steeringreservoir.
NewtotheForesteris theuse ofthemodule type
windshield wiper system. All components are
located behind the cowling.
The engine under cover is equipped with an
accessdoor toreach theoil filterand theoildrain
plug.
15
16
17
18
19
20

9June 2002
2003 New Model Update (912) Forester
The door is opened by remove the 6 trim plugs
andturning thedoor to thepassenger sideof the
vehicle.
Twovisual inspectiondoors arelocatednear the
front of the engine under cover .
Forester is now equipped with same type of
subframe introduced with the Impreza WRX.
Thestub axles ofthe front differentialhave been
deleted and replaced with stub axles made onto
the end of the drive axle inner joint. The end of
the axle has a small circlip that locks the stub
axle to the side gear of the differential.
Theaxleis removedfromthedifferentialbyusing
ST28399SA000and applyingpressure between
the axle joint and the differential.
21
22
23
24
25

10 June 2002
2003 New Model Update (912) Forester
The tool is directional. The higher side is placed
next to the differential when servicing manual
transmission vehicles while the shorter side is
placed next to the differential when servicing
automatic transmission vehicles.
A new oil seal installer for the differential is
available.
An axle oil seal protector is used to prevent
damage to the seal when installing the axle.
26
27
28
29