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)
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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.
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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)
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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.
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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.
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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.
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11 June 2002
2003 New Model Update (912) Forester
Interior
Compartment storage configuration has
changed to provide more convenience.
Child seat anchors now have easy open covers
to conceal the anchor when not in use.
Themoonroof onthe 2.5XS and2.5XS premium
package model operates slightly different than
previous Subaru moonroofs. When activated to
open the moonroof will continue to open with no
continued contact with the open button to the ¾
open position.
Pushing the button again and releasing the
button will carry the moonroof to the fully open
position.
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12 June 2002
2003 New Model Update (912) Forester
When activated to close the moonroof will
continue to close with no continued contact with
theclosebuttontothe¾closedposition.Pushing
the button again and releasing it will carry the
moonroof to the fully closed position.
An increase in the amount of current closing the
moonroof will activate an obstruction safety
feature that will interrupt the auto close feature
andreversethemoonroof toopenabout 6inches
beyond the obstruction. Removing the
obstruction and pushing the close switch again
should restore the auto close of the moonroof. If
the safety feature continues to operate the auto
close feature will turn off. It will only be restored
after the safety feature circuit has cooled down.
A vehicle speed sensor input is supplied to the
moonroof control unit it will increase the
sensitivity of the obstruction detection.
New cup holders for the driver and passenger.
Gate type shifter is now equipped on the
Forester.
All Forester models are equipped with a front
seatash tray andlighter receptacle. Nolighter is
delivered with the vehicle. Use only lighter
86719SA000 as other lighters may be too long
and make contact with the ashtray door when it
is closed, engaging the lighter.
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13 June 2002
2003 New Model Update (912) Forester
Overheadstorage ismoreconvenientbythe use
of an additional compartment.
The Subaru logo now appears on the steering
wheel.
The new clock position makes it necessary to
open the center dash storage door to adjust the
time.
The window controls in the front and rear seats
are illuminated when ever the ignition is in.
Combination meter configuration including the
gear shift indicator. The fuel gauge also has a
low fuel warning light illuminating when the fuel
level is 2.4 gallons (9 liters) or less.
Tempand odometerstaysilluminated 5seconds
after the key is turned off.
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2003 New Model Update (912) Forester
Supplemental Restraint
System
All Forester models are equipped with front side
airbags. The seat covers are tagged as a
reminder for technicians.
The airbag is attached to the upper seat frame
andinflatestoform alargerpillow whenactivated
in a side collision.
All Forester front seats are also equipped with
active head restraint.
SRS wires routed through the seat are not
covered with the yellow plastic cover.
Normal position.
Position during rear impact.
Drivers airbag module.
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15 June 2002
2003 New Model Update (912) Forester
All 2003 Forester models will be equipped with
driver and passenger front SRS Airbags, seat
beltpretensionersand driverandpassenger side
airbags. The side airbags when deployed are
larger and provide protection for the chest and
head.
The location of the front Satellite discrimination
sensors have been relocated due to the new
vehicle design.
The connector and connector lock on all
deploymentdeviceshas changed.The newstyle
requires the release of the yellow tab by pulling
up on the tab and then separating the connector
from the deployment device.
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2003 New Model Update (912) Forester
Brakes
Forester 2.5XS and 2.5XS Premium Package
models are equipped with Electronic Brake
Distribution(EBD). Thisnew systemcontrols the
brake fluid pressure to the rear wheels by taking
advantage of existing ABS 5.3I components.
This process eliminates the mechanical
proportioning valve. The hydraulic control unit will activate the inlet
solenoid valves to achieve pressure hold
controlling the pressure to the rear wheels.
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17 June 2002
2003 New Model Update (912) Forester
The control unit built inside the HCU monitors
the wheel speed of the front and rear wheels to
decide how much braking force is generated
fromtherearwheels.Thewheelspeeddifference
between the front and rear on a vehicle with a
lightcargo load generates a higherwheel speed
differenceand resultsinlower brakingforce from
the rear wheels. Heavier cargo loads in the rear
generate lower speed differences between the
front and rear and can receive higher brake fluid
pressure.
Hill Holder
The2003 Forester5speed manualtransmission
model is equipped with a hill holder. The hill
holder activates with the clutch and brake pedal
pushed when the vehicle is at about a 3 degree
incline. Releasing the brake and holding the
clutchwill trap thebrake pressurein the leftfront
and right rear.
Operation of the pressure control valve (PHV) is
accomplished by means of a cable connected
to the clutch pedal and routed through the bulk
head to the PHV. The end of the cable at the
PHV is adjustable.
If the vehicle does not hold on the described
incline tighten the adjustment. If the hill holder
releases later than the clutch loosen the
adjustment. If the hill holder releases too soon
tighten the adjustment.
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2003 New Model Update (912) Forester
Clutch Pedal in
Clutch Pedal Out
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2003 New Model Update (912) Forester
Automatic Air Conditioning
The Forester 2.5 XS and 2.5 XS premium package models will be equipped with Automatic air
conditioning. The 3 control dials of the system communicate their set position to the driver by
illuminated LEDs.
Control Dial 1
Driver sets the desired temperature from 65 to 85 degrees Fahrenheit.
Auto button sets the system to automatic. Air flow direction, temperature and speed will be
automatically controlled.
Offbutton turnsthesystem off.
Holding the off button will change the brightness of the LEDs.
Control Dial 2
Driver can set the fan to the desired speed
Indicates the fan speed
Indicates the position of the fresh air door
Driver can set the position of the fresh air door
Driver can activate the Air Compressor for manual A/C control
Indicates the operation of the Air Compressor
Control Dial 3
Indicates the position of the mode door (Air flow direction)
Driver can set the position of the mode door
Driver can activate the front defogger mode
Indicates the operation of the front defogger mode
Driver can activate the rear defogger
Indicates the operation of rear defogger
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2003 New Model Update (912) Forester
Self Diagnostic Procedure
Push and hold the “DEF” and the “A/C” switch while starting the engine.
All of the LEDs will turn on and off in following sequence of 5 steps.
Step Fan Mode Def RearDef A/C Recirc Auto
1 1 Vent On
2 2 Bilevel On
3 3 Heat On
4 4 Def/Heat On
5 4 Def/Heat On
This process will cycle twice. At the end of the second cycle all LEDs should be off.
Except the A/C LED.Except the A/C LED.
Except the A/C LED.Except the A/C LED.
Except the A/C LED. LEDs remaining on indicate a problem and the condition of that problem.
The chart below describes how to interpret the LED and corresponding problem,
Step Sensor LED
1 In-vehicle Vent
2 Ambient Bi-Level
3 Evaporator Heat
4 Sunload Def/Heat
5 Air mix door PBR Fan Speed 1
6 CombinationMeter Fan Speed 2
Communication
If the “DEF” led“DEF” led
“DEF” led“DEF” led
“DEF” led is offoff
offoff
off during any of the 6 steps for sensor checks an open circuitopen circuit
open circuitopen circuit
open circuitcan be assumed.
If the “DEF” led“DEF” led
“DEF” led“DEF” led
“DEF” ledisonon
onon
on during anyof the6 stepsfor sensorchecks a shorted circuitshorted circuit
shorted circuitshorted circuit
shorted circuitcanbe assumed.
If the Rear window defogger LEDRear window defogger LED
Rear window defogger LEDRear window defogger LED
Rear window defogger LEDisoffoff
offoff
off during any of the 6 steps for sensor checks the problem is
a current failurecurrent failure
current failurecurrent failure
current failure.
If the Rear window defogger LEDRear window defogger LED
Rear window defogger LEDRear window defogger LED
Rear window defogger LEDisonon
onon
on during any of the 6 steps for sensor checks the problem is
a previous failureprevious failure
previous failureprevious failure
previous failure.