Subaru Forester 2.5X 2003 Technicians Reference Booklet Download | Manualshive

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Technicians

Reference

Booklet

2003 New Model

Updates

Module 912

MSA5P0250C

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Summary of Contents for Forester 2.5X 2003

Page 1: ...Technicians Reference Booklet 2003 New Model Updates Module 912 MSA5P0250C ...

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Page 3: ...s permission of 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 ...

Page 4: ...2003 New Model Update 912 4 ...

Page 5: ...e of Contents Introduction 6 2003 Forester 6 Exterior 6 Interior 11 Supplemental Restraint System 14 Brakes 16 Automatic Air Conditioning 19 Legacy 23 VCU VIU Remove 29 SPORTSHIFT 31 Baja 33 New for Pre Delivery Inspection 39 Slide Sequence 41 ...

Page 6: ... 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 Legacy and Impreza in a new more aerodynamic body style The Forester is also the continuing effort by Subaru to increase safety and drivability by introd...

Page 7: ...rovides 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 o...

Page 8: ...dary 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 use of a remote located power steering reservoir New to the Forester is the use of the module type windshield wiper system All components are located behind the cowling The engine under cover is equipped with an access door to reach th...

Page 9: ...equipped with same type of subframe introduced with the Impreza WRX The stub axles of the front differential have 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 The axle is removed from the differential by using ST28399SA000 and applying pressure between ...

Page 10: ...rential 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 ...

Page 11: ...l the anchor when not in use The moonroof on the 2 5XS and 2 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 open position Pushing the button again and releasing the button will carry the moonroof to the fully open position 33 32 31 34 35 ...

Page 12: ...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 ...

Page 13: ...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 Temp and odometer stays illuminated 5 seconds after the key is turned ...

Page 14: ...inder for technicians The airbag is attached to the upper seat frame and inflates to form a larger pillow when activated 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 47 48 49 50 51 ...

Page 15: ...ags 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 deployment devices has changed The new style requires the release of the yellow tab by pulling up on the tab and then separating the connector from the deployment device 52 53 ...

Page 16: ...stribution EBD This new system controls 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 59 60 61 62 ...

Page 17: ...e Hill Holder The 2003 Forester 5 speed manual transmission 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 clutch will trap the brake pressure in the left front and right rear Operation of the pressure control valve PHV is accomplished by means of a cable conne...

Page 18: ...18 May 2002 2003 New Model Update 912 Forester Clutch Pedal in Clutch Pedal Out 70 71 ...

Page 19: ... Off button turns the system 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 Indi...

Page 20: ...Communication If the DEF led DEF led DEF led DEF led DEF led is off off off off off during any of the 6 steps for sensor checks an open circuit open circuit open circuit open circuit open circuit can be assumed If the DEF led DEF led DEF led DEF led DEF led is on on on on on during any of the 6 steps for sensor checks a shorted circuit shorted circuit shorted circuit shorted circuit shorted circui...

Page 21: ...ED Fan Speed Mode Intake Door Air Mix Compressor 1 Vent Lo Vent Fresh Full Cool Off 2 BI Level Lo Vent Recirc Full Cool On 3 Heat ML Vent Recirc Full Cool On 4 Def Heat ML Bi Level Fresh 50 Hot On 5 Fan Speed 1 ML Heat Fresh 100 Hot On 6 Fan Speed 2 MH Heat Fresh 100 Hot On 7 Fan Speed 3 MH Def Heat Fresh 100 Hot On 8 Fan Speed 4 High Def Fresh 100 Hot On Pressing the auto button after entering co...

Page 22: ...22 June 2002 2003 New Model Update 912 Forester 8 Ambient sensor 1 Mode Door Actuator 3 Sunload sensor 4 Intake door actuator 5 Blower motor 6 Evaporator sensor 7 Air mix door actuator 74 75 76 77 78 ...

Page 23: ...he vehicles systems and the OnStar system are networked to provide cellular phone service automatic emergency cellular phone call to OnStar concierge service and vehicle assistance The cellular phone strength of the OnStar system is approximately 3 watts compared to the approximately 1 watt of hand held cell phones Components of the OnStar system Vehicle Cell Unit VCU Vehicle Interface Unit VIU 3 ...

Page 24: ...green LED indicates no problem and OnStar is ready for operation The VCU is the cell phone unit of the vehicle It is connected to the combined cellular GPS antenna and the VIU The VIU receives input signals and provides out put signals to perform cellular phone service and vehicle assistance The Radio receives output signals from the VIU The VIU will turn the Radio on if it is off bypass the norma...

Page 25: ...re on when the system is ready to operate The SRS Air Bag System provides two types of input signals to the VIU normal and deployed The normal signal prevents the VIU from illuminating the trouble indicator 2 colored led The deployed signal will result in the VIU outputting a signal to the VCU The VCU will then make an emergency cellular phone call to OnStar OnStar will then call the vehicle If no...

Page 26: ...l to ground the coil of the coil of the relay for flashing the headlights This is done to also assist with locating the vehicle The microphone provides voice input to the VIU This is used to communicate to the onboard OnStar system and to provide voice input during phone calls 92 93 ...

Page 27: ...sually commanded together although independent control is possible The driver of the vehicle can call OnStar from a separate phone and request that the vehicle be locked unlocked or security system turned on or off The Horn relay receives a signal from the VIU that will supply a ground to the coil of the relay to beep the horn This is performed if the driver calls OnStar from a separate phone to a...

Page 28: ...de The EEPROM checksum error DTC shows a transition in the memory but does not mean there is a fault Therefore no DTCs are displayed The SRS signal fault DTC will only show as history in the DTC display mode Requires ignition to enable algorithm and the ignition is the only reference for entering the DTC display mode The DTC codes will be displayed in two cycles Current codes are always displayed ...

Page 29: ...essure around the shifter trim plate until it can be removed Remove the two screws that secure the coin tray The forward end of the tray has a point that is set into a notch under the ash tray Remove the two screws in the area indicated by the two fingers A third screw is under the tray near the back Apply gentle up pressure to the radio HVAC bezel Apply pressure around the bezel until it can be r...

Page 30: ...ar buttons Remove the two screws from the driver side of the radio Remove the two screws from the Passenger side of the radio Complete radio HVAC removal is then required Remove the aspirator from the connector above the accelerator pedal The aspirator tube is routed between this bracket and harness Protect the radio and shifter from scratches during removal and installation Carefully disconnect a...

Page 31: ...cial SPORTSHIFT gate Operation is accomplished by placing the vehicle in D range and moving the shift lever to the right Once in the SPORTSHIFT gate the shifter can be tapped forward for up shifting or tapped backwards for down shifting Changing of the gears in SPORTSHIFT must be timed with the SPORTSHIFT indicator light on the combination meter A small box at the top of the shift indicator will c...

Page 32: ...solenoid The sports shift solenoid is used to turn the low and reverse clutch on and off to provide engine braking should the 1st gear be chosen while in SPORTSHIFT The transmission trouble code for a failed SPORTSHIFT solenoid is 78 There are no codes for the micro switches Spring tension is applied to the shifter lever while in SPORTSHIFT by two spring loaded pistons that push on the front and b...

Page 33: ...satility and passenger carrying capabilities for four people The BAJA is available in a single trim level coming standard with a 2 5 liter engine and a 5 speed all wheel drive transmission The gas cap is opened from the outside of the vehicle and is not equipped with an interior release The front bumper tow hook cover must be removed to access the tow hook 117 118 119 121 120 ...

Page 34: ...witch on the left side of the steering column and is operable with the key on or off The bed liner of the cargo area is equipped with a water drain in each front corner The bed liner is also the access point to lower the temporary spare tire The full size flat is stored in the cargo area using the full size tire holder and the captured nut in the bed 122 123 124 125 126 121 127 ...

Page 35: ...r side The mechanism that lowers the spare tire is located under the vehicle and has enough travel to pull the spare tire beyond the rear bumper for removal from the storage cable The spare tire is secured to the storage cable by positioning the tire with the valve stem facing up and holding the keeper sideways Push the keeper through the rim and allow gravity to pull the keeper into place 128 129...

Page 36: ...the rear seat and pull upward Lift the seat 90 degrees and then pull on the upper seat cushion release handle on either the driver or passenger side Lower the upper cushion until it engages with the provided catches on the lower seat back The Switchback release handle can be activated to lower the Switchback 134 135 136 137 138 139 ...

Page 37: ...ense plate holder upward by about 90 degrees The holder will lock into position Removing the plastic cover and metal cover over the tailgate accesses the taillights mounted in the tailgate 137 The backside of the upper seat frame is equipped with 2 child seat anchor points Any time the Switchback is open the Switchback position indicator light will be illuminated The light will blink for about 5 s...

Page 38: ...38 June 2002 2003 New Model Update 912 Baja The rear suspension on all Legacy vehicles including the Baja has been enhanced with the introduction of an additional sub frame support NOTES 146 ...

Page 39: ...Pre Delivery Inspection All models will be equipped with rotor covers Remove rotor covers at PDI Tires do not need to be removed Operate vehicles at slow speeds until covers are removed Invert the A C relay on all Legacy models at PDI 149 148 NOTES ...

Page 40: ... 9 23 Subframe 9 24 Stub Axle 9 25 Special Tool Usage 9 26 Special Tool 10 27 Oil Seal Installer 10 28 Oil Seal Tool 10 29 Oil Seal Tool Usage 10 30 Title Slide Interior 11 31 Cargo Area 11 32 Storage Configuration 11 33 Child Seat Anchors 11 34 Moonroof Closed 11 35 Moonroof Open 11 36 Moonroof Open 12 37 Moonroof Closed 12 38 Cup Holders 12 39 Gate Shifter 12 40 Ash Tray 12 41 Overhead Storage 1...

Page 41: ...utch Pedal 17 70 Clutch Pedal In 18 71 Clutch Pedal Out 18 72 Title Slide Automatic Air Conditioning 19 73 Control Dials 19 Control Dials 20 74 Component Location 22 75 Ambient Sensor 22 76 Sunload Sensor 22 77 Mode door Actuator 22 78 Behind Glove Box 22 79 Title Slide Legacy 23 80 Title Slide OnStar 23 81 Radio 23 82 VCU VIU 23 83 Three Button 23 84 Microphone 23 85 Antenna 23 86 Three Button 24...

Page 42: ...itch 34 124 Water Drain 34 125 Full Size Storage 34 126 Full Size Holder 34 127 Lowering Spare 34 128 Tool Kit Storage 35 129 Jack 35 130 Spare 35 131 Lowering Mechanism 35 132 Spare in Place 35 133 Connecting Spare 35 134 Tail Gate Open 36 135 Rear Seat Bottom 36 136 Rear Upper Seat Down 36 137 Under Rear Bottom Seat 36 138 Switch Back Closed 36 139 Switch Back Open 36 140 Switch Back Indicator L...

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