Subaru Forester 2.5X 2003 Technicians Reference Booklet
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Subaru Forester 2.5X 2003 Technicians Reference Booklet

New model updates
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Technicians
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Booklet
2003 New Model
Updates
Module 912
MSA5P0250C

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Summary of Contents for Subaru Forester 2.5X 2003

  • Page 1 Technicians Reference Booklet 2003 New Model Updates Module 912 MSA5P0250C...
  • Page 3 All rights reserved. This book may not be reproduced in whole or in part without the express permission of Subaru of America, Inc. Subaru of America, Inc. reserves the right at any time to make changes or modifications to systems, procedures, descriptions, and illustrations contained in this book without necessarily updating this document.
  • Page 4 2003 New Model Update (912)

  • Page 5: Table Of Contents

    2003 New Model Update (912) Table 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 ........................

  • Page 6: Introduction

    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 introducing to the new Forester such items as the active head restraint, high pillow side airbags and reduced turning radius.
  • Page 7 2003 New Model Update (912) Forester XS models have a larger side view mirror than Servicing of the taillight bulbs is achieved by the X model and are equipped with heated side opening the rear gate and removing two 6 mm view mirrors which are activated by the front bolts and removing the taillight assemble from windshield deicer switch.
  • Page 8 2003 New Model Update (912) Forester The lower hood line of the vehicle requires the The new (aluminum) hood line is lower on the use of a remote located power steering reservoir. 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.
  • Page 9 2003 New Model Update (912) Forester The door is opened by remove the 6 trim plugs The stub axles of the front differential have been and turning the door to the passenger side of the deleted and replaced with stub axles made onto vehicle.
  • Page 10 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. An axle oil seal protector is used to prevent damage to the seal when installing the axle.

  • Page 11: Interior

    Interior 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 ¾ open position.
  • Page 12 2003 New Model Update (912) Forester When activated to close the moonroof will New cup holders for the driver and passenger. continue to close with no continued contact with the close button to the ¾ closed position. Pushing the button again and releasing it will carry the moonroof to the fully closed position.
  • Page 13 Combination meter configuration including the The Subaru logo now appears on the steering gear shift indicator. The fuel gauge also has a wheel. low fuel warning light illuminating when the fuel level is 2.4 gallons (9 liters) or less.

  • Page 14: Supplemental Restraint System

    2003 New Model Update (912) Forester Supplemental Restraint System Normal position. All Forester models are equipped with front side airbags. The seat covers are tagged as a reminder for technicians. Position during rear impact. The airbag is attached to the upper seat frame and inflates to form a larger pillow when activated in a side collision.
  • Page 15 2003 New Model Update (912) Forester All 2003 Forester models will be equipped with driver and passenger front SRS Airbags, seat belt pretensioners and driver and passenger side airbags. The side airbags when deployed are larger and provide protection for the chest and head.

  • Page 16: Brakes

    2003 New Model Update (912) Forester Brakes Forester 2.5XS and 2.5XS Premium Package models are equipped with Electronic Brake Distribution (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.
  • Page 17 2003 New Model Update (912) Forester 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.
  • Page 18 2003 New Model Update (912) Forester Clutch Pedal in Clutch Pedal Out May 2002...

  • Page 19: Automatic Air Conditioning

    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.
  • Page 20 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 Mode Rear Def Recirc Auto Vent...
  • Page 21 2003 New Model Update (912) Forester At the end of the sensor check a compulsory check mode can be activated by pushing the “RECIRC” switch. The system will automatically perform the following functions. Check the air flow direction, temperature and speed to determine if any problems are present. Read the chart from left to right.
  • Page 22 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 June 2002...

  • Page 23: Legacy

    2003 New Model Update (912) Legacy Components of the OnStar system Legacy OnStar OnStar, a system that provides communications and other services, will be equipped on all 6- cylinder Legacy vehicles. Vehicle Cell Unit (VCU), Vehicle Interface Unit (VIU) 3-button control module These vehicles will receive a one-year membership to the services provided by OnStar, which begin on the sale date of the vehicle.
  • Page 24 2003 New Model Update (912) Legacy The VCU and VIU are installed above and below The VIU receives input signals and provides out the radio. These parts as well as the remaining put signals to perform cellular phone service and OnStar components are installed at SIA.
  • Page 25 2003 New Model Update (912) Legacy The SRS Air Bag System provides two types of input signals to the VIU, normal and deployed. A single wire carries the commands from the 3 The normal signal prevents the VIU from buttons to the VIU. The 2 color led is controlled illuminating the trouble indicator (2 colored led).
  • Page 26 2003 New Model Update (912) Legacy The headlight relay receives a signal 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.
  • Page 27 2003 New Model Update (912) Legacy The Keyless Entry control module receives a Door unlock and Door lock signal from the VIU. Each command uses its own wire. The control of the security system and the keyless entry system are usually commanded together although independent control is possible.
  • Page 28 2003 New Model Update (912) Legacy Exceptions During microprocessor communication fault, DTC occurs that disables the button module the VIU will not enter the DTC display mode. The EEPROM checksum error, DTC shows a transition in the memory but does not mean there is a fault.

  • Page 29: Vcu / Viu Remove

    2003 New Model Update (912) Legacy VCU / VIU Remove Set the Parking Brake Turn the ignition switch to the on position. Place the shifter in the neutral position. Turn the ignition switch off and disconnect the battery. Apply gentle up pressure to the corner of the shifter trim plate.
  • Page 30 2003 New Model Update (912) Legacy Remove the two screws from the Passenger side Disconnect the electrical connectors from the back of the radio / HVAC bezel. of the radio. Complete radio / HVAC removal is then required. Remove the aspirator from the connector above the accelerator pedal.

  • Page 31: Sportshift

    2003 New Model Update (912) Legacy SPORTSHIFT Slowly begin to slide the radio outward. This tab The 2003 Legacy GT model is equipped with will catch on the area below the A/C vent. Push VTD and a SPORTSHIFT type gate shifter. This it down slightly to clear.
  • Page 32 2003 New Model Update (912) Legacy Automatic up shifting is not performed while in SPORTSHIFT. Engine over rev protection is accomplished with a fuel cut and a full vehicle stop will result in the TCM activating 1 gear. At this point the driver will need to advance the forward gears with the shift lever.

  • Page 33: Baja

    2003 New Model Update (912) Baja Baja The gas cap is opened from the outside of the The BAJA is an all-new hybrid vehicle vehicle and is not equipped with an interior developed and built on the Legacy Outback release. platform.
  • Page 34 2003 New Model Update (912) Baja The rear of the passenger compartment is equipped with a cargo light that will illuminate the cargo area. The light is operated from a switch on the left side of the steering column and is operable with the key on or off.
  • Page 35 2003 New Model Update (912) Baja The mechanism that lowers the spare tire is The tool used for lowering the spare is located located under the vehicle and has enough travel in the tool kit provided with the vehicle. The kit is to pull the spare tire beyond the rear bumper for stored in the passenger compartment behind the removal from the storage cable.
  • Page 36 2003 New Model Update (912) Baja To reconfigure the rear seats locate the fabric pull handle under the passenger side of 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.
  • Page 37 2003 New Model Update (912) Baja Operation of the vehicle with the tail gate down The backside of the upper seat frame is equipped requires that the license plate be repositioned. with 2 child seat anchor points. Before opening the tailgate push the top of the black release tabs in and swing the license plate holder upward by about 90 degrees.
  • Page 38 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 June 2002...

  • Page 39: New For Pre-Delivery Inspection

    2003 New Model Update (912) NOTES New for 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. June 2002...
  • Page 40 Slide Sequence Slide No. Description Page No. Title Slide (2003 NMUD) Created By Teaching Aids Introduction Title Slide (2003 Forester) Forester Forester RH Side Title Slide (Exterior) Tailgate Rear Light Rear Defogger Side View Mirror “C” Pillar Trim Door Lock Secondary Hood Release Head Light Grill Area...

  • Page 41: Slide Sequence

    Slide Sequence Slide No. Description Page No. Airbag Module Side Airbags (Artwork) Satellite Discrimination Sensors (SDC Sensor) Connector Connector Lock Lock-Up Lock Down Title Slide (Brakes) Proportioning Valve Normal Hydraulic Control (Artwork) Pressure Hold Hydraulic Control (Artwork) Big Graph (Artwork) Ideal (Artwork) PCV Operation (Artwork) EBD (Artwork)
  • Page 42 Slide Sequence Slide No. Description Page No. HVAC Trim Electrical Connectors Removing Trim Screw Driver Side Passenger Side Aspirator Tube Location Radio Removal Three Button Module Title Slide (SPORTSHIFT) Shifter P-R-N-D-3-2-1 Micro Switch Plate Spring Pistons Lever Engaged Lever Disengaged Title Slide (BAJA) Baja Name Plate...

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Forester 2.5xs 2003

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