2003 Subaru Forester Service & Repair Manual Software
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
FUJI HEAVY INDUSTRIES LTD. G8080GE7
03-04 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
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, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance 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 specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)
AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTIC) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEM WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOW/MIRROR GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEAT SE
SECURITY AND LOCK SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANEL EB
03-04 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G8080GE7
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4SO)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4DOTC)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4DOTC 2.5)
IMMOBILIZER (DIAGNOSTIC) IM
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
AC
Page
1. General Description .................................................................................... 2
2. Refrigerant Pressure with Manifold Gauge Set ......................................... 25
3. Refrigerant Recovery Procedure............................................................... 26
4. Refrigerant Charging Procedure ............................................................... 27
5. Refrigerant Leak Check ............................................................................ 30
6. Compressor Oil ......................................................................................... 31
7. Blower Motor Unit Assembly ..................................................................... 32
8. Blower Resistor (Manual A/C Model) ........................................................ 33
9. Heater Core............................................................................................... 34
10. Control Unit ............................................................................................... 35
11. Compressor............................................................................................... 36
12. Condenser................................................................................................. 37
13. Condenser (Sub Fan) ................................................................................ 38
14. Heater Cooling Unit ................................................................................... 39
15. Evaporator................................................................................................. 40
16. Hose and Tube.......................................................................................... 41
17. Relay and Fuse ......................................................................................... 42
18. Pressure Switch (Triple Pressure Switch) ................................................. 43
19. Ambient Sensor (Auto A/C Model) ............................................................ 44
20. Sunload Sensor (Auto A/C Model) ............................................................ 45
21. Air Vent Grille ............................................................................................ 46
22. Heater Duct ............................................................................................... 47
23. Heater Vent Duct ....................................................................................... 48
24. Heater Cock Solenoid Valve ..................................................................... 49
25. General Diagnostics .................................................................................. 50
AC-2
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
1. General Description
A: SPECIFICATION
1. HEATER SYSTEM
2. A/C SYSTEM
• AUTO A/C MODEL
Item Specifications Condition
Heating capacity
5.0 kW (4,300 kcal/h,
17,062 BTU/h) or more
• Mode selector switch: HEAT
• Temperature control switch: FULL HOT
• Temperature difference between hot water
and inlet air: 65°C (149°F)
• Hot water flow rate: 3602 (95.1 US gal, 79.2
Imp gal)/h
Air flow rate
280 m
3
(9,888 cu ft)/h
Heat mode (FRESH), FULL HOT at 12.5 V
Max air flow rate
480 m
3
(16,951 cu ft)/h
• Temperature control switch: FULL COLD
• Blower fan speed: 4th position
• Mode selector lever: RECIRC
Heater core size
(height×length×width)
134.1×224.3×32 mm
(5.28×8.83×1.26 in)
—
Blower motor
Type
Auto A/C (Brushless motor)
230 W or less
12.5 V
Manual A/C (Cylinder motor)
260 W or less
12.5 V
Fan type and size
(diameter×width)
Sirocco fan type
150×75 mm (5.91×2.95 in)
—
Item Specifications
Type of air conditioner Reheat air-mix type
Cooling capacity
5.1 kW
(4,386 kcal/h, 17,403 BTU/h)
Refrigerant
HFC-134a (CH
2
FCF
3
)
[0.6±0.05 kg (1.32±0.11 lb)]
Compressor
Type Vane rotary, fix volume (DKV-14G)
Discharge
140 cm
3
(8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Magnet clutch
Type Dry, single-disc type
Power consumption 38 W (DC 12 V-25°C)
Type of belt V-belt 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Condenser
Type Corrugated fin (Sub cool type)
Core face area
0.234 m
2
(2.52 sq ft)
Core thickness 16 mm (0.63 in)
Radiation area
5.6 m
2
(62.28 sq ft)
Receiver drier Effective inner capacity
220 cm
3
(13.42 cu in)
Expansion valve Type External equalizing
Evaporator
Type Single tank
Dimensions (W×H×T)
176.5×266×60 mm
(6.95×10.47×2.36 in)
Blower fan
Fan type Sirocco fan
Outer diameter×width 150×75 mm (5.91×2.95 in)
Power consumption 230 W or less at 12.5 V
AC-3
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• MANUAL A/C MODEL
Condenser fan (Sub fan)
Motor type Magnet
Power consumption
2.5 L turbo model and turbo AT model for EC and
EK:
120 W at 12 V
Other model than above:
70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
Radiator fan (Main fan)
Motor type Magnet
Power consumption
2.5 L turbo model and turbo AT model for EC and
EK:
120 W at 12 V
Other model than above:
70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
Idling speed (A/C ON) MPFI model 800±100 rpm
Triple switch
(Pressure switch)
Low-pressure switch
operating pressure
ON → OFF
177±25 kPa
(1.80±0.25 kg/cm
2
, 25.60±3.56 psi)
OFF → ON
206±30 kPa
(2.10±0.31 kg/cm
2
, 29.86±4.41 psi)
High-pressure switch
operating pressure
ON → OFF
2,940±200 kPa
(29.98±2.03 kg/cm
2
, 426.32±28.87 psi)
OFF → ON
590±200 kPa
(6.02±2.03 kg/cm
2
, 85.6±28.87 psi)
Middle pressure switch
operating pressure
ON → OFF
1370±120 kPa
(13.97±1.22 kg/cm
2
, 198.65±17.35 psi)
OFF → ON
1,770±100 kPa
(18.05±1.02 kg/cm
2
, 256.81±14.50 psi)
Thermo control amplifier working temperature
(Evaporator outlet air)
Item Specifications
Type of air conditioner Reheat air-mix type
Cooling capacity 5.1 kW (4,386 kcal/h, 17,403 BTU/h)
Refrigerant
HFC-134a (CH
2
FCF
3
)
[600±50 g (1.32±0.11 lb)]
Compressor
Type Vane rotary, fix volume (DKV-14G)
Discharge
140 cm
3
(8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Magnet clutch
Type Dry, single-disc type
Power consumption 38 W (DC12 V — 25°C)
Type of belt V-belt 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Item Specifications
AC-00082
OFF
ON
3.0 0.3
AC-4
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
Condenser
Type Corrugated fin (Sub cool type)
Core face area
0.234 m
2
(2.52 sq ft)
Core thickness 16 mm (0.63 in)
Radiation area
5.6 m
2
(6.26 sq ft)
Receiver drier Effective inner capacity
220 cm
3
(13.42 cu in)
Expansion valve Type External equalizing
Evaporator
Type Single tank
Dimensions (W×H×T)
176.5×266×60 mm
(6.95×10.47×2.36 in)
Blower fan
Fan type Sirocco fan
Outer diameter×width 150×75 mm (5.91×2.95 in)
Power consumption 260 W or less at 12.5 V
Condenser fan (Sub fan)
Motor type Magnet
Power consumption
2.5 L turbo model and turbo AT model for EC and
EK:
120 W at 12 V
Other model than above:
70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
Radiator fan (Main fan)
Motor type Magnet
Power consumption
2.5 L turbo model and turbo AT model for EC and
EK:
120 W at 12 V
Other model than above:
70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
Idling speed (A/C ON) MPFI model 800±100 rpm
Triple switch
(Pressure switch)
Low-pressure switch
operating pressure
ON → OFF
177±25 kPa
(1.80±0.25 kg/cm
2
, 25.60±3.56 psi)
OFF → ON
206±30 kPa
(2.10±0.31 kg/cm
2
, 29.86±4.41 psi)
High-pressure switch
operating pressure
ON → OFF
2,940±200 kPa
(29.98±2.03 kg/cm
2
, 426.32±28.87 psi)
OFF → ON
590±200 kPa
(6.02±2.03 kg/cm
2
, 85.6±28.87 psi)
Middle pressure switch
operating pressure
ON → OFF
1,370±120 kPa
(13.97±1.22 kg/cm
2
, 198.65±17.35 psi)
OFF → ON
1,770±100 kPa
(18.05±1.02 kg/cm
2
, 256.81±14.50 psi)
Thermo control amplifier working temperature
(Evaporator outlet air)
Item Specifications
AC-00082
OFF
ON
3.0 0.3
AC-5
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
B: COMPONENT
1. HEATER COOLING UNIT
• LHD MODEL WITH AUTO A/C
(1) Evaporator cover (10) Heater core (19) O-ring
(2) Mode actuator (11) Drain hose (20) Expansion valve
(3) Mode main lever (12) Mix actuator (21) Evaporator
(4) Vent door lever (13) Mix door lever (22) Evaporator lining
(5) Foot door lever (14) Foot door lever (B) (23) Evaporator sensor
(6) Mode actuator link (15) Upper case
(7) Defroster lever (16) Aspirator Tightening torque: N·m (kgf-m, ft-lb)
(8) Foot duct (17) Packing T: 7.5 (0.76, 5.5)
(9) Lower case (18) Cooling unit pipe
AC-00358
(1)
(9)
(8)
(10)
(18)
(12)
(13)
(3)
(4)
(5)
(2)
(6)
(7)
(17)
(21)
(19)
(20)
(19)
(22)
(23)
(14)
(15)
T
T
T
(16)
(11)
AC-6
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• RHD MODEL WITH AUTO A/C
(1) Evaporator cover (10) Heater core (19) Cooling unit pipe
(2) Mode actuator (11) Drain hose (20) O-ring
(3) Mode main lever (12) Mix actuator (21) Expansion valve
(4) Vent door lever (13) Mix door lever (22) Evaporator
(5) Foot door lever (A) (14) Foot door lever (B) (23) Evaporator lining
(6) Mode actuator link (15) Upper case (24) Evaporator sensor
(7) Defroster lever (16) Aspirator hose
(8) Foot duct (17) Aspirator Tightening torque: N·m (kgf-m, ft-lb)
(9) Lower case (18) Packing T: 7.5 (0.76, 5.5)
AC-00001
(1)
(9)
(8)
(10)
(11)
(16)
(19)
(12)
(13)
(3)
(4)
(5)
(2)
(6)
(7)
(18)
(22)
(20)
(21)
(20)
(23)
(24)
(14)
(15)
(17)
T
T
T
AC-7
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• LHD MODEL WITH MANUAL A/C
(1) Evaporator cover (9) Heater core (17) Expansion valve
(2) Mode main lever (10) Drain hose (18) Evaporator
(3) Vent door lever (11) Mix actuator lever (19) Evaporator lining
(4) Foot door lever (12) Foot door lever (20) Evaporator sensor
(5) Mode actuator link (13) Upper case
(6) Defroster lever (14) Packing Tightening torque: N·m (kgf-m, ft-lb)
(7) Foot duct (15) Cooling unit pipe T: 7.5 (0.76, 5.5)
(8) Lower case (16) O-ring
AC-00359
(1)
(8)
(7)
(9)
(15)
(11)
(2)
(3)
(4)
(5)
(6)
(14)
(18)
(16)
(17)
(16)
(19)
(20)
(12)
(13)
T
T
T
(10)
AC-8
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• RHD MODEL WITH MANUAL A/C
(1) Evaporator cover (10) Heater core (19) Expansion valve
(2) Side rod (11) Drain hose (20) Evaporator
(3) Mode actuator lever (12) Mix actuator rod (21) Evaporator lining
(4) Vent door lever (13) Mix actuator lever (22) Evaporator sensor
(5) Foot door lever (14) Foot door lever
(6) Mode actuator link (15) Upper case Tightening torque: N·m (kgf-m, ft-lb)
(7) Defroster lever (16) Packing T: 7.5 (0.76, 5.5)
(8) Foot duct (17) Cooling unit pipe
(9) Lower case (18) O-ring
AC-00084
(1)
(9)
(8)
(10)
(11)
(17)
(12)
(13)
(3)
(4)
(5)
(2)
(6)
(7)
(16)
(20)
(18)
(19)
(18)
(21)
(22)
(14)
(15)
T
T
T
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$36.99
Viewed 85 Times Today
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$36.99
If you are in need of a repair manual for the 2003 Subaru Forester, look no further. Our comprehensive repair manual software is now available in a convenient digital format, making it an ideal resource for both professional mechanics and DIY enthusiasts.
Gone are the days of purchasing traditional service manuals in book format at a higher cost. Our accessible repair manual software provides the same valuable information at a more affordable price and in a more user-friendly format.
Whether you are looking to address brake issues, replace suspension components, troubleshoot engine problems, or perform standard maintenance, our repair manual software for the Subaru Forester has you covered. It contains all the necessary service information for various vehicle systems including brakes, engine, suspension, steering, drivetrain, electrical, heating, and air conditioning.
By utilizing this repair manual software, you can save a significant amount of money on vehicle repairs. Avoid the high costs charged by mechanics and take matters into your own hands with the guidance provided in the 2003 Subaru Forester repair manual software.
Our manual is designed for ease of use and is compatible with Windows, Mac computers, smartphones, and tablets, ensuring accessibility across a wide range of devices.
