compressor SUBARU FORESTER 2004 Service User Guide

AC-28
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Charging Procedure
6) Leave it at least 5 to 10 minutes after closing the
valves on low-/high-pressure sides, and then check
the low-pressure gauge reading for any changes.
When the gauge reading changes, this is a sign of
leakage. Check the pipe or hose connector points,
and repair if necessary. Repeat the procedure from
1) after repairing the faulty part.
7) If there are no leaks, further evacuate the sys-
tem 20 to 30 minutes.
8) Close all valves and stop the vacuum pump.
9) Following the can tap operation manual instruc-
tions, install it to refrigerant can.
10) Disconnect the vacuum pump from center
hose, and connect the hose to tap valve.
11) When a 13.6 kg (30 lb) refrigerant container is
used, measure the refrigerant amount in use using
a weighting scale before connecting to center hose.
12) Open the valve on HFC-134a source.13) Loosen the center hose connection on manifold
gauge (if applicable, press a purge valve on mani-
fold gauge) only for a couple of seconds to allow
the air in the center hose to escape by the refriger-
ant.
14) Make sure that the high-pressure valve of man-
ifold gauge is closed, and then open the low-pres-
sure side valve only to charge the refrigerant.
CAUTION:
Do not open the high-pressure valve. Be sure to
open the low-pressure valve.
15) Close the low-pressure valve when the low-
pressure gauge reading reaches 200 kPa (1,500
mmHg, 59.1 inHg).
16) Using a leak tester, check the system for refrig-
erant leaks.
17) After confirming that there are no leaks with the
leak test, charge the required amount of refrigerant.
18) If the HFC-134a source is empty, close the low-
pressure valve and then close the valve on can tap
before replacing the empty source. Restart charg-
ing operation after replacing the HFC-134a source
with a new one and purging.
19) Close the low-pressure valve if the charge rate
of refrigerant becomes worse.
20) Confirm that both the low-/high-pressure
valves are closed. Start the engine with A/C switch
OFF.
21) Quickly repeat A/C switch ON-OFF cycles a
few times to prevent initial compressor damage.
(1) Tap valve
(2) To center manifold hose
(1) Refrigerant container (HFC-134a)
(2) Weighting scale
AC-00214
(1)
(2)
AC-00215
(1)
(2)
(1) Open
(2) Close
AC-00216
AC-00217
(1)
(2)

AC-30
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Leak Check
5. Refrigerant Leak Check
A: INSPECTION
1) Operate the A/C system for approx. 10 minutes,
and confirm that the high-pressure side shows at
least 690 kPa (7.03 kg/cm
2, 100 psi). Then stop the
engine to start the leak test.
2) Starting from the connection between the high-
pressure pipe and evaporator, check the system for
leaks along the high-pressure side through the
compressor. The following items must be checked
thoroughly.
3) Check the joint and seam between the pressure
switch (triple pressure switch) and high-pressure
pipe.
4) Check the connections between the condenser
and pipes, and welded joints on the condenser.
The leak tester may detect the oil on the condenser
fins as a leak.
5) Check the joint between the compressor and
hoses.
6) Check the machined area of compressor and
other joints on the compressor.
7) Check the compressor shaft seal at the area
near the center of compressor clutch pulley.
Some shaft seals show a slight amount of leakage
about 28 g (1.0 oz) per year. This is not a problem.
8) Starting from the connection between the low-
pressure pipe and evaporator, check the system for
leakage along the low-pressure side through the
compressor. The following items must be checked
thoroughly.
 Connection between two parts
 Connection between the pipe and plate
9) Visually check the rubber area of the flexible
hose for cracks.
Check the entire length of the flexible hose, espe-
cially the connection with the metal hose end.CAUTION:
Carefully check the external surface of hoses
and tubes at approx. 25 mm (0.98 in) per sec-
ond.
10) Disconnect the drain hose from the heater
case, and check the hose end for at least 10 sec-
onds.
After the test is finished, reconnect the drain hose.
11) Turn the ignition switch to ON, and run the
blower at high speed for 1 minute. Stop the blower
to check the ventilation grille on the instrument pan-
el. While moving the tester closer to the grille, run
the blower for 1 or 2 seconds, then stop it. Check
the grille at that point for at least 10 seconds.
12) Check the valve in the service port.
13) Visually check the rubber seal in the service
port cap.
AC-00035
(A) Flexible hose
AC-00036
(A)
AC-00037
AC-00038

AC-31
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Compressor Oil
6. Compressor Oil
A: OPERATION
NOTE:
Before making repairs, conduct the oil return oper-
ation to return the compressor oil in circulation with
the refrigerant to the compressor.
1) Increase the engine speed to 1,500 rpm.
2) Turn ON the A/C switch.
3) Turn the temperature control dial to MAX COOL.
4) Set the air inlet select switch to RECIRC posi-
tion.
5) Turn the fan dial to HI.
6) Leave in this condition for 10 minutes.
B: REPLACEMENT
NOTE:
 If a component is replaced, add an appropriate
amount of compressor oil (same as the amount of
remaining oil in removed component).
 When replacing the compressor, the new com-
pressor will already have the specified amount of
oil in it. Install the new compressor after removing
the same amount of oil that is remaining in the com-
pressor removed.
Replacement parts Amount of oil replenishment
EvaporatorApprox. 50 cm
3
(1.7 US fl oz, 1.8 Imp fl oz)
CondenserApprox. 30 cm
3
(1.0 US fl oz, 1.1 Imp fl oz)
HoseApprox. 10 cm
3
(0.4 US fl oz, 0.4 Imp fl oz)
Receiver dryerApprox. 10 cm
3
(0.4 US fl oz, 0.4 Imp fl oz)

AC-36
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Compressor
11.Compressor
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
1) Check the clearance of the entire circumference
around the drive plate and pulley.
Standard:
0.3 — 0.6 mm (0.0118 — 0.0236 in)
2. MAGNETIC CLUTCH OPERATION
1) Disconnect the compressor connector.
2) Connect the battery positive (+) terminal to the
No. 3 terminal of the compressor connector.
3) Make sure the magnet clutch engages.
If NG, replace the compressor.
B: REMOVAL
1) Perform the compressor oil return operation.
<Ref. to AC-31, OPERATION, Compressor Oil.>
2) Turn the A/C switch OFF and stop the engine.
3) Using the refrigerant recovery system, discharge
refrigerant. <Ref. to AC-26, OPERATION, Refriger-
ant Recovery Procedure.>
4) Disconnect the ground cable from battery.
5) Remove the V-belt. <Ref. to ME(H4SO)-43, RE-
MOVAL, V-belt.> <Ref. to ME(H4DOTC)-52, RE-
MOVAL, V-belt.>
6) Remove the generator. <Ref. to SC(H4SO)-15,
REMOVAL, Generator.>
7) Remove the low-pressure hose and high-pres-
sure hose.
8) Disconnect the compressor harness from body
harness.9) Remove the bolts to remove compressor brack-
et.
10) Remove the bolts and then separate compres-
sor and bracket.
C: INSTALLATION
1) Install in the reverse order of removal.
2) Replace the O-rings on low-/high-pressure hos-
es with new ones, then apply compressor oil.
3) When replacing compressor, adjust amount of
compressor oil. <Ref. to AC-31, OPERATION,
Compressor Oil.>
4) Charge refrigerant. <Ref. to AC-27, OPERA-
TION, Refrigerant Charging Procedure.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. <Ref. to AC-16, AIR CONDITIONING
UNIT, COMPONENT, General Description.>
<Ref. to AC-18, COMPRESSOR, COMPO-
NENT, General Description.>
AC-00048
AC-00049
AC-00336
AC-00051

AC-37
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Condenser
12.Condenser
A: REMOVAL
1) Using the refrigerant recovery system, discharge
refrigerant. <Ref. to AC-26, OPERATION, Refriger-
ant Recovery Procedure.>
2) Disconnect the ground cable from battery.
3) Disconnect the pressure hose and pipe from
condenser.
4) Remove the radiator bracket (A).
5) Remove the two bolts. While lifting the condens-
er, pull it out through the space between radiator
and radiator panel.
CAUTION:
Be careful not to damage the radiator fins and
condenser fins. If a damaged fin is found, repair
it using a thin screwdriver.
If the condenser is replaced, add appropriate
amount of compressor oil to the compressor.
<Ref. to AC-31, REPLACEMENT, Compressor
Oil.>
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Replace the O-rings on hoses or pipes with new
ones, and then apply compressor oil. Confirm
that lower guide of condenser has been fitted
into holes on radiator panel.
2) Charge refrigerant. <Ref. to AC-27, OPERA-
TION, Refrigerant Charging Procedure.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion.
<Ref. to AC-16, AIR CONDITIONING UNIT,
COMPONENT, General Description.>
<Ref. to CO(H4SO)-7, RADIATOR AND RADI-
ATOR FAN, COMPONENT, General Descrip-
tion.>
C: INSPECTION
1) Check that no dust or insects are found on the
condenser fins. Air-blow or flush fins with water as
needed.
2) Check that no oil leaks from condenser. If a fail-
ure is found, replace the condenser with a new one.
AC-00246
AC-00053(A)
AC-00091
AC-00092

AC-40
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Evaporator
15.Evaporator
A: REMOVAL
1) Perform the refrigerant recovery operation, and
then disconnect the toe board area A/C pipe. <Ref.
to AC-26, OPERATION, Refrigerant Recovery Pro-
cedure.>
2) Remove the glove box.
3) Remove blower motor unit assembly. <Ref. to
AC-32, REMOVAL, Blower Motor Unit Assembly.>
4) Loosen the screws and remove evaporator cov-
er.
5) Remove the A/C pipes in unit.
6) Rotate the upper part of evaporator tilt toward
the front vehicle and the lower part tilt toward the in-
terior, respectively. Then pull out the heater case to
the left side.
7) Remove the two bolts to remove expansion
valve.
CAUTION:
If the evaporator is replaced, add appropriate
amount of compressor oil to evaporator. <Ref.
to AC-31, REPLACEMENT, Compressor Oil.>
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Replace the O-ring for A/C pipe with a new one,
and then apply compressor oil.
AC-00867
AC-00868

AC-41
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Hose and Tube
16.Hose and Tube
A: REMOVAL
CAUTION:
 When disconnecting/connecting hoses, do not
apply excessive force to them. Confirm that no
torsion and excessive tension exists after install-
ing.
 Seal the disconnected hose with a plug or vi-
nyl tape to prevent foreign matters from enter-
ing.
1) Disconnect the ground cable from battery.
2) Using the refrigerant recovery system, dis-
charge refrigerant. <Ref. to AC-26, OPERATION,
Refrigerant Recovery Procedure.>
3) Remove the evaporator unit mounting bolt (A).
4) Remove the low-pressure hose attaching bolts
(B).
5) Disconnect the low-pressure hose from evapo-
rator unit.
6) Disconnect the low-pressure hose from com-
pressor.
7) Remove the low-pressure hose from vehicle.
8) Remove the high-pressure hose attaching bolts
(C).
9) Disconnect the high-pressure hose from com-
pressor.
10) Disconnect the high-pressure hose from con-
denser.
11) Remove the high-pressure hose from vehicle.
12) Remove the high-pressure tube attaching bolt
(D).
13) Remove the high-pressure tube from vehicle.
B: INSTALLATION
CAUTION:
 When disconnecting/connecting hoses, do
not apply an excessive force to them. Confirm
that no torsion and excessive tension exists af-
ter installing.
 Seal the disconnected hose with a plug or vi-
nyl tape to prevent foreign matters from enter-
ing.
 Replace the o-rings for hoses and pipes with
new ones, and then apply compressor oil.
1) Install in the reverse order of removal.
2) Charge refrigerant. <Ref. to AC-27, OPERA-
TION, Refrigerant Charging Procedure.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. <Ref. to AC-16, AIR CONDITIONING
UNIT, COMPONENT, General Description.>
C: INSPECTION
NOTE:
Check the hoses for cracks, damage and expan-
sion. If any failure is found, replace them with new
ones.
AC-00869
(A)
(C) (B)
(D)

AC-50
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Diagnostics
25.General Diagnostics
A: INSPECTION
Symptom Repair order
Blower motorDoes not run.Fuse
Blower motor relay
Wiring harness
Blower motor
Blower motor resistor (Manual A/C model)
Blower switch
Noise Blower motor
CompressorDoes not run.Refrigerant
Fuse
A/C relay
Wiring harness
Magnet clutch
Compressor
Pressure switch
A/C switch
Blower switch
NoiseV- B e l t
Magnet clutch
Compressor
Condenser fanDoes not run.Fuse
Sub fan relay
Wiring harness
Noise Condenser fan motor
Cold air not emitted.Refrigerant
V- B e l t
Magnet clutch
Compressor
Pressure switch
Blower fan relay, Blower motor
A/C switch
Blower switch
Wiring harness
Heater duct
Heater vent duct
Control unit
Expansion valve
Evaporator
Air mix actuator (Auto A/C), Temperature control cable (Manual
A/C)
Warm air not emitted.Engine coolant
Aspirator hose
Blower switch
Air mix actuator (Auto A/C), Temperature control cable (Manual
A/C)
Heater core
Heater cock solenoid valve (Non-turbo model for EC/EK)

AC-4
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
General Description
5. CONTROL SWITCHES
Start and warm-up the engine completely.
1) Inspection using switches
2) Compressor operation inspection
3) Inspection of illumination control
No. Point to check Switch operation Judgment standard
1 Fan speed control dial Turn the fan speed control dial clockwise.Fan speed changes 1st → 2nd → 3rd → 4th
as dial turn.
2AUTO switch1) Press the AUTO switch.
2) Turn the temperature control dial to the left
fully, and set maximum cool position. Outlet air temperature: COOL
 Fan speed: 4th
 Outlet opening: VENT
 Inlet opening: RECIRC
 Compressor: AUTO
3) Turn the temperature control dial to the right
slowly, and change the setting from maximum
cool position to maximum hot position gradually. Outlet air temperature: COOL → HOT
 Fan speed: AUTO
 Outlet opening: AUTO
 Inlet opening: AUTO
 Compressor: AUTO
4) Turn the temperature control dial to the right
fully, and set maximum hot position. Outlet air temperature: HOT
 Fan speed: 4th
 Outlet opening: HEAT
 Inlet opening: FRESH
 Compressor: AUTO
3 Defroster switch Press the defroster switch. Outlet air temperature: AUTO
 Fan speed: AUTO
 Outlet opening: DEF
 Inlet opening: FRESH
 Compressor: ON
4FRESH/RECIRC
switchPress the FRESH/RECIRC switch.Inlet opening switches RECIRC → FRESH or
FRESH → RECIRC each time pressing the
switch.
5 Mode control dial Press the mode control dial.Outlet opening switches VENT → BI-LEVEL
→ HEAT → DEF/HEAT each time dialing
clockwise.
No. Point to check Switch operation Judgment standard
1 Compressor1) A/C switch is turned to ON.
2) Turn the fan speed control clockwise.Compressor: ON
No. Point to check Switch operation Judgment standard
1 Illumination1) Turn the lighting switch to ON. Illumination comes on.
2) Press the OFF switch one second or more. Illumination dimming is cancelled.

AC-5
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Electrical Component Location
3. Electrical Component Location
A: LOCATION
1. ENGINE COMPARTMENT
(1) A/C compressor (3) Pressure switch (4) Ambient sensor
(2) A/C relay
AC-00097 (1)
(2)
(4)
(1)
(3)
(2)
(3)