radiator SUBARU FORESTER 2004 Service Repair Manual

AC-3
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
 MANUAL A/C MODEL
Condenser fan (Sub fan)Motor type Magnet
Power consumption2.5 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 consumption2.5 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 pressureON → OFF177±25 kPa
(1.80±0.25 kg/cm
2, 25.60±3.56 psi)
OFF → ON206±30 kPa
(2.10±0.31 kg/cm
2, 29.86±4.41 psi)
High-pressure switch
operating pressureON → OFF2,940±200 kPa
(29.98±2.03 kg/cm
2, 426.32±28.87 psi)
OFF → ON590±200 kPa
(6.02±2.03 kg/cm
2, 85.6±28.87 psi)
Middle pressure switch
operating pressureON → OFF1370±120 kPa
(13.97±1.22 kg/cm
2, 198.65±17.35 psi)
OFF → ON1,770±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)
RefrigerantHFC-134a (CH
2FCF3)
[600±50 g (1.32±0.11 lb)]
CompressorType Vane rotary, fix volume (DKV-14G)
Discharge
140 cm
3 (8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Magnet clutchType 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
OFFON
3.0
0.3

AC-4
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
CondenserType 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
EvaporatorType Single tank
Dimensions (W×H×T)176.5×266×60 mm
(6.95×10.47×2.36 in)
Blower fanFan 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 consumption2.5 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 consumption2.5 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 pressureON → OFF177±25 kPa
(1.80±0.25 kg/cm
2, 25.60±3.56 psi)
OFF → ON206±30 kPa
(2.10±0.31 kg/cm
2, 29.86±4.41 psi)
High-pressure switch
operating pressureON → OFF2,940±200 kPa
(29.98±2.03 kg/cm
2, 426.32±28.87 psi)
OFF → ON590±200 kPa
(6.02±2.03 kg/cm
2, 85.6±28.87 psi)
Middle pressure switch
operating pressureON → OFF1,370±120 kPa
(13.97±1.22 kg/cm
2, 198.65±17.35 psi)
OFF → ON1,770±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
OFFON
3.0
0.3

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-38
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Condenser (Sub Fan)
13.Condenser (Sub Fan)
A: REMOVAL
<Ref. to CO(H4SO)-35, REMOVAL, Radiator Main
Fan and Fan Motor.>
B: INSTALLATION
<Ref. to CO(H4SO)-37, INSTALLATION, Radiator
Main Fan and Fan Motor.>

AC-39
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Heater Cooling Unit
14.Heater Cooling Unit
A: REMOVAL
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) Drain the engine coolant from radiator.
4) Remove the bolt securing expansion valve and
pipe in engine compartment. Release the heater
hose clamps in engine compartment to remove the
hoses.
5) Remove the instrument panel. <Ref. to EI-40,
REMOVAL, Instrument Panel Assembly.>
6) Remove the support beam.
7) Remove the blower motor unit assembly. <Ref.
to AC-32, REMOVAL, Blower Motor Unit Assem-
bly.>
8) Disconnect the servo motor connectors.
9) Remove the bolt and nuts to remove the heater
and cooling unit.
B: INSTALLATION
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-5, HEATER COOLING UNIT,
COMPONENT, General Description.>
AC-00870
AC-00055

AC-44
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Ambient Sensor (Auto A/C Model)
19.Ambient Sensor (Auto A/C
Model)
A: REMOVAL
1) Open the front hood.
2) Disconnect the ground cable from battery.
3) Disconnect the ambient sensor connector.
4) Remove the ambient sensor from radiator lower
panel.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
<Ref. to AC-32, AMBIENT SENSOR, Diagnostic
Procedure for Sensors.>
AC-00125

AC-41
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
General Diagnostic Table
9. General Diagnostic Table
A: INSPECTION
Symptom Problem parts
A/C system fails to operate.Fuse
 Connector (Poor contact)
Ground
 Auto A/C control module
 Blower fan motor
 Blower fan relay
 A/C Relay
 Compressor (Magnet clutch)
 Evaporator sensor
Fuse is blown out.Fuse
 Connector (Poor contact)
Illumination cannot dim.Fuse
 Connector (Poor contact)
 Auto A/C control module
Blower fan does not rotate or fan speed cannot be controlled.Fuse
 Connector (Poor contact)
Ground
 Auto A/C control module
 Blower fan motor
 Blower fan relay
Unable to switch suction vents. Connector (Poor contact)
 Auto A/C control module
 Intake door actuator
Unable to switch blow vents. Connector (Poor contact)
 Auto A/C control module
 Mode door actuator
Compartment temperature does not increase. (No hot air is dis-
charged.) Connector (Poor contact)
 Auto A/C control module
 Air mix door actuator
 In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
 In-vehicle sensor aspirator hose
Compartment temperature does not decrease. (No cool air is
discharged.) Connector (Poor contact)
 Auto A/C control module
 Air mix door actuator
 A/C Relay
 Compressor (Magnet clutch)
 Radiator fan motor
 Radiator fan relay
 In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
 In-vehicle sensor aspirator hose
Compartment temperature is higher or lower than setting tem-
perature. Auto A/C control module
 Air mix door actuator
 In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
 In-vehicle sensor aspirator hose
Compartment temperature does not quickly respond to setting
temperature. Air mix door actuator
 In-vehicle sensor, ambient sensor, evaporator sensor and
sunload sensor
 In-vehicle sensor aspirator hose
Radiator fan does not rotate during A/C operation. Radiator fan motor
 Radiator fan relay

BS-4
BODY STRUCTURE
Datum Points
(1) Radiator panel gauge hole 6 mm
(0.24 in) dia. (Vehicle center)(14) Fender attaching hole 10 mm
(0.39 in) dia. (Symmetrical)(31) Harness attaching hole 7 mm
(0.28 in) dia. (Symmetrical)
(2) Radiator attaching hole 12 mm
(0.47 in) dia.(15) Fender attaching hole 10 mm
(0.39 in) dia. (Symmetrical)(32) Trim attaching hole 8.5 mm (0.33
in) dia. (Symmetrical)
(3) Headlight attaching hole 7 mm
(0.28 in) dia. (Symmetrical)(16) Front door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)(33) Trim attaching hole 7 mm (0.28 in)
dia. (Symmetrical)
(4) Frame plate gauge hole 8 mm
(0.31 in) dia. (Symmetrical)(17) Front door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)(34) Harness attaching hole 7×7 mm
(0.28×0.28 in) (Symmetrical)
(5) Bumper beam attaching hole 11
mm (0.43 in) dia. (Symmetrical)(20) Front door switch attaching hole
4.1 mm (0.16 in) dia. (Symmetri-
cal)(35) Tonneau cover bracket attaching
hole 5.5 mm (0.22 in) dia. (Sym-
metrical)
(6) Fender attaching hole 7 mm (0.28
in) dia. (Symmetrical)
(21) Rear door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)(36) Rear strut attaching hole 10 mm
(0.39 in) (Symmetrical)
(7) Fender attaching hole 9 mm (0.35
in) dia. (Symmetrical)
(22) Rear door hinge attaching hole 12
mm (0.47 in) dia. (Symmetrical)(37) Floor mat attaching hole 8 mm
(0.31 in) dia.
(8) Power steering tank attaching hole
RH ATF cooler pipe attaching hole
LH 9 mm (0.35 in) dia.(23) Front weather strip attaching hole
5.2 mm (0.20 in) dia. (Symmetri-
cal)(38) Trim attaching hole 9×9 mm
(0.35×0.35 in) (Symmetrical)
(9) Fender attaching hole 10 mm
(0.39 in) dia. (Symmetrical)(39) Trim attaching hole 8 mm (0.31 in)
dia. (Symmetrical)
(25) Rear weather strip attaching hole
5.2 mm (0.20 in) dia. (Symmetri-
cal) (10) Fender attaching hole 7 mm (0.28
in) dia. (Symmetrical)(40) Trim attaching hole 8 mm (0.31 in)
dia. (Symmetrical)
(11) Modular bracket gauge hole 8 mm
(0.31 in) dia. (Vehicle center)(26) Rear door switch attaching hole
4.1 mm (0.16 in) dia. (Symmetri-
cal)
(12) Front strut attaching hole 9.5 mm
(0.37 in) dia. (Symmetrical)
(29) Trim attaching hole 8.5 mm (0.33
in) dia. (Symmetrical)
(13) Front glass attaching hole LH
6.5×10.5 mm (0.26×0.41 in) RH
6.5×7 mm (0.26×0.28 in)(30) Pad attaching hole 5 mm (0.20 in)
dia. (Symmetrical)

BS-6
BODY STRUCTURE
Datum Points
(12) Front strut attaching hole 9.5 mm
(0.37 in) dia. (Symmetrical)(56) Transverse link attaching hole 16
mm (0.63 in) dia. (Symmetrical)(62) Rear cross member gauge hole
16 mm (0.63 in) dia. (Symmetri-
cal)
(36) Rear strut attaching hole 10 mm
(0.39 in) dia. (Symmetrical)(57) Sub-frame attaching hole 16 mm
(0.63 in) dia. (Symmetrical)
(63) Rear cross member attaching hole
12 mm (0.47 in) dia. (Symmetri-
cal) (51) Radiator lower frame gauge hole
12 mm (0.47 in) dia. (Symmetri-
cal)(58) Transmission cross member
attaching hole 14 mm (0.55 in)
dia. (Symmetrical)
(64) Rear bumper beam attaching hole
RH 15 mm (0.57 in) dia. LH 19×15
mm (0.75×0.59 in) (52) Side frame gauge hole 20 mm
(0.79 in) dia. (Symmetrical)(59) Rear side frame gauge hole 15
mm (0.59 in) dia. (Symmetrical)
(53) Sub-frame attaching hole 16 mm
(0.63 in) dia. (Symmetrical)(60) Rear side frame gauge hole 18
mm (0.71 in) dia. (Symmetrical)(65) Front cross member attaching
hole 12.4 mm (0.49 in) dia. (Sym-
metrical)
(54) Front cross member attaching
hole 12.4 mm (0.49 in) dia. (Sym-
metrical)(61) Rear differential attaching hole 16
mm (0.63 in) dia. (Symmetrical)
(66) Rear cross member attaching hole
16 mm (0.63 in) dia. (Symmetri-
cal)
(55) Transverse link attaching hole 17
mm (0.69 in) dia. (Symmetrical)
BS-00003
(52)(53)(54)(65)(12)(55)(61)
(61)
(64)
(64)
(51)
(51)
(36)
(36)(66)
(66)(56)(57)(58)(59)(60)
(52)(53) (54)
(65)
(12)(55)
(56)(57)(58)
(59)
(60)(62)
(62)(63)
(63)

IDI-17
INSTRUMENTATION/DRIVER INFO
Ambient Sensor
8. Ambient Sensor
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the ambient sensor connector.
3) Remove the ambient sensor (A) from radiator lower
panel.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Measure the ambient sensor resistance.
If NG, replace the ambient sensor.
Terminal Resistance
1 and 2 3 kΩ/25°C (77°F)
IDI00008
(A)
IDI-00009
21