Blow by SUBARU FORESTER 2004 Service Repair Manual

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 capacity5.0 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)/hHeat 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 motorTy p eAuto A/C (Brushless motor)
230 W or less12.5 V
Manual A/C (Cylinder motor)
260 W or less12.5 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 capacity5.1 kW
(4,386 kcal/h, 17,403 BTU/h)
RefrigerantHFC-134a (CH
2FCF3)
[0.6±0.05 kg (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 (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
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 (62.28 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 230 W or less at 12.5 V

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-9
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
2. BLOWER MOTOR UNIT
 LHD MODEL WITH AUTO A/C
(1) Upper case (4) Link lever (7) Lower case
(2) Air inlet select actuator (5) Filter cover (8) Blower motor ASSY
(3) Air inlet select link (6) Cover
AC-00334
(1)
(5)
(3)(2)
(4)
(6)
(7)
(8)

AC-10
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
 RHD MODEL WITH AUTO A/C
(1) Upper case (4) Link lever (7) Lower case
(2) Air inlet select actuator (5) Filter cover (8) Blower motor ASSY
(3) Air inlet select link (6) Cover
AC-00332
(1)
(5)
(3)(2)
(4)
(6)
(7)
(8)

AC-11
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
 LHD MODEL WITH MANUAL A/C
(1) Upper case (4) Link rod (7) Cover
(2) Air inlet select actuator (5) Filter cover (8) Lower case
(3) Air inlet select link (6) Blower resistor (9) Blower motor ASSY
AC-00209
(1)
(5)
(3)(2)
(4)
(7)
(8)
(6)
(9)

AC-12
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
 RHD MODEL WITH MANUAL A/C
(1) Upper case (4) Air inlet select link (7) Cover
(2) Air inlet select actuator (5) Filter cover (8) Lower case
(3) Air inlet select lever (6) Blower resister (9) Blower motor ASSY
AC-00085
(1)
(5)
(3)(2)
(4)
(7)
(8)
(6)
(9)

AC-29
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Charging Procedure
22) Set up the vehicle to the following status:
 A/C switch ON
 Engine running at 1,500 rpm
 Blower speed setting to “HI”
 Temperature setting to “MAX COOL”
 Air inlet setting to “RECIRC”
 Window open
23) Open the low-pressure valve and charge the
specified amount of refrigerant.
24) Close all valves and disconnect the hoses from
service port after charging the refrigerant.
25) Install the cap to service port.

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-32
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Blower Motor Unit Assembly
7. Blower Motor Unit Assembly
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the glove box. AL, Glove Box.>
3) Loosen the nut to remove the support beam
stay.
4) Disconnect the connectors of blower motor and
intake actuator resistor.
5) Loosen the bolt and nut to remove blower motor
unit assembly.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. COMPONENT, General Description.> AC-9, BLOWER MOTOR UNIT, COMPONENT,
General Description.>
C: INSPECTION
Inspection of Auto A/C Brush-less Motor
Operation
Connect the motor connector terminal 1 from the
battery to the positive (+) lead and terminal 2 and 5
at the same time to the negative (−) lead. Make
sure the motor runs smoothly.
AC-00218
AC-00219
AC-00220
AC-00244
22
55
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