ECO mode 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-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.

AB-33
AIRBAG SYSTEM (DIAGNOSTIC)
Clear Memory Mode
10.Clear Memory Mode
A: OPERATION
1) Turn the ignition switch to ON.
2) Connect the ground terminal (ground, terminal
“A”) to diagnosis connector terminal No. 1 in the in-
strument panel lower cover area.
3) While the airbag warning light flashes, connect
another ground terminal (ground, terminal “B”) to
diagnosis connector terminal No. 2.
4) Once the memory is erased, the airbag warning
light returns to the normal flash rate (0.6 sec on).
The failure to recover the normal flash rate indi-
cates that trouble parts still remain. Having re-
paired such parts, erase the memory again and
confirm that the normal flash rate has returned.
5) When the memory has been cleared, disconnect
the ground terminal from the diagnosis connector.
6) Wind tape around the ground terminal and return
it to its original position.
(1) Diagnosis connector
(2) Ground terminal “B”
(3) Ground terminal “A”
AB-00138B821
34 562(3)(2)
(1)

AB-35
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
1. LHD MODEL
WIRING DIAGRAM:
Step Check Yes No
1 CHECK POOR CONTACT IN CONNECTORS
(AB1) AND (B31).
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Remove the side sill cover. (Driver’s side)
3) Confirm that firm contact is secured
between connectors (AB1) and (B31).Is the poor contact in connec-
tors (AB1) and (B31)?Repair the body
harness or replace
the airbag main
harness with body
harness.Go to step 2.
AB-00739
12
34561
2345678910123456789101112131415161718192021222324252627282930
B31 i11AB3
i10
B:
C: i10
i11
AIRBAG
WARNING
LIGHTCOMBINATION
METERB9
B8
B10
NO.14
i3B38 28
i2B37 19
5
AIRBAG CONTROL MODULEAB3
B31
AB1
3
3
AIRBAG
CIRCUIT
E
BATTERY
1234567891011121314151617
1819202122232425262728
IGNITION
SWITCH
B: C:

AB-37
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
2. RHD MODEL
WIRING DIAGRAM:
Step Check Yes No
1 CHECK POOR CONTACT IN CONNECTORS
(AB1) AND (B31).
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Remove the side sill cover. (Driver’s side)
3) Confirm that firm contact is secured
between connectors (AB1) and (B31).Is the poor contact in connec-
tors (AB1) and (B31)?Repair the body
harness or replace
the airbag main
harness with body
harness.Go to step 2.
AB-00740
12
34561
2345678910123456789101112131415161718192021222324252627282930
B31 i11AB3
i10
B:
C: i10
i11
AIRBAG
WARNING
LIGHTCOMBINATION
METERB9
B8
B10
NO.14
i3B38 20
10
16
AIRBAG CONTROL MODULEAB3
B31
AB1
1
3
AIRBAG
CIRCUIT
E
BATTERY
1234567891011121314151617
1819202122232425262728
IGNITION
SWITCH

AB-39
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
B: AIRBAG WARNING LIGHT REMAINS OFF.
DIAGNOSIS:
 Fuse No. 14 (in fuse box) is blown.
 Body harness circuit is open.
 Airbag warning light is faulty.
 Airbag main harness is faulty.
 Airbag control module is faulty.
CAUTION:
 Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait more than 20 seconds before starting to work.
 After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor,
reconnect each part and confirm that the airbag warning light operates properly.
 When inspecting the airbag main harness, disconnect the airbag module connector of the driver
and passenger seats for safety reasons.
1. LHD MODEL
WIRING DIAGRAM:
AB-00739
12
34561
2345678910123456789101112131415161718192021222324252627282930
B31 i11AB3
i10
B:
C: i10
i11
AIRBAG
WARNING
LIGHTCOMBINATION
METERB9
B8
B10
NO.14
i3B38 28
i2B37 19
5
AIRBAG CONTROL MODULEAB3
B31
AB1
3
3
AIRBAG
CIRCUIT
E
BATTERY
1234567891011121314151617
1819202122232425262728
IGNITION
SWITCH
B: C:

AB-54
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
E: DTC 21
DIAGNOSIS:
Airbag control module is faulty.
CAUTION:
 Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait more than 20 seconds before starting to work.
 After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor,
reconnect each part and confirm that the airbag warning light operates properly.
Step Check Yes No
1 CHECK IF DTC 21 IS INDICATED.
Read the DTC. tic Trouble Code (DTC).>Is the airbag warning light DTC
21 indicated?Replace the airbag
control module.
Airbag Control
Module.>Perform the clear
memory mode.
Clear Memory
Mode.>

AB-58
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
H: DTC 24
DIAGNOSIS:
 Airbag control module is faulty.
 Airbag main harness circuit is open.
 Fuse No. 11 (in fuse and relay box) is blown.
 Body harness circuit is open.
CAUTION:
 Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait more than 20 seconds before starting to work.
 After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor,
reconnect each part and confirm that the airbag warning light operates properly.
 When inspecting the airbag main harness, disconnect the driver’s airbag module and passenger’s
airbag module connectors for safety reasons.
1. LHD MODEL
WIRING DIAGRAM:
AB-00623
AB3
AIRBAG CONTROL MODULEAB3
B31
AB1
AB1
1
6
BATTERY
IG SW
NO.11
B31
12
34561
23 45 61234567891011121314151617
1819202122232425262728

AB-62
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
I: DTC 25
DIAGNOSIS:
 Airbag control module is faulty.
 Airbag main harness circuit is open.
 Fuse No. 6 (in joint box) is blown.
 Body harness circuit is open.
CAUTION:
 Before diagnosing the airbag system, be sure to turn the ignition switch to OFF, disconnect the
ground cable from battery, and wait more than 20 seconds before starting to work.
 After replacing the airbag module, seat belt pretensioner, roll connector, control module or sensor,
reconnect each part and confirm that the airbag warning light operates properly.
 When inspecting the airbag main harness, disconnect the driver’s airbag module and passenger’s
airbag module connectors for safety reasons.
1. LHD MODEL
WIRING DIAGRAM:
AB-00624
AB3
AIRBAG CONTROL MODULEAB3
B31
AB1
AB1
2
5
BATTERY
IG SW
NO.6
B31
12
34561
23 45 61234567891011121314151617
1819202122232425262728

AB-67
AIRBAG SYSTEM (DIAGNOSTIC)
Diagnostic Procedure with Diagnostic Trouble Code (DTC)
Step Check Yes No
1 CHECK FRONT SUB-SENSOR (RH) AND
AIRBAG HARNESS.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Disconnect the connector (AB3) from the
airbag control module, and connect the con-
nector (1R) in test harness R. Airbag Control Module.>
3) Measure the resistance of the connector
(3R) in test harness R.
Connector & terminal
(3R) No. 7 — (3R) No. 9: Is the resistance 750 Ω and 1
KΩ? Replace the airbag
control module.
Airbag Control
Module.>Go to step 2.
2 CHECK AIRBAG MAIN HARNESS AND
FRONT SUB-SENSOR HARNESS (RH).
1) Disconnect the connector (AB15) from the
front sub-sensor. Sensor.>
2) Connect the connector (IH) in test harness
H to connector (AB15).
3) Measure the resistance between connector
(3R) in test harness R and connector (3H) in
test harness H.
Connector & terminal
(3R) No. 7 — (3H) No. 5:
(3R) No. 9 — (3H) No. 6: Is the resistance less than 10
Ω?Go to step 3.LHD model:
Replace the airbag
main harness and
front sub-sensor
harness with body
harness.
RHD model:
Go to step 4.
3 CHECK AIRBAG MAIN HARNESS AND
FRONT SUB-SENSOR HARNESS (RH).
Measure the resistance between connector
(3R) in test harness R and the chassis ground.
Connector & terminal
(3R) No. 7 — Chassis ground:
(3R) No. 9 — Chassis ground: Is the resistance more than 1
MΩ?Go to step 8.LHD model:
Replace the airbag
main harness and
front sub-sensor
harness with body
harness.
RHD model:
Go to step 4.
4 CHECK AIRBAG MAIN HARNESS
1) Disconnect the connector (AB13) from
(AB14), and connect the connector (1L) in test
harness L to connector (AB13).
2) Measure the resistance between connector
(3R) in test harness R and connector (3L) in
test harness L.
Connector & terminal
(3R) No. 7 — (3L) No. 4:
(3R) No. 9 — (3L) No. 3: Is the resistance less than 10
Ω?Go to step 5.Replace the airbag
main harness with
body harness.
5 CHECK AIRBAG MAIN HARNESS
Measure the resistance between connector
(3R) in test harness R and the chassis ground.
Connector & terminal
(3R) No. 7 — Chassis ground:
(3R) No. 9 — Chassis ground:Is the resistance more than 1
MΩ?Go to step 6.Replace the airbag
main harness with
body harness.
6 CHECK FRONT SUB-SENSOR HARNESS
(RH).
1) Connect the connector (2L) in test harness
F to the connector (AB14).
2) Measure the resistance between connector
(3H) in test harness H and connector (3L) in
the test harness L.
Connector & terminal
(3L) No. 5 — (3H) No. 5:
(3L) No. 6 — (3H) No. 6: Is the resistance less than 10
Ω?Go to step 7.Replace the front
sub-sensor har-
ness (RH) with
body harness.