air box SUBARU FORESTER 2004 Service Repair Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 2004, Model line: FORESTER, Model: SUBARU FORESTER 2004Pages: 2870, PDF Size: 38.67 MB
Page 59 of 2870
AC-3
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
General Description
2. General Description
A: CAUTION
1) Never connect the battery in reverse polarity.
Auto A/C control module may be destroyed instant-
ly.
2) Do not disconnect the battery terminals while the
engine is running.
A large counter electromotive force will be generat-
ed in the generator, and this voltage may damage
electronic parts such as auto A/C control module,
etc.
3) Before disconnecting the connectors of each
sensor and the auto A/C control module, be sure to
turn off the ignition switch.
Auto A/C control module may be damaged.
4) Every A/C-related part is a precision part. Do not
drop them.
5) Airbag system wiring harness is routed near the
A/C control panel (auto A/C control module) and
junction box.
CAUTION:
For airbag system, yellow-colored wiring har-
ness and connectors are all used. Do not use
the electrical test equipment on these circuits.
Be careful not to damage the airbag system
wiring harness when servicing the A/C control
panel (auto A/C control module) and junction
box.
B: INSPECTION
Before performing the diagnosis, check the follow-
ing items which might affect A/C system problems.
1. BATTERY
1) Measure battery voltage and specific gravity of
electrolyte.
Standard voltage: 12 V
Specific gravity: More than 1.260
2) Check the condition of the fuses for A/C system
power supply and other fuses.
3) Check the condition of harness and harness
connector connections.
2. ASPIRATOR HOSE
1) Turn the ignition switch to ON, and press the A/
C switch.
2) Turn the temperature control dial at maximum
hot position.
3) Press the defroster switch.
4) Turn the fan speed control dial to 4th position.5) Approach a strip of paper (b) in front of the in-ve-
hicle sensor suction port (a) located in the instru-
ment lower cover, and check that air is being
sucked into the port by seeing the paper moving to-
wards port.
NOTE:
Be careful not to let the paper get sucked into port.
6) If the paper does not move at all, remove the in-
strument panel lower cover
for improper connection of the aspirator hose (a),
in-vehicle sensor and heater unit, and repair them if
necessary.
3. A/C LINE
Check the connection for A/C line (A) and lower
side high-pressure pipe.
4. CONTROL LINKAGE
1) Check the state of mode door linkage.
2) Check the state of air mix door linkage.
3) Check the state of intake door linkage.
AC-00094
(a)
(a)
(b)
AC-00065
(a)
AC-00096
(A)
Page 69 of 2870
AC-13
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostics for A/C System Malfunction
Step Check Yes No
1 CHECK FUSE.
1) Turn the ignition switch to OFF.
2) Remove the fuse No. 2 from main fuse box.
3) Check the condition of fuse.Is the fuse blown-out? Replace the fuse. Go to step 2.
2 CHECK FUSE.
1) Turn the ignition switch to OFF.
2) Remove the fuse No. 17 from fuse & relay
box.
3) Check the condition of fuse.Is the fuse blown-out? Replace the fuse. Go to step 3.
3 CHECK AUTO A/C CONTROL MODULE
POWER CIRCUIT.
1) Pull out the auto A/C control module con-
nector.
2) Measure the voltage between auto A/C
control module connector terminal and chassis
ground after turning the ignition switch to OFF
position.
Connector & terminal
(i49) No. 4 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 4.Check open or
short circuit in har-
ness between auto
A/C control mod-
ule and fuse.
4 CHECK AUTO A/C CONTROL MODULE
POWER CIRCUIT.
Measure the voltage between auto A/C control
module connector terminal and chassis ground
after turning the ignition switch to ON position.
Connector & terminal
(i49) No. 5 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 5.Check open or
short circuit in har-
ness between auto
A/C control mod-
ule and fuse.
5 CHECK AUTO A/C CONTROL MODULE
GROUND CIRCUIT.
Measure the resistance in harness between
auto A/C control module and chassis ground.
Connector & terminal
(i49) No. 11 — Chassis ground:Is the resistance less than 1
Ω?Go to step 6.Repair the har-
ness for ground
line.
6 CHECK POOR CONTACT.
Check poor contact in auto A/C control module
connector.Is there poor contact in con-
nector?Repair the con-
nector.Replace the auto
A/C control mod-
ule.
Page 71 of 2870
AC-15
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostics for A/C System Malfunction
Step Check Yes No
1 CHECK FUSE.
1) Remove the fuse No. 1, 2 and 17 from fuse
& relay box.
2) Check the condition of fuse.Is any fuse blown-out? Replace the fuse. Go to step 2.
2 CHECK POWER SUPPLY FOR BLOWER
MOTOR.
1) Turn the ignition switch to ON.
2) Turn the fan speed control dial clockwise.
3) Measure the voltage between blower motor
and chassis ground.
Connector & terminal
(B87) No. 1 (+) — Chassis ground (
−):Is the voltage more than 8 V (at
normal temperature)?Go to step 3.Repair the open
circuit of blower
motor power sup-
ply line harness.
3 CHECK BLOWER MOTOR RELAY.
1) Turn the ignition switch to OFF.
2) Remove the blower motor relay.
3) Connect the battery positive (+) terminal to
terminal No. 1 of blower motor relay, and nega-
tive (−) terminal to terminal No. 3.
4) Measure the resistance between terminals
No. 2 and 4.
Te r m i n a l s
No. 2 — No. 4:Is the resistance less than 1
Ω?Go to step 4.Replace the
blower motor relay.
4 CHECK BLOWER MOTOR.
1) Disconnect the connector from blower
motor.
2) Connect the battery positive (+) terminal to
terminal No. 1 of blower motor connector, and
negative (−) terminal to terminal No. 2 and No.
5.
3) Make sure the blower motor runs.Does the blower motor run? Go to step 5.Replace the
blower motor.
5 CHECK POOR CONTACT.
Check poor contact in auto A/C control module
connector.Is there poor contact in con-
nector?Repair the con-
nector.Replace the auto
A/C control mod-
ule.
Page 74 of 2870
AC-18
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostics for A/C System Malfunction
Step Check Yes No
1 CHECK FUSE.
1) Turn the ignition switch to OFF.
2) Remove the main fan fuse and sub fan fuse
in main fuse box.
3) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Go to step 2.
2 CHECK THE POWER SUPPLY TO PRES-
SURE SWITCH.
1) Disconnect the connector from pressure
switch.
2) Turn the ignition switch to ON.
3) Measure the voltage between harness con-
nector and chassis ground.
Connector & terminal
(F79) No. 1 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 3.Repair the har-
ness for pressure
switch power sup-
ply circuit.
3 CHECK THE HARNESS BETWEEN PRES-
SURE SWITCH AND A/C RELAY HARNESS.
1) Turn the ignition switch to OFF.
2) Remove the A/C relay in the main fuse box.
3) Measure the resistance between A/C relay
and pressure switch connector.
Connector & terminal
(F27) No. 17 — (F79) No. 2:Is the resistance less than 1
Ω?Go to step 4.Repair the har-
ness between A/C
relay and pres-
sure switch.
4 CHECK THE PRESSURE SWITCH.
Measure the resistance between pressure
switch terminals.
Te r m i n a l s
No. 1 — No. 2:Is the resistance less than 1
Ω?Go to step 5.Replace the pres-
sure switch.
5 CHECK THE A/C CUT SIGNAL CIRCUIT.
1) Disconnect the connector from auto A/C
control module.
2) Measure the resistance between auto A/C
control module and pressure switch connector.
Connector & terminal
(i48) No. 10 — (F79) No. 2:Is the resistance less than 1
Ω?Go to step 6.Repair the har-
ness between auto
A/C control mod-
ule and pressure
switch.
6 CHECK THE A/C ON SIGNAL CIRCUIT.
1) Disconnect the connector from ECM.
2) Measure the resistance between ECM and
auto A/C control module connector.
Connector & terminal
Turbo model
(B137) No. 17 — (i49) No. 17:
Non-turbo model
(B136) No. 11 — (i49) No. 17:Is the resistance less than 1
Ω?Go to step 7.Repair the har-
ness between auto
A/C control mod-
ule and ECM.
7 CHECK A/C RELAY.
1) Remove the A/C relay in main fuse box.
2) Check the A/C relay.
OK?Go to step 8.Replace the A/C
relay.
8 CHECK POWER SUPPLY TO MAGNET
CLUTCH OF A/C COMPRESSOR.
1) Turn the ignition switch to OFF, and then
connect the A/C relay connector and all
removed connectors.
2) Start the engine, and turn A/C switch to
ON.
3) Set the temperature control dial to maxi-
mum cold position.
4) Measure the voltage between magnet
clutch harness connector and chassis ground.
Connector & terminal
(F24) No. 1 (+) — Chassis ground (
−):Is the voltage more than 10.5 V
(at normal temperature)?Go to step 9.Repair the har-
ness for power
supply line of A/C
compressor.
Page 94 of 2870
AC-38
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostic Procedure for Sensors
Step Check Yes No
1 CHECK EVAPORATOR SENSOR.
1) Turn the ignition switch to OFF.
2) Remove the glove box.
3) Disconnect the connector from evaporator
sensor.
4) Measure the resistance between connector
terminals of evaporator sensor.
Te r m i n a l s
No. 1 — No. 2:Is the resistance approx. 2.7
kΩ at 20°C (68°F)?Go to step 2.Replace the evap-
orator sensor.
2 CHECK INPUT SIGNAL FOR EVAPORATOR
SENSOR.
1) Turn the ignition switch to ON.
2) Measure the voltage between connector
(B256) terminal and chassis ground.
Connector & terminal
(B256) No. 1 (+) — Chassis ground (
−):Is the voltage approx. 5 V? Go to step 5.Go to step 3.
3 CHECK AUTO A/C CONTROL MODULE
OUTPUT SIGNAL.
1) Turn the ignition switch to OFF.
2) Remove the auto A/C control module.
3) Turn the ignition switch to ON.
4) Measure the voltage between connector
terminals of auto A/C control module.
Connector & terminal
(i49) No. 2 (+) — (i48) No. 16 (
−):Is the voltage approx. 5 V? Go to step 4.Go to step 6.
4 CHECK HARNESS CONNECTOR BETWEEN
AUTO A/C CONTROL MODULE AND EVAP-
ORATOR SENSOR.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from auto A/C
control module.
3) Measure the resistance in harness
between auto A/C control module and evapo-
rator sensor.
Connector & terminal
(B256) No. 1 — (i49) No. 2:Is the resistance less than 1Ω? Go to step 5.Repair the open
circuit in harness
between auto A/C
control module
and evaporator
sensor.
5 CHECK HARNESS CONNECTOR BETWEEN
AUTO A/C CONTROL MODULE AND EVAP-
ORATOR SENSOR.
Measure the resistance in harness between
auto A/C control module and evaporator sen-
sor.
Connector & terminal
(B256) No. 3 — (i48) No. 16:Is the resistance less than 1
Ω?Go to step 6.Repair the open
circuit in harness
between auto A/C
control module
and evaporator
sensor.
6 CHECK POOR CONTACT.
Check poor contact in auto A/C control module
connector.Is there poor contact in con-
nector?Repair the con-
nector.Replace the auto
A/C control mod-
ule.
Page 115 of 2870
AB-15
AIRBAG SYSTEM
Passenger’s Airbag Module
5. Passenger’s Airbag Module
A: REMOVAL
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module.
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery, and
wait for at least 20 seconds before starting work.
3) Remove the glove box.
4) Detach the airbag connector from support beam
bracket, and then disconnect the airbag connector.
5) Remove the three bolts, and then carefully re-
move the airbag module.
6) Refer to “CAUTION” for handling of removed air-
bag module.
B: INSTALLATION
Install in the reverse order of removal.
CAUTION:
Do not allow harness and connectors to inter-
fere or get tangled up with other parts.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion”
C: INSPECTION
CAUTION:
Refer to “CAUTION” in General Description be-
fore handing the airbag module.
Check for the following, and replace damaged
parts with new ones.
Airbag module, harness, connector, and mounting
bracket are damaged.
tion Locations After a Collision.>
AB-00117
Page 118 of 2870
AB-18
AIRBAG SYSTEM
Airbag Control Module
7. Airbag Control Module
A: REMOVAL
CAUTION:
Do not disassemble the airbag control mod-
ule.
If the airbag control module is deformed or if
water damage is suspected, replace the airbag
control module with a new part.
Do not drop the airbag control module.
After removal, keep the airbag control mod-
ule on a dry, clean surface away from moisture,
heat, and dust.
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery, and
wait for at least 20 seconds before starting work.
3) Remove the console cover.
4) Remove the center console panel.
5) Disconnect the connector from airbag control
module.
6) Remove the four bolts, and then remove the air-
bag control module.
B: INSTALLATION
CAUTION:
Use new bolts (for airbag control module only)
during reassembly.
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” in “General Descrip-
tion”
C: INSPECTION
Check for the following, and replace damaged
parts with new ones.
Control module, connector, and mounting brack-
et are damaged.
Airbag is deployed.
Side airbag is deployed.
AB-00035
Page 123 of 2870
AB-23
AIRBAG SYSTEM
Airbag Module Disposal (Deployment Processing On Vehicle)
8) Extend the wiring of deployment tool to the limit,
and make sure that the vehicle is empty. Close all
the windows, sunroof and rear gate completely.
9) Move the battery at least 5 m (16 ft) from vehicle,
and secure the nearby area. Connect the deploy-
ment tool alligator clip to the battery negative (−)
terminal.
10) Connect the other cable of deployment tool to
the battery positive (+) terminal, and deploy the air-
bag module.
CAUTION:
After deployment, the airbag module will be
especially hot, leave it unattended for 40 min-
utes, and then discard it.
Do not let water get on the deployed airbag
module.
11) Remove the airbag module.
12) Wrap the deployed airbag module in airtight vi-
nyl bag, and discard it.2. PASSENGER’S AIRBAG MODULE
1) Turn the ignition switch to OFF.
2) Disconnect the ground cable from battery and
wait for at least 20 seconds before starting work.
3) Remove the glove box.
4) Disconnect the airbag connectors (AB4) and
(AB27).
5) Short the terminal to alligator clip furnished as
deployment tool (A)
6) Connect the deployment tool (A) and deploy-
ment adapter E (B).
CAUTION:
The deployment tool should be kept shorted
terminals until just before deployment of airbag
module.
7) Connect the deployment adapter E to the airbag
connector (AB27).
SB-00017
SB-00018
AB-00043
(A) Deployment tool:
(Tool number 98299PA030)
(B) Deployment adapter E:
(Tool number 98299SA030)
(1) Deployment adapter E:
(Tool number 98299SA030)
SB-00016
AB-00199
AB27
(1)
Page 168 of 2870
AB-36
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
2 CHECK AIRBAG WARNING LIGHT.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (1T) in test harness
T to body harness connector (B31).
3) Connect the connector (1M) in test harness
M to connector (2T) in test harness T.
4) Connect the battery ground cable and turn
the ignition switch to ON.
5) Connect the connectors, (3M) and (4M) in
test harness M.Is the airbag warning light
turned off?Go to step 4.Go to step 3.
3 CHECK BODY HARNESS.
Check the body harness.
N
OTE:
After problem has been eliminated, disconnect
the connectors (3M) and (4M).Is the anything unusual to body
harness? Repair the body
harness.Replace the com-
bination meter
printed circuit.
Meter Assembly.>
4 CHECK POOR CONTACT.
Confirm that firm contact is secured between
the airbag control module and the connector
(AB3).
tor (AB3)?Replace the airbag
main harness with
body harness or
replace the airbag
control module.
Module.>Go to step 5.
5 CHECK AIRBAG MAIN HARNESS.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (AB1) to (B31).
3) Disconnect the connectors (AB2) and
(AB30).
4) Remove the glove box and disconnect the
connectors (AB4).
5) Disconnect the connector (AB3) from the
airbag control module, and connect the con-
nector (1R) in test harness R.
6) Connect the battery ground cable and turn
the ignition switch to ON.
7) Connect the connectors (5R) and (6R) in
test harness R.
N
OTE:
After problem has been eliminated, disconnect
the connectors (5R) and (6R).Is the airbag warning light
turned off?Go to step 6.Replace the airbag
main harness with
body harness.
6 CHECK GROUNDING CIRCUIT.
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.
3) Connect the connector (1R) in test harness
R to body harness connector (AB3).
4) Measure the resistance between connector
(2R) in test harness R and the chassis ground.
Connector & terminal
(2R) No. 10 — Chassis ground:
(2R) No. 11 — Chassis ground: Is the resistance less than 10
Ω?Replace the airbag
control module.
Module.>Repair the body-
grounding circuit. Step Check Yes No
Page 170 of 2870
AB-38
AIRBAG SYSTEM (DIAGNOSTIC)
Airbag Warning Light Failure
2 CHECK AIRBAG WARNING LIGHT.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (1M) in test harness
M to body harness connector (B31).
3) Connect the battery ground cable and turn
the ignition switch to ON.
4) Connect the connectors, (3M) and (4M) in
test harness M.Is the airbag warning light
turned off?Go to step 4.Go to step 3.
3 CHECK BODY HARNESS.
Check the body harness.
N
OTE:
After problem has been eliminated, disconnect
the connectors (3M) and (4M).Is the anything unusual to body
harness?Repair the body
harness.Replace the com-
bination meter
printed circuit.
Meter Assembly.>
4 CHECK POOR CONTACT.
Confirm that firm contact is secured between
the airbag control module and the connector
(AB3).
tor (AB3)? Replace the airbag
main harness with
body harness or
replace the airbag
control module.
Module.>Go to step 5.
5 CHECK AIRBAG MAIN HARNESS.
1) Turn the ignition switch to OFF, disconnect
the battery ground cable, and wait more than
20 seconds.
2) Connect the connector (AB1) to (B31).
3) Disconnect the connectors (AB21) and
(AB26).
4) Remove the glove box and disconnect the
connectors (AB4).
5) Disconnect the connector (AB3) from the
airbag control module, and connect the con-
nector (1R) in test harness R.
6) Connect the battery ground cable and turn
the ignition switch to ON.
7) Connect the connectors (5R) and (6R) in
test harness R.
N
OTE:
After problem has been eliminated, disconnect
the connectors (5R) and (6R).Is the airbag warning light
turned off? Go to step 6.Replace the airbag
main harness with
body harness.
6 CHECK GROUNDING CIRCUIT.
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.
3) Connect the connector (1R) in test harness
R to body harness connector (AB3).
4) Measure the resistance between connector
(2R) in test harness R and the chassis ground.
Connector & terminal
(2R) No. 10 — Chassis ground:
(2R) No. 11 — Chassis ground: Is the resistance less than 10
Ω?Replace the airbag
control module.
Module.>Repair the body-
grounding circuit. Step Check Yes No