clutch SUBARU FORESTER 2004 Service Repair Manual

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-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-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-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.

2) Turn the A/C switch OFF and stop the engine.
3) Using the refrigerant recovery system, discharge
refrigerant. ant Recovery Procedure.>
4) Disconnect the ground cable from battery.
5) Remove the V-belt. MOVAL, V-belt.> MOVAL, V-belt.>
6) Remove the generator. 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. Compressor Oil.>
4) Charge refrigerant. TION, Refrigerant Charging Procedure.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. UNIT, COMPONENT, General Description.>
NENT, General Description.>
AC-00048
AC-00049
AC-00336
AC-00051

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-10
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostic Chart for Self-Diagnosis
Step Check Yes No
1 SELECT CONTROL PANEL TO SELF-DIAG-
NOSIS MODE.
1) Turn the ignition switch to OFF.
2) Start the engine while pressing defroster
switch and A/C switch.
N
OTE:
Self-diagnosis can also be performed with the
ignition switch ON, but start the engine be-
cause telling the magnet clutch operation is dif-
ficult.
3) The LED in A/C control panel blinks.Does the self-diagnosis mode
operate?Go to step 2. C OR SELF-DIAG-
NOSIS SYS-
TEMS DO NOT
OPERATE, Diag-
nostics for A/C
System Malfunc-
tion.>
2 CHECK LED ILLUMINATION.
Make sure that three LED blink in turn on A/C
control panel (5 patterns are repeated 2 times).Do all LED blink? Go to step 3.Go to step 5.
3 CHECK SENSORS MALFUNCTION.
1) After completing the LED check or when
AUTO switch is pressed, the A/C switch LED
illuminates, and then the sensor check is
started.
2) Check the input signal of each sensor in
turn. If there are any trouble for each sensor,
DEF, MODE and fan speed LEDs are blinked.
Also check for each sensor is possible respec-
tively every time AUTO switch is pressed. (At
this time, the AUTO switch LED illuminates.)
3) If there is no trouble, DEF, MODE and fan
speed LEDs are turned off.
N
OTE:
Rear window defogger LED illuminates in case
of stored malfunction but does not illuminate in
case of present malfunction.Does each DEF, MODE and
fan speed LED turn off?Go to step 4.Confirm the com-
bination of illumi-
nating LEDs by
using Sensor
Check Table, and
identify the mal-
functioning sensor
before repairing.
SENSOR CHECK
TABLE, OPERA-
TION, Diagnostic
Chart for Self-
Diagnosis.>
4 CHECK OPERATION OF EACH ACTUATOR,
COMPRESSOR AND FAN MOTOR.
1) Press the FRESH/RECIRC switch
(FRESH/RECIRC switch LED illuminates at
this time.).
2) Refer to OPERATING MODE TABLE to
check the operation of each actuator, compres-
sor and fan motor. ING MODE TABLE, OPERATION, Diagnostic
Chart for Self-Diagnosis.>
Also check for each step is possible respec-
tively every time AUTO switch pressed. (At this
time, the AUTO switch LED illuminates.)Does each actuator, compres-
sor and fan motor operate
according to operating mode
table?Press the OFF
switch or turn the
ignition switch to
OFF and finish the
self-diagnosis
mode.Refer to each
diagnostics chart
for actuator, com-
pressor and fan
motor, and repair
the malfunctioning
par t as necessary.
Diagnostics for A/
C System Mal-
function.> AC-21, Diagnostic
Procedure for
Actuators.>
5 CHECK POOR CONTACT.
Check the auto A/C control module connector
for poor contact.Is there a poor contact in con-
nector?Replace the auto
A/C control mod-
ule.Repair the con-
nector.

AC-11
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostic Chart for Self-Diagnosis
1. SENSOR CHECK TABLE
NOTE:
When the sunload sensor is checked indoors or in the shade, open circuit might be indicated. Always check
the sunload sensor at a place where sun shines directly on it.
*1: Only present malfunction is indicated for open circuit of sunload sensor. (However, stored malfunction can be indicated for
short circuit of sunload sensor.)
2. OPERATING MODE TABLE
Diag-
nostic
stepsChecked sensorOpen circuit Short circuitPresent
malfunctionStored
malfunction
DEF LEDMODE/FAN
LEDDEF LEDMODE/FAN
LEDREAR WINDOW
DEFOGGER LED
1 In-vehicle sensor
Tu r n o f fVENT
LED blinks
IlluminateVENT
LED blinks
Turn off Illuminate 2 Ambient sensorBI-LEVEL
LED blinksBI-LEVEL
LED blinks
3 Evaporator sensorHEAT
LED blinksHEAT
LED blinks
4 Sunload sensor*1DEF/HEAT
LED blinksDEF/HEAT
LED blinks
5 Air mix door actuator P.B.R.Fan speed
1st
LED blinksFan speed
1st
LED blinks
6Combination meter commu-
nication (Ambient sensor)Fan speed
2nd
LED blinksFan speed
2nd
LED blinks
When all parts are in good condition Turn off
Step 12345678
Illuminating LEDVENT
LEDBI-LEVEL
VENTHEAT LEDDEF/HEAT
LEDFan speed
1st LEDFan speed
2nd LEDFan speed
3rd LEDFan speed
4th LED
Fan speed LO LO ML ML ML MH MH HI
Mode actuator VENT VENT VENT BI-LEVEL HEAT HEAT DEF/HEAT DEF
Intake actuator FRESH RECIRC RECIRC FRESH FRESH FRESH FRESH FRESH
Air mix door actuatorFULL
COOL
(0%)FULL
COOL
(0%)FULL
COOL
(0%)MEDIUM
(50%)MEDIUM
(50%)FULL HOT
(100%)FULL HOT
(100%)FULL HOT
(100%)
Compressor
(magnet clutch)OFFONONONONONONON

AC-16
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostics for A/C System Malfunction
C: COMPARTMENT TEMPERATURE DOES NOT CHANGE, OR A/C SYSTEM
DOES NOT RESPOND PROMPTLY.
TROUBLE SYMPTOM:
 Compartment temperature is not changed. (No cool air is discharged.)
 A/C system does not respond quickly.
WIRING DIAGRAM:
 LHD model
AC-00882
A: B134 :
B: B135 :
B202
D: B137 :C: B136 :
F2F27
EA:
i48
F27
F17
F79
F45
B62
B202
i41
F24
F24
F16F79
F45
F17
B:
i49A:
B134 B136
B135 B137C:
B:D:IGNITION
SWITCHBATTERY
A/C RELAY HOLDER
FAN RELAY
FAN RELAY
A/C RELAY
PRESSURE SWITCH
COMPRESSOR
MAGNET
CLUTCH FAN MODE RELAYSUB FAN FUSE
MAIN FAN FUSE
MAIN FAN MOTOR
1
M
SBF-1SBF-4F/B NO.17
F/B NO.18
1
2
3
2
1
4
3033
32 31
34
86
7 9
5
2926
27 28
25
1916
15 18
17
43
21
B15A10B17
F17
MAIN FAN MOTOR
M
F16
SUB FAN MOTOR
M
F16
SUB FAN MOTOR
M
1
2112 1314
15 16171819
20
10
1121222324
2526272829
3031323334
35
36
12
93456
7
82 314
567
82 1
94
310
24 22 23 251112131415
26 27
281617181920 21
4
1
53
2618 15 167891011
17 19
20121314
1234567891011121314151617181920212223242526272829303132333435
AUTO A/C
CONTROL MODULE ECM
2421
1234 5678910 11 12 13 14 15 16 17 18 19 20
123 4567
8910 11 12 13 14 15 16
56
78 2 1
94
310
24 22 23 251112131415
261617181920 21
34 12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 24567
D: B137 :
B: B135 :C: B136 :
A: i48
12345678
910 11 12 13 14 15 16
B: i49
12345678910
11 12 13 14 15 1617 18 19 20
: TURBO MODEL : B33
NON-TURBO MODEL : A91*
: TURBO MODEL : B24
NON-TURBO MODEL : A132*
: TURBO MODEL : B25
NON-TURBO MODEL : A143*
: TURBO MODEL : C30
NON-TURBO MODEL : B114*
: TURBO MODEL : D17
NON-TURBO MODEL : C115*
: TURBO MODEL : D13
NON-TURBO MODEL : D136*
: TURBO MODELTB
: NON-TURBO MODEL
NA
: EXCEPT NON-TURBO
AT MODEL
ET
ETNA
TB
TBNANANATB
1112
10
3
18 1
*2*3*4*5*6*
2F2
B100
ET
ETTA
TA
ET
TA
ET
: TURBO AT MODEL
TATA
TA
ET
:
ET :
F16
F17
TA :
TA :
567
82 1
94 310
24 22 23 2511 12 13 14 15
26 27
2816 17 18 19
20 21
29 30 31 32 33 34 3556
782 1
94 310
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35
567
82 1
94 310
22 23 11 12 13 14 15
24 25
2616 17
18 19 20 21
27 28 29 30 31
12
1
2
2 1
12

AC-17
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostics for A/C System Malfunction
 RHD model
AC-00883
A: B134 :
B: B135 :
B202
D: B137 :C: B136 :
F2F27
EA:
i48
F27
F17
F79
B202
i41
B201
i40
F24
F16F79
B201
F17
B:
i49A:
B134 B136
B135 B137C:
B:D:IGNITION
SWITCHBATTERY
A/C RELAY HOLDER
FAN RELAY
FAN RELAY
A/C RELAY
PRESSURE SWITCH
COMPRESSOR
MAGNET
CLUTCH FAN MODE RELAYSUB FAN FUSE
MAIN FAN FUSE
MAIN FAN MOTOR
1
M
SBF-1SBF-4F/B NO.17
F/B NO.18
1
2
3
2
1
4
3033
32 31
34
86
7 9
5
2926
27 28
25
1916
15 18
17
43
21
B15A10B17
F17
MAIN FAN MOTOR
M
F16
SUB FAN MOTOR
M2
1
F16
SUB FAN MOTOR
M
2112 1314
15 16171819
20
10
1121222324
2526272829
3031323334
35
36
12
93456
7
82 314
567
82 1
94
310
24 22 23 251112131415
26 27
281617181920 21
4
1
53
2618 15 167891011
17 19
20121314
1234567891011121314151617181920212223242526272829303132333435
AUTO A/C
CONTROL MODULE ECM
2123
56
78 2 1
94
310
24 22 23 251112131415
261617181920 21
34 12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 24567
D: B137 :
B: B135 :C: B136 :
A: i48
12345678
910 11 12 13 14 15 16
B: i49
12345678910
11 12 13 14 15 1617 18 19 20
: TURBO MODEL : B33
NON-TURBO MODEL : A91*
: TURBO MODEL : B24
NON-TURBO MODEL : A132*
: TURBO MODEL : B25
NON-TURBO MODEL : A143*
: TURBO MODEL : C30
NON-TURBO MODEL : B114*
: TURBO MODEL : D17
NON-TURBO MODEL : C115*
: TURBO MODEL : D13
NON-TURBO MODEL : D136*
: TURBO MODELTB
: NON-TURBO MODEL
NA
: EXCEPT NON-TURBO
AT MODEL
ET
ETNA
TB
TBNANANATB
1918
7
2122
3 1
*2*3*4*5*6*
F2
B100
ET
ETTA
TA
ET
TA
ET
: TURBO AT MODEL
TATA
TA
ET
:
ET :
567
82 1
94 310
24 22 23 2511 12 13 14 15
26 27
2816 17 18 19
20 21
29 30 31 32 33 34 3556
782 1
94 310
24 22 23 2511 12 13
1415
26 27
2816
17 18 19 20 21
33 34 29
32 30
31 35
567
82 1
94 310
22 23 11 12 13 14 15
24 25
2616 17
18 19 20 21
27 28 29 30 31
12345 678910
11
1219 20 21
13 14 151617
18 22
34 12 8910 11
12 13 14 15 16 17 18 19 20 21 22 23 2456 7
F24
1
F16
F17
TA :
TA :
12
2 1
2 1

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. INSPECTION, Relay and Fuse.>Is the operation of the 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.