cooling 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-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-5
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
B: COMPONENT
1. HEATER COOLING UNIT
 LHD MODEL WITH AUTO A/C
(1) Evaporator cover (10) Heater core (19) O-ring
(2) Mode actuator (11) Drain hose (20) Expansion valve
(3) Mode main lever (12) Mix actuator (21) Evaporator
(4) Vent door lever (13) Mix door lever (22) Evaporator lining
(5) Foot door lever (14) Foot door lever (B) (23) Evaporator sensor
(6) Mode actuator link (15) Upper case
(7) Defroster lever (16) AspiratorTightening torque: N·m (kgf-m, ft-lb)
(8) Foot duct (17) PackingT: 7.5 (0.76, 5.5)
(9) Lower case (18) Cooling unit pipe
AC-00358
(1)
(9)
(8)
(10)
(18)
(12)(13)
(3)
(4)(5)
(2)
(6)(7)
(17)
(21)(19)
(20) (19)(22)
(23)
(14)(15)
T
T
T
(16)
(11)

AC-6
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
 RHD MODEL WITH AUTO A/C
(1) Evaporator cover (10) Heater core (19) Cooling unit pipe
(2) Mode actuator (11) Drain hose (20) O-ring
(3) Mode main lever (12) Mix actuator (21) Expansion valve
(4) Vent door lever (13) Mix door lever (22) Evaporator
(5) Foot door lever (A) (14) Foot door lever (B) (23) Evaporator lining
(6) Mode actuator link (15) Upper case (24) Evaporator sensor
(7) Defroster lever (16) Aspirator hose
(8) Foot duct (17) AspiratorTightening torque: N·m (kgf-m, ft-lb)
(9) Lower case (18) PackingT: 7.5 (0.76, 5.5)
AC-00001
(1)
(9)
(8)
(10)
(11)
(16) (19)
(12)(13)(3)
(4)(5)
(2)
(6)(7)
(18)
(22)
(20)(21)
(20)
(23)
(24)
(14)(15)
(17)
T
T
T

AC-7
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
 LHD MODEL WITH MANUAL A/C
(1) Evaporator cover (9) Heater core (17) Expansion valve
(2) Mode main lever (10) Drain hose (18) Evaporator
(3) Vent door lever (11) Mix actuator lever (19) Evaporator lining
(4) Foot door lever (12) Foot door lever (20) Evaporator sensor
(5) Mode actuator link (13) Upper case
(6) Defroster lever (14) PackingTightening torque: N·m (kgf-m, ft-lb)
(7) Foot duct (15) Cooling unit pipeT: 7.5 (0.76, 5.5)
(8) Lower case (16) O-ring
AC-00359
(1)
(8)
(7)
(9)
(15)
(11)
(2)
(3)(4)
(5)(6)
(14)
(18)(16)
(17) (16)(19)
(20)
(12)(13)
T
T
T
(10)

AC-8
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
 RHD MODEL WITH MANUAL A/C
(1) Evaporator cover (10) Heater core (19) Expansion valve
(2) Side rod (11) Drain hose (20) Evaporator
(3) Mode actuator lever (12) Mix actuator rod (21) Evaporator lining
(4) Vent door lever (13) Mix actuator lever (22) Evaporator sensor
(5) Foot door lever (14) Foot door lever
(6) Mode actuator link (15) Upper caseTightening torque: N·m (kgf-m, ft-lb)
(7) Defroster lever (16) PackingT: 7.5 (0.76, 5.5)
(8) Foot duct (17) Cooling unit pipe
(9) Lower case (18) O-ring
AC-00084
(1)
(9)
(8)
(10)
(11)
(17)
(12) (13)
(3)
(4)(5)
(2)
(6)(7)
(16)
(20)
(18)(19)
(18)
(21)
(22)
(14)(15)
T
T
T

AC-20
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
C: CAUTION
1. HFC-134a A/C SYSTEM
 The cooling system components for the HFC-
134a system such as the refrigerant and compres-
sor oil are different from the old conventional HFC-
12 system components and they are incompatible
with each other.
 Vehicles with the HFC-134a system can be iden-
tified by the label (A) attached to the vehicle.
Before maintenance, check which A/C system is in-
stalled in the vehicle.
2. COMPRESSOR OIL
 HFC-134a compressor oil has no compatibility
with that for R12 system.
 Use only the manufacturer-authorized compres-
sor oil for the HFC-134a system; only use
ZXL200PG.
 Do not mix multiple compressor oils.
If HFC-12 compressor oil is used in a HFC-134a A/
C system, the compressor may become stuck due
to poor lubrication, or the refrigerant may leak due
to swelling of rubber parts.
On the other hand, if HFC-134a compressor oil is
used in a HFC-12 A/C system, the durability of the
A/C system will be lowered.
 HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from the atmosphere us-
ing a plug or tape. In order to avoid moisture, store
the oil in a container with its cap securely closed.
3. REFRIGERANT
 The HFC-12 refrigerant cannot be used in the
HFC-134a A/C system. The HFC-134a refrigerant,
also, cannot be used in the HFC-12 A/C system.
 If an incorrect or no refrigerant is used, poor lu-
brication will result and the compressor itself may
be damaged.
4. HANDLING OF REFRIGERANT
 The refrigerant boils at approx. −30°C (−22°F).
When handling it, be sure to wear safety goggles
and protective gloves. Direct contact of the refriger-
ant with skin may cause frostbite.
If the refrigerant gets into your eye, avoid rubbing
your eyes with your hands. Wash your eye with
plenty of water, and receive medical treatment from
an eye doctor.
 Do not heat a service can. If a service can is di-
rectly heated, or put into boiling water, the inside
pressure will become extremely high. This may
cause the can to explode. If a service can must be
warmed up, use hot water in 40°C (104°F) max.
 Do not drop or impact a service can. (Observe
the precautions and operation procedure described
on the refrigerant can.)
 When the engine is running, do not open the
high-pressure valve of the manifold gauge. The
high-pressure gas will back-flow resulting in an ex-
plosion of the can.
 Provide good ventilation and do not work in a
closed area.
 In order to prevent global warming, avoid releas-
ing HFC-134a into the atmosphere. Using a refrig-
erant recovery system, discharge and reuse it.
AC-00006
(A)
(A) Goggles
(B) Gloves
(C) Avoid open flame
(D) No direct heat on container
(E) Do not discharge
(F) Loosen
(A)
(B)
(C) (D)
(E) (F)
AC-00007

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
1 1

AC-34
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Heater Core
9. Heater Core
A: REMOVAL
1) Remove the heater cooling unit. REMOVAL, Heater Cooling Unit.>
2) Remove the screws to remove the heater core
pipe cover (RHD model).
3) Remove the screws to remove mode actuator.
4) Remove the screws to remove foot duct.
5) Remove the screws to remove evaporator cover.6) Remove the screws to remove lower case.
7) Remove the heater core.
B: INSTALLATION
Install in the reverse order of removal.
AC-00042
AC-00043
AC-00044
AC-00867
AC-00046
AC-00047