dimensions 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-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

GW-19
GLASS/WINDOW/MIRROR
Front Door Glass
6) Adjust so that the upper and lower ends of cen-
ter pillar are the same size.
7) For glass stroke adjustment, close the door, raise
glass until positional relationship between glass and
weather strip becomes as shown. And secure the
glass so that the upper stopper lightly touches the
glass holder.For preventing wind noise, adjust the glass at the
position where tip of gusset is raised up a little.
8) After stabilizer adjustment, carry out the glass
crimp adjustment. First, visually ensure positional
relationship between retainer & molding and glass
of the roof side, and then begin with rear sash ad-
justment. Adjust two adjusting bolts alternately step
by step to obtain dimensions shown below (cross-
section A).
NOTE:
If two nuts are loosened at the same time, sash
moves back and forth. Therefore, when one nut is
adjusted, secure the other.
9) Make the same adjustment of two adjusting bolts
of rear sash.
(1) Narrow
(2) Wide
(3) Glass tilts too far rearward
(4) Glass tilts too far forward
(5) Raise B channel
(6) Lower B channel
(1) 3.5±0.8 mm (0.137±0.031 in)
(2) 9.5±1 mm (0.374±0.039 in)
GW-00139 (6) (5)
(4)
(1)(2) (1)
(2) (3)
A
A
(1)
(2)
GW-00066
(A) 0 — 1.5 mm (0 — 0.059 in)
(1) 3.5±0.8 mm (0.137±0.031 in)
(2) 9.5±1 mm (0.374±0.039 in)
GW-00024
A
A
(1)
(2)
GW-00066

GW-23
GLASS/WINDOW/MIRROR
Rear Door Glass
B: INSTALLATION
1) Install in the reverse order of removal.
CAUTION:
Make sure that the glass stay is placed securely
in sash.
2) Adjust the rear door glass. JUSTMENT, Rear Door Glass.>
Tightening torque:
Refer to COMPONENT in General Descrip-
tion. COMPONENT, General Description.>
C: ADJUSTMENT
NOTE:
The rear door glass, as a rule, should be adjusted in
the same manner as front glass, although they are
different in dimension. Special notes for the rear
glass are given below.
1) Adjust the glass position using the following di-
mensions as a guide line. (Clearance between up-
per side and lower side is within 1.5 mm (0.059 in).)
NOTE:
 If the dimensions are smaller than the given di-
mensions, glass may get caught in weather strip
during lifting/lowering operation. In the worst case, it
may cause the glass not to be opened fully.
 After adjustment, move the glass up and down to
check whether it is caught.2) Adjust the crimp of glass using the following di-
mensions as a guide line.
NOTE:
 If the crimp of rear glass is higher than neces-
sary, glass may get caught in weather strip of cen-
ter pillar corner, resulting in early wear of weather
strip. Be careful when adjusting.
 After adjustment, move the glass up and down to
check whether it is caught.
(1) 12±1 mm (0.472±0.039 in)
AA
A-A
(1)
(1)
GW-00067
(1) 3.5±0.8 mm (0.137±0.031 in)
(2) 9.5±1 mm (0.374±0.039 in)
A
A
(1)
(2)
GW-00068

BODY STRUCTURE
BS
Page
1. General Description ....................................................................................2
2. Datum Points...............................................................................................3
3. Datum Dimensions ....................................................................................11

BS-11
BODY STRUCTURE
Datum Dimensions
3. Datum Dimensions
A: MEASUREMENT
Refer to LOCATION for details on measurement
points.
NOTE:
 Using a tram tracking gauge, measure all dimen-
sions.
 When using a tape measure, carefully measure
dimensions without letting the tape measure sag or
twist.
 Measure the linear dimensions between cores of
holes.
 Suffixes “RH” and “LH” indicate right-hand and
left-hand.
 Measure at the center of the circle around the
outside of the body panel.
(1) Tram tracking gauge
(1) Datum point
(2) Body panel
(3) Outside
BS-00033
(1)
BS-00034
(1)
(3)
(2)

BS-12
BODY STRUCTURE
Datum Dimensions
1. CENTER STRUCTURE
*1: Standard line
*2: Side sill
*3: Upper surface
Unit: mm (in)
BS-00035
(54)(53)(52)
(55)(59)(57)(58)
(12)
(52)
(52)
(55)
(55)
(56)
(56)
(57)
(57)
(58)
(58)
(59)
(53)
(53)
(54)
(54)
(12)
(12)2
9(0.35)11(0.43)
77(3.03)
620(24.41)
910(35.83)
906(35.67)
856(33.70)
(62)(64)
(61)
(36)
1 13
694(27.32)
230(9.06)1070(42.13) 1270(50.00)
585(23.03)
500(19.69)
(61)
(61)
(64)
(64)
(63)
(63)
(62)
(62)
(36)
(36)
1136(44.72)
1221(48.07)
3
474(18.66)
621(24.45)
(51)
(51)860(33.86)1065(41.93)
(60)
(59)(60)
630(24.80)
(52)
(55)
(57)
(53)
(53)
(54)
924(36.38)917(36.10)
1209(47.60)
1005(39.57)
(61)(64)
(62)(59)(60)
1207(47.52)1124(44.25)
206(8.11)77(3.03)20(0.79) 14(0.55)
135(5.31)669(26.34)205(8.07)
356(14.02)
485(19.09)317(12.48)
329(12.95)
1110(43.70)920(36.22)920(36.22)838(32.99)529(20.83)780(30.71)776(30.55)
878(34.57)
1438(56.61)
1332(52.44)1205(47.44)
882(34.72)954(37.56)

BS-13
BODY STRUCTURE
Datum Dimensions
2. SUSPENSION CROSSMEMBER
*1: Standard line
*2: Side sill
Unit: mm (in)
BS-00036
(54)
(54)
(65)
(65)
(54)
(66)(63)2
75(2.95)
150(5.91) 2547(100.28)
860(33.86)
840(33.07)
(62)
(65)
1 1
(66)
(66)
(63)
(63)
(62)
(62)
920(36.22)
206(8.11)139(5.47)205(8.07)

BS-14
BODY STRUCTURE
Datum Dimensions
3. FRONT STRUCTURE
Unit: mm (in)
Point to point Dimension Point to point Dimension
(1) to (11) 822 (32.36) (7) LH to (15) LH 1,067 (42.01)
(2) RH to (11) 842 (33.15) (8) RH to (8) LH 921 (36.26)
(2) LH to (11) 875 (34.45) (9) RH to (9) LH 1,396 (54.96)
(3) RH to (3) LH 716 (28.19) (9) RH to (10) RH 398 (15.67)
(4) RH to (4) LH 978 (38.50) (9) LH to (10) LH 398 (15.67)
(5) RH to (5) LH 1,049 (41.30) (9) RH to (11) 767 (30.20)
(6) RH to (6) LH 1,341 (52.80) (9) LH to (11) 767 (30.20)
(6) RH to (9) RH 349 (13.74) (10) RH to (11) 722 (28.43)
(6) LH to (9) LH 349 (13.74) (10) LH to (11) 722 (28.43)
(6) RH to (11) 944 (37.17) (10) RH to (13) RH 907 (35.71)
(6) LH to (11) 944 (37.17) (10) LH to (13) LH 907 (35.71)
(7) RH to (14) RH 1,155 (45.47) (11) to (12) RH 565 (22.24)
(7) LH to (14) LH 1,155 (45.47) (11) to (12) LH 565 (22.24)
(7) RH to (15) RH 1,067 (42.01) (12) RH to (12) LH 1,065 (41.93)
(6) (6)
(5)
(5) (4)
(4)(1)
(3)(2) (9)(10)(13)
BS-00037
(2)
(13)
(11)(10)
(12)(14)
(15)
(3)
(9)
(8)
(7)
(8)
(12)

BS-15
BODY STRUCTURE
Datum Dimensions
Unit: mm (in)
Point to point Dimension Point to point Dimension
(16) RH to (20) RH 980 (38.58) (30) LH to (33) LH 796 (31.34)
(16) LH to (20) LH 980 (38.58) (31) RH to (34) RH 759 (29.88)
(17) RH to (20) RH 982 (38.66) (31) LH to (34) LH 759 (29.88)
(17) LH to (20) LH 982 (38.66) (35) RH to (38) RH 665 (26.18)
(21) RH to (25) RH 853 (33.58) (35) LH to (38) LH 665 (26.18)
(21) LH to (25) LH 853 (33.58) (35) RH to (39) RH 711 (27.99)
(22) RH to (26) RH 895 (35.24) (35) LH to (39) LH 711 (27.99)
(22) LH to (26) LH 895 (35.24) (35) RH to (40) RH 784 (30.87)
(23) LH to (23) RH 1,429 (56.26) (35) LH to (40) LH 784 (30.87)
(29) RH to (32) RH 674 (26.54) (36) LH to (36) RH 1,221 (48.07)
(29) LH to (32) LH 674 (26.54) (36) RH to (37) RH 1,067 (42.01)
(30) RH to (33) RH 796 (31.34) (36) LH to (37) LH 1,067 (42.01)
BS-00038
(30)
(29)
(17)
(16)(22)
(26)
(25)(36)
(36)
(37)(38)
(39)
(40)
(35)
(20)
(21)
(23)
(33)
(34)
(31)
(32)