meter 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-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

AC-21
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
5. O-RING CONNECTIONS
 Use new O-rings.
 In order to keep the O-rings free of lint which will
cause a refrigerant gas leak, perform operations
without gloves and shop cloths.
 Apply the compressor oil to the O-rings to avoid
sticking, then install them.
 Use a torque wrench to tighten the O-ring fittings:
Over-tightening will damage the O-ring and tube
end distortion.
 If the operation is interrupted before completing a
pipe connection, recap the tubes, components, and
fittings with a plug or tape to prevent foreign mat-
ters from entering.
 Visually check the surfaces and mating surfaces
of O-rings, threads, and connecting points. If a fail-
ure is found, replace the applicable parts.
 Install the O-rings at right angle to the tube
beards. Use compressor oil specified in the service man-
ual to lubricate the O-rings.
Apply the oil to the top and sides of the O-rings be-
fore installation.
Apply compressor oil to the bead of tube.
 After tightening, use a clean cloth to remove ex-
cess compressor oil from the connections and any
oil which may have run on the vehicle body or other
parts.
 If any leakage is suspected after tightening, do
not retighten the connections, disconnect the con-
nections, remove the O-rings, and check the O-
rings, threads, and connections.
D: PREPARATION TOOL
CAUTION:
When working on vehicles with the HFC-134a
system, only use HFC-134a specified tools and
parts. Do not mix with CFC-12 tools and parts. If
HFC-134a and CFC-12 refrigerant or compres-
sor oil is mixed, poor lubrication will result and
the compressor itself may be destroyed.
In order to help prevent mixing HFC-134a and
CFC-12 parts and liquid, the tool and screw
type and the type of service valves used are dif-
ferent. The gas leak detectors for the HFC-134a
and CFC-12 systems must also not be inter-
changed.(A) Seal
(A) O-ring
(B) OK
(C) NG
(D) Bead
(A)
AC-00008
AC-00009
(D) (B)
(C)
(C)
(A)
HFC-134a CFC-12
Tool & screw type Millimeter size Inch size
Valve type Quick joint type Screw-in type
AC-00010

AC-23
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
Syringe
A graduated plastic SYRINGE will be needed to add oil back into the
system. The syringe can be available at a pharmacy or a drug store.
Vacuum pump
A VACUUM PUMP (in good working condition) is necessary, and can
be available at either a refrigerant supplier or an automotive equipment
supplier.
Can tap
A CAN TAP for the 397 g (14 oz) can is available at an automotive
equipment supplier.
Thermometer
Pocket THERMOMETERS are available at either a industrial hardware
store or a refrigerant suppliers. Illustration Tools and Equipment
AC-00015
AC-00016
AC-00017
AC-00018

AC-8
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Auto A/C Control Module I/O Signal
*1: Battery voltage is indicated when motor running, 0 V or battery voltage pulse signal is output when motor stops.
*2: Battery voltage is indicated when motor running, 0 V is indicated when motor stops.
*3: Voltage can not be measured because of pulse signal.
B: WIRING DIAGRAM:

A14Combination meter (ambient temperature sig-
nal)*3 *3
A13 Mode door actuator position detection signal OutletVENT, BI-LEVEL, HEAT 5 V
DEF/HEAT, DEF 0 V
A12 Mode door actuator position detection signal OutletVENT, DEF/HEAT 5 V
BI-LEVEL, HEAT, DEF 0 V
A10 A/C cutout signalA/C: ON Battery voltage
Pressure switch operated 0 V
A9 Illumination ground When there is continuity to chassis ground 0 Ω Terminal No. Content Measuring conditionSpecified
value

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-32
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostic Procedure for Sensors
8. Diagnostic Procedure for Sensors
A: AMBIENT SENSOR
TROUBLE SYMPTOM:
 Fan speed is not switched when the fan speed control dial is in AUTO position.
 Malfunction related to ambient sensor is indicated in self diagnosis.
WIRING DIAGRAM:
 LHD model
AC-00107
A:
i48B:
i49B:
i10
12345678
910 11 12 13 14 15 1612345678910
11 12 13 14 15 16 17 18 19 20
3
4 128910 11
12 13 14 15 16 17 18 19 20 21 22 23 24567
i41
B202
B202B38
i3
B38
B:
i10
COMBINATION
METER
A:
i48B:
i49
19
A14
24
B30
123456789101112131415161718192021222324252627282930
219
32
1234 5610 11 12 13 14 15716
23 3019 20
22 26 27 28 29817
24 3118
25
AUTO A/C
CONTROL
MODULE
i2
B37
141521
B24
B25
12
B62F45F78AMBIENT
SENSOR
B37
3
4 12
8910 11 12 13 14 15 16567
F45
12
F78

AC-33
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostic Procedure for Sensors
 RHD model
AC-00884
A:
i48B:
i49B:
i10
12345678
910 11 12 13 14 15 1612345678910
11 12 13 14 15 16 17 18 19 20
3
4 128910 11
12 13 14 15 16 17 18 19 20 21 22 23 24567
i41
B202
B202
B:
i10
COMBINATION
METER
A:
i48B:
i49
3 A14
B30
123456789101112131415161718192021222324252627282930
AUTO A/C
CONTROL
MODULE
i2
B37
141521
B24
B25
1817
B100F2F78AMBIENT
SENSOR
F2
12
F78
21
1413 16
: MT MODEL
: AT MODEL
3
4 128910
11
12 13 14 15 16 17 18 19 20 21 225673
4 12 8
910 11
12 13 14 15 16 17 185
67
i2 :
i2 :
MT AT
AT
MT AT MT

AC-34
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Diagnostic Procedure for Sensors
Step Check Yes No
1 CHECK HARNESS CONNECTOR BETWEEN
AUTO A/C CONTROL MODULE AND COM-
BINATION METER.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from auto A/C
control module and combination meter.
3) Measure the resistance in harness
between auto A/C control module and combi-
nation meter.
Connector & terminal
(i10) No. 30 — (i48) No. 14:Is the resistance less than 1
Ω?Go to step 2.Repair the har-
ness between auto
A/C control mod-
ule and combina-
tion meter.
2 CHECK AMBIENT SENSOR CIRCUIT.
Check the ambient sensor circuit. 8, CHECK OUTSIDE TEMPERATURE INDI-
CATOR, INSPECTION, Combination Meter
System.>Is the ambient sensor circuit
normal?Go to step 3.Repair the ambi-
ent sensor circuit.
3 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 A/C
control module.