sensor 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-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-44
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Ambient Sensor (Auto A/C Model)
19.Ambient Sensor (Auto A/C
Model)
A: REMOVAL
1) Open the front hood.
2) Disconnect the ground cable from battery.
3) Disconnect the ambient sensor connector.
4) Remove the ambient sensor from radiator lower
panel.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Procedure for Sensors.>
AC-00125

AC-45
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Sunload Sensor (Auto A/C Model)
20.Sunload Sensor (Auto A/C
Model)
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the sunload sensor connector.
CAUTION:
Be careful not to damage the sensors and inte-
rior trims when removing them.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Procedure for Sensors.>
AC-00126

HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
AC
Page
1. Basic Diagnostics Procedure ......................................................................2
2. General Description ....................................................................................3
3. Electrical Component Location ...................................................................5
4. Auto A/C Control Module I/O Signal............................................................7
5. Diagnostic Chart for Self-Diagnosis ............................................................9
6. Diagnostics for A/C System Malfunction ...................................................12
7. Diagnostic Procedure for Actuators ..........................................................21
8. Diagnostic Procedure for Sensors ............................................................32
9. General Diagnostic Table..........................................................................41

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 MOVAL, Instrument Panel Assembly.> and check
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)

AC-5
HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
Electrical Component Location
3. Electrical Component Location
A: LOCATION
1. ENGINE COMPARTMENT
(1) A/C compressor (3) Pressure switch (4) Ambient sensor
(2) A/C relay
AC-00097 (1)
(2)
(4)
(1)
(3)
(2)
(3)