service SUBARU FORESTER 2004 Service Repair Manual

FUJI HEAVY INDUSTRIES LTD. G8080GE7
2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTIC) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEM WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOW/MIRROR GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEAT SE
SECURITY AND LOCK SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANEL EB

2004 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G8080GE7
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)CC(H4SO)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)CC(H4DOTC)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)CC(H4DOTC 2.5)
IMMOBILIZER (DIAGNOSTIC) IM

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-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-22
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
Illustration Tools and Equipment
Wrench
Va r i o u s WRENCHES will be required to service any A/C system. A 7 to
40 N·m (0.7 to 4.1 kgf-m, 5 to 30 ft-lb) torque wrench and various crow-
foot wrenches will be needed. Open end or flare nut wrenches will be
needed for back-up on the tube and hose fittings.
Applicator bottle
A small APPLICATOR BOTTLE is recommended to apply refrigerant
oil to the various parts. They can be available at a hardware or drug
store.
Manifold gauge set
A MANIFOLD GAUGE SET (with hoses) can be available at from
either a refrigerant supplier or an automotive equipment supplier.
Refrigerant recovery system
A REFRIGERANT RECOVERY SYSTEM is used for the recovery and
reuse of A/C system refrigerant after contaminants and moisture have
been removed from the refrigerant.
AC-00213
AC-00012
AC-00013
AC-00014

AC-26
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Recovery Procedure
3. Refrigerant Recovery Proce-
dure
A: OPERATION
CAUTION:
 During operation, be sure to wear safety gog-
gles and protective gloves.
 Connect the refrigerant recovery system with
the manifold gauge set to discharge the refrig-
erant from the A/C system and reuse it.
 When reusing the discharged refrigerant, keep
service cans on hand. Because the discharge
rate with the recovery system is approx. 90%, ser-
vice cans are necessary to charge the refrigerant.
 Follow the detailed operation procedure de-
scribed in the operation manual attached to the
refrigerant recovery system.
1) Perform the compressor oil return operation.

2) Stop the engine.
3) Make sure the valves on low-/high-pressure
sides of manifold gauge set are fully closed.4) Install the low-/high-pressure hoses to the ser-
vice ports on the low-/high-pressure sides of the
vehicle respectively.
5) Connect the center hose to the refrigerant recov-
ery system.
6) Follow the operation manual to activate the re-
frigerant recovery system.
L: Low-pressure gauge
H: High-pressure gauge
(1) Low-pressure valve
(2) Vacuum pump valve
(3) High-pressure valve
(4) For low-pressure
(5) For vacuum pump
(6) For high-pressure
AC-00146
(2) (4)
(5)(6)
(3)(3)
(2) (1)H L
(1)
(1) Low-pressure service port
(2) High-pressure service port
(3) Close
AC-00147
(3) (2) (1)

AC-27
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Charging Procedure
4. Refrigerant Charging Proce-
dure
A: OPERATION
CAUTION:
 During operation, be sure to wear safety gog-
gles and protective gloves.
 If air is mixed in refrigeration cycle, poor cool-
ing may result, and also if moisture is mixed in re-
frigeration cycle, clogging (freezing) or rust may
result.
Before charging the refrigerant, evacuate the
system using vacuum pump to remove air and
moisture in the system. Moisture can be evapo-
rated and removed easily even at normal tem-
perature, if the system is evacuated using
vacuum pump.
1) Close all valves of manifold gauge.2) Install the low-/high-pressure hoses to corre-
sponding service ports on vehicle.
CAUTION:
Be sure that the hoses are securely connected.
3) Connect the center hose of manifold gauge with
vacuum pump.
4) Activate the vacuum pump and then open the
valves on low-/high-pressure sides.
CAUTION:
Be sure to evacuate the system using vacuum
pump.
5) After at least 5 minutes of evacuation, if the low-
pressure gauge reading shows 100.0 kPa (750
mmHg, 29.5 inHg) or higher, close the valves on
center hose to stop the vacuum pump.
L: Low-pressure gauge
H: High-pressure gauge
(1) Low-pressure valve
(2) Vacuum pump valve
(3) High-pressure valve
(4) For low-pressure
(5) For vacuum pump
(6) For high-pressure
AC-00146
(2) (4)
(5)(6)
(3)(3)
(2) (1)H L
(1)
(1) Low-pressure service port
(2) High-pressure service port
(3) Close
(1) Vacuum pump
(2) Open
AC-00147
(3) (2) (1)
AC-00148
(1)(2)

AC-29
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Refrigerant Charging Procedure
22) Set up the vehicle to the following status:
 A/C switch ON
 Engine running at 1,500 rpm
 Blower speed setting to “HI”
 Temperature setting to “MAX COOL”
 Air inlet setting to “RECIRC”
 Window open
23) Open the low-pressure valve and charge the
specified amount of refrigerant.
24) Close all valves and disconnect the hoses from
service port after charging the refrigerant.
25) Install the cap to service port.

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-43
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Pressure Switch (Triple Pressure Switch)
18.Pressure Switch (Triple Pres-
sure Switch)
A: INSPECTION
1) Connect the manifold gauge to the service valve
on the high-pressure side.
2) Remove the pressure switch harness connector.
Using a circuit tester, inspect the ON-OFF opera-
tion of the pressure switch.
AC-00248
31
4
2
Terminal
No.OperationStandard
kPa (kg/cm2, psi)
High and low pressure switch 1 and 2Tu r n s O F F.Pressure increases up to 2,940±200 (30.0±2, 427±28).
Pressure decreases down to 177±25 (1.8±0.3, 26±4).
Tu r n s O N .Pressure increases up to 206±30 (2.1±0.3, 30±4).
Pressure decreases down to 2,350±200 (24±2, 341±28).
Middle pressure switch 3 and 4Turns OFF. Pressure decreases down to 1,370±120 (14±1, 199±14).
Turns ON. Pressure increases up to 1,770±100 (18±1, 256±14).