torque SUBARU FORESTER 2004 Service Repair Manual

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-16
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
4. AIR CONDITIONING UNIT
 LHD MODEL
(1) Condenser (5) CompressorTightening torque: N·m (kgf-m, ft-lb)
(2) High-pressure hose (6) O-ringT1: 7.4 (0.75, 5.4)
(3) Low-pressure hose (7) Triple pressure switchT2: 15 (1.5, 10.8)
(4) Pipe
AC-00866
(1)(3)
(4)
(7) (5)
(2)
T1
T1T2(6) (6)
(6)(6)
(6) T2(6)

AC-17
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
 RHD MODEL
(1) Condenser (5) CompressorTightening torque: N·m (kgf-m, ft-lb)
(2) High-pressure hose (6) O-ringT1: 7.4 (0.75, 5.4)
(3) Low-pressure hose (7) Triple pressure switchT2: 15 (1.5, 10.8)
(4) Pipe
AC-00243
(1)(3)
(4)
(7)
(5)
(2)
T1
T1
T2
(6)
(6)
(6)
(6)
(6)
T2

AC-18
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
5. COMPRESSOR
(1) Idler pulley bracket (7) Compressor belt cover (Non-turbo
model)Tightening torque: N·m (kgf-m, ft-lb)
(2) Idler pulley adjusterT1: 4.0 (0.40, 2.95)
(3) Idler pulley (8) Compressor stayT2: 22.6 (2.3, 16.6)
(4) Compressor bracketT3: 23.0 (2.35, 17.0)
(5) CompressorT4: 28.9 (2.95, 21.3)
(6) V-beltT5: 35 (3.6, 26)
AC-00335
(1)
(3)
(2)
(4)
(5)
(8)
(6)
(7)
T3
T2
T1
T5
T5
T5
T4T4

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-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