Subaru 2004 Forester Manuel utilisateur

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

HVAC SYSTEM

(HEATER, VENTILATOR AND A/C)

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-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 capacity 5.0 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 m3(9,888 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V

Max air flow rate 480 m3(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 motor

Ty p e

Auto A/C (Brushless motor)

230 W or less 12.5 V

Manual A/C (Cylinder motor)

260 W or less 12.5 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 capacity 5.1 kW

(4,386 kcal/h, 17,403 BTU/h)

Refrigerant HFC-134a (CH2FCF3)

[0.6±0.05 kg (1.32±0.11 lb)]

Compressor

Type Vane rotary, fix volume (DKV-14G)

Discharge 140 cm3(8.54 cu in)/rev

Max. permissible speed 7,000 rpm

Magnet clutch

Type 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

Condenser

Type Corrugated fin (Sub cool type)

Core face area 0.234 m2(2.52 sq ft)

Core thickness 16 mm (0.63 in)

Radiation area 5.6 m2(62.28 sq ft)

Receiver drier Effective inner capacity 220 cm3(13.42 cu in)

Expansion valve Type External equalizing

Evaporator

Type Single tank

Dimensions (W×H×T) 176.5×266×60 mm

(6.95×10.47×2.36 in)

Blower fan

Fan 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 consumption

2.5 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 consumption

2.5 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 pressure

ON →OFF 177±25 kPa

(1.80±0.25 kg/cm2, 25.60±3.56 psi)

OFF →ON 206±30 kPa

(2.10±0.31 kg/cm2, 29.86±4.41 psi)

High-pressure switch

operating pressure

ON →OFF 2,940±200 kPa

(29.98±2.03 kg/cm2, 426.32±28.87 psi)

OFF →ON 590±200 kPa

(6.02±2.03 kg/cm2, 85.6±28.87 psi)

Middle pressure switch

operating pressure

ON →OFF 1370±120 kPa

(13.97±1.22 kg/cm2, 198.65±17.35 psi)

OFF →ON 1,770±100 kPa

(18.05±1.02 kg/cm2, 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)

Refrigerant HFC-134a (CH2FCF3)

[600±50 g (1.32±0.11 lb)]

Compressor

Type Vane rotary, fix volume (DKV-14G)

Discharge 140 cm3(8.54 cu in)/rev

Max. permissible speed 7,000 rpm

Magnet clutch

Type 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

OFF

3.0 0.3

AC-4

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

General Description

Condenser

Type Corrugated fin (Sub cool type)

Core face area 0.234 m2(2.52 sq ft)

Core thickness 16 mm (0.63 in)

Radiation area 5.6 m2(6.26 sq ft)

Receiver drier Effective inner capacity 220 cm3(13.42 cu in)

Expansion valve Type External equalizing

Evaporator

Type Single tank

Dimensions (W×H×T) 176.5×266×60 mm

(6.95×10.47×2.36 in)

Blower fan

Fan 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 consumption

2.5 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 consumption

2.5 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 pressure

ON →OFF 177±25 kPa

(1.80±0.25 kg/cm2, 25.60±3.56 psi)

OFF →ON 206±30 kPa

(2.10±0.31 kg/cm2, 29.86±4.41 psi)

High-pressure switch

operating pressure

ON →OFF 2,940±200 kPa

(29.98±2.03 kg/cm2, 426.32±28.87 psi)

OFF →ON 590±200 kPa

(6.02±2.03 kg/cm2, 85.6±28.87 psi)

Middle pressure switch

operating pressure

ON →OFF 1,370±120 kPa

(13.97±1.22 kg/cm2, 198.65±17.35 psi)

OFF →ON 1,770±100 kPa

(18.05±1.02 kg/cm2, 256.81±14.50 psi)

Thermo control amplifier working temperature

(Evaporator outlet air)

Item Specifications

AC-00082

OFF

3.0 0.3

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) Aspirator Tightening torque: N·m (kgf-m, ft-lb)

(8) Foot duct (17) Packing T: 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

(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) Aspirator Tightening torque: N·m (kgf-m, ft-lb)

(9) Lower case (18) Packing T: 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)

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) Packing Tightening torque: N·m (kgf-m, ft-lb)

(7) Foot duct (15) Cooling unit pipe T: 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

(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 case Tightening torque: N·m (kgf-m, ft-lb)

(7) Defroster lever (16) Packing T: 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)

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