Subaru FORESTER2001 Manuel utilisateur

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, reassem-

bling, inspection and adjustment of com-

ponents and diagnostics for guidance 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 genu-

ine parts.

All information, illustration and specifica-

tions contained in this manual are based

on the latest product information avail-

able at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD.

2001 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX

BODY SECTION

G8050GE6

HVAC SYSTEM (HEATER, VENTILATOR

AND A/C) AC

Page

1. General Description.....................................................................................2

2. Refrigerant Pressure with Manifold Gauge Set........................................18

3. Refrigerant Recovery Procedure...............................................................19

4. Refrigerant Charging Procedure...............................................................20

5. Refrigerant Leak Check ............................................................................23

6. Compressor Oil .........................................................................................25

7. Heater Unit................................................................................................26

8. Blower Motor Assembly.............................................................................27

9. Power Transistor (Heater Blower Resistor) ..............................................28

10. Heater Core...............................................................................................29

11. Control Unit ...............................................................................................30

12. Compressor...............................................................................................32

13. Condenser.................................................................................................34

14. Receiver Drier ...........................................................................................35

15. Intake Unit.................................................................................................36

16. Flexible Hose.............................................................................................38

17. Relay and Fuse.........................................................................................39

18. Pressure Switch (Dual Switch)..................................................................40

19. Air Vent Grille............................................................................................41

20. Heater Duct...............................................................................................42

21. Heater Vent Duct.......................................................................................43

22. General Diagnostics..................................................................................44

1. General Description S701001

A: SPECIFICATIONS S701001E49

1. HEATER SYSTEM S701001E4901

Item Specifications Condition

Heating capacity

LHD model 5.1 kW (4,386 kcal/h, 17,404 BTU/h)

or more

쐌Mode selector switch: HEAT

쐌Temperature control switch: FULL HOT

쐌Temperature difference between hot

water and inlet air: 65°C (149°F)

쐌Hot water flow rate: 360 (95.1 US gal,

79.2 Imp gal)/h

RHD model 4.93 kW (4,240 kcal/h, 16,824 BTU/h)

or more

Air flow rate LHD model 280 m

(9,887 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V

RHD model 300 m

(10,593 cu ft)/h

Max air flow rate LHD model 480 m

(16,949 cu ft)/h 쐌Temperature control switch: FULL COLD

쐌Blower fan speed: 4th position

쐌Mode selector lever: RECIRC

RHD model 460 m

(16,243 cu ft)/h

Heater core size

(height ×length ×width)

LHD model 193.5 ×152 ×35.0 mm

(7.62 ×5.98 ×1.378 in) —

RHD model 161.4 ×176.4 ×32 mm

(6.35 ×6.94 ×1.26 in)

Blower

motor

Type LHD model Magnet motor 260 W or less at 12 V

RHD model Magnet motor 250 W or less

Fan type and size

(diameter ×width)

LHD model Sirocco fan type

150 ×75 mm (5.91 ×2.95 in) —

RHD model Sirocco fan type

150 ×75 mm (5.91 ×2.95 in)

AC-2

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

2. A/C SYSTEM S701001E4902

쐌LHD Model:

Item Specifications

Type of air conditioner Reheat air-mix type

Cooling capacity 5.117 kW

(4,400 kcal/h, 17,459 BTU/h)

Refrigerant HFC-134a (CH

FCF

)

[0.65±0.05 kg (1.43±0.11 lb)]

Compressor Type 5-vane rotary, fix volume (KC50G)

Discharge 140 cm

(8.54 cu in)/rev

Max. permissible speed 7,000 rpm

Magnet clutch

Type Dry, single-disc type

Power consumption 38 W

Type of belt V-Ribbed 4 PK

Pulley dia. (effective dia.) 125 mm (4.92 in)

Pulley ratio 1.064

Condenser

Type Corrugated fin (Multi-flow)

Core face area 0.255 m

(2.74 sq ft)

Dimensions (W ×H×T) 22 ×374 ×683 mm

(0.87 ×14.72 ×26.89 in)

Radiation area 6.52 m

(70 sq ft)

Receiver drier Effective inner capacity 250 cm

(15.26 cu in)

Expansion valve Type Internal equalizing

Evaporator Type Single tank

Dimensions (W ×H×T) 60 ×224 ×235 mm

(2.36 ×8.82 ×9.25 in)

Blower fan Fan type Sirocco fan

Outer diameter ×width 150 ×75 mm (5.91 ×2.95 in)

Power consumption 260 W at 12 V

Condenser fan (Sub fan) Motor type Magnet

Power consumption 70 W at 12 V

Fan outer diameter 320 mm (12.60 in)

Radiator fan (Main fan) Motor type Magnet

Power consumption 70 W at 12 V

Fan outer diameter 320 mm (12.60 in)

Dual switch

(Pressure switch)

Low-pressure switch

operating pressure

ON →OFF 177±25 kPa

(1.80±0.25 kg/cm

, 25.6±3.6 psi)

OFF →ON Less than 216 kPa

(2.2 kg/cm

, 31 psi)

High-pressure switch

operating pressure

ON →OFF 2,940±200 kPa

(29.98±2.04 kg/cm

, 426.3±29.0 psi)

DIFF 590±200 kPa

(6.02±2.04 kg/cm

, 85.6±29.0 psi)

Compressor relief valve blow-out pressure 3,600±300 kPa

(36.71±3.06 kg/cm

, 522.0±43.5 psi)

Thermo control amplifier working temperature

(Evaporator outlet air)

S4M0511A

AC-3

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

쐌RHD Model:

Item Specifications

Type of air conditioner Reheat air-mix type

Cooling capacity 5.059 kW (4,350 kcal/h, 17,261 BTU/h)

Refrigerant HFC-134a (CH

FCF

)

[0.65±0.05 kg (1.43±0.11 lb)]

Compressor Type 5-vane rotary, fix volume (KC50G)

Discharge 140 cm

(8.54 cu in)/rev

Max. permissible speed 7,000 rpm

Magnet clutch

Type Dry, single-disc type

Power consumption 38 W

Type of belt V-Ribbed 4 PK

Pulley dia. (effective dia.) 125 mm (4.92 in)

Pulley ratio 1.064

Condenser

Type Corrugated fin (Multi-flow)

Core face area 0.231 m

(2.48 sq ft)

Dimensions (W ×H×T) 20 ×331 ×698 ×mm

(0.79 ×13.03 ×27.48 in)

Radiation area 7.2 m

(77 sq ft)

Receiver drier Effective inner capacity 250 cm

(15.26 cu in)

Expansion valve Type Internal equalizing

Evaporator Type Single tank

Dimensions (W ×H×T) 60 ×224 ×235 mm

(2.36 ×8.82 ×9.25 in)

Blower fan Fan type Sirocco fan

Outer diameter ×width 150 ×75 mm (5.91 ×2.95 in)

Power consumption 250 W at 12 V

Condenser fan (Sub fan) Motor type Magnet

Power consumption 70 W at 12 V

Fan outer diameter 320 mm (12.60 in)

Radiator fan (Main fan) Motor type Magnet

Power consumption 70 W at 12 V

Fan outer diameter 320 mm (12.60 in)

Dual switch

(Pressure switch)

Low-pressure switch

operating pressure

ON →OFF 177±25 kPa

(1.8±0.25 kg/cm

,26±3.6 psi)

OFF →ON Less than 216 kPa

(2.2 kg/cm

, 31 psi)

High-pressure switch

operating pressure

ON →OFF 2,650±200 kPa

(27.02±2.04 kg/cm

, 384±29 psi)

OFF →ON 1,471±200 kPa

(15±2.04 kg/cm

, 213±29 psi)

Compressor relief valve blow-out pressure 3,600±300 kPa

(36.71±3.06 kg/cm

, 522.0±43.5 psi)

Thermo control amplifier working temperature

(Evaporator outlet air)

S4M0275A

AC-4

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

B: COMPONENT S701001A05

1. HEATER UNIT S701001A0501

쐌LHD Model:

H4M1045B

(1) Vent door

(2) DEF door

(3) DEF lever

(4) Heater core

(5) Heater case FRONT

(6) Mix door

(7) Mix lever

(8) Foot door

(9) Foot duct

(10) Heater case REAR

(11) Foot lever lower

(12) Foot lever upper

(13) Vent lever

(14) Side link

Tightening torque: N·m (kgf-m, ft-lb)

T: 7.35 (0.750, 5.421)

AC-5

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

쐌RHD Model:

S4M0309A

(1) Heater case upper A

(2) Heater case upper B

(3) Vent door

(4) DEF door

(5) Sealing sponge

(6) DEF door lever

(7) DEF door link

(8) Vent door lever

(9) Side link

(10) Foot door

(11) Mix door

(12) Heater core

(13) Heater case lower

(14) Foot door lever

(15) Mix door lever

(16) Foot duct

Tightening torque: N·m (kg-m, ft-lb)

T: 7.35 (0.750, 5.421)

AC-6

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

2. INTAKE UNIT WITH EVAPORATOR S701001A0505

쐌LHD Model:

S4M0501A

(1) Evaporator (With A/C model)

(2) Boot

(3) Block expansion valve (With A/C

model)

(4) Link

(5) Lever (A)

(6) Lever (B)

(7) Door (A)

(8) Door (B)

(9) Intake unit case inlet

(10) Thermistor (With A/C model)

(11) Intake unit case upper

(12) Intake unit case lower

(13) Drain hose

(14) Resistor

(15) Blower motor ASSY

(16) Aspirator pipe

(17) Cover

(18) Separator

(19) Rod

Tightening torque: N·m (kgf-m, ft-lb)

T: 7.35 (0.750, 5.421)

AC-7

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

쐌RHD Model:

S4M0545A

(1) Door (A)

(2) Sealing sponge

(3) Door (B) lever

(4) Intake unit case upper

(5) Separator

(6) Cover

(7) Intake unit case lower

(8) Blower motor ASSY

(9) Door (B)

(10) Link

(11) Door (A) lever

(12) Evaporator (With A/C model)

(13) Thermo control amplifier (With

A/C model)

(14) Clamp

(15) Pipe (With A/C model)

(16) Expansion valve (With A/C

model)

(17) Drain hose

Tightening torque: N·m (kgf-m, ft-lb)

T: 7.35 (0.750, 5.421)

AC-8

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

3. CONTROL UNIT S701001A0503

S4M0083A

(1) Temperature control cable

(2) Recirc control cable

(3) Clip

(4) Blower switch ASSY

(5) Harness ASSY

(6) Bulb

(7) A/C switch ASSY

(8) Mode control cable

(9) Control dial knob

(10) A/C switch knob

(11) Control lever knob

(12) Plate

(13) Base unit

AC-9

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

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