Subaru 2004 Forester User 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

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-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
ON
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
ON
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
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) 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)
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) 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
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 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)
T
T
T

AC-9
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
2. BLOWER MOTOR UNIT
• LHD MODEL WITH AUTO A/C
(1) Upper case (4) Link lever (7) Lower case
(2) Air inlet select actuator (5) Filter cover (8) Blower motor ASSY
(3) Air inlet select link (6) Cover
AC-00334
(1)
(5)
(3)
(2)
(4)
(6)
(7)
(8)

AC-10
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• RHD MODEL WITH AUTO A/C
(1) Upper case (4) Link lever (7) Lower case
(2) Air inlet select actuator (5) Filter cover (8) Blower motor ASSY
(3) Air inlet select link (6) Cover
AC-00332
(1)
(5)
(3) (2)
(4)
(6)
(7)
(8)

AC-11
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• LHD MODEL WITH MANUAL A/C
(1) Upper case (4) Link rod (7) Cover
(2) Air inlet select actuator (5) Filter cover (8) Lower case
(3) Air inlet select link (6) Blower resistor (9) Blower motor ASSY
AC-00209
(1)
(5)
(3)
(2)
(4)
(7)
(8)
(6)
(9)

AC-12
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• RHD MODEL WITH MANUAL A/C
(1) Upper case (4) Air inlet select link (7) Cover
(2) Air inlet select actuator (5) Filter cover (8) Lower case
(3) Air inlet select lever (6) Blower resister (9) Blower motor ASSY
AC-00085
(1)
(5)
(3) (2)
(4)
(7)
(8)
(6)
(9)

AC-13
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
3. CONTROL UNIT
• AUTO A/C MODEL
(1) Panel (4) Control case (front) (7) Control case (rear)
(2) Control dial (5) Bulb
(3) Switch (6) Control unit circuit
AC-00210
(7)
(6)
(5)
(4)
(1)
(2) (3)

AC-14
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• LHD MODEL WITH MANUAL A/C
(1) Panel (5) A/C switch (9) Mode control cable
(2) Temperature control dial (6) Air inlet select switch (10) Temperature control cable
(3) Fan dial (7) Rear defogger switch (11) Bulb
(4) Mode control dial (8) Switch circuit board
AC-00211
(2)
(6)
(5)
(7)
(4) (3)
(1)
(8)
(10)
(9)
(11)

AC-15
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• RHD MODEL WITH MANUAL A/C
(1) Panel (5) A/C switch (9) Mode control cable
(2) Mode control dial (6) Rear defogger switch (10) Temperature control cable
(3) Fan dial (7) Air inlet select switch (11) Bulb
(4) Temperature control dial (8) Switch circuit board
AC-00333
(2)
(6) (5) (7)
(4)
(3)
(1)
(8)
(10)
(9)
(11)

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

AC-17
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• RHD MODEL
(1) Condenser (5) Compressor Tightening torque: N·m (kgf-m, ft-lb)
(2) High-pressure hose (6) O-ring T1: 7.4 (0.75, 5.4)
(3) Low-pressure hose (7) Triple pressure switch T2: 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 adjuster T1: 4.0 (0.40, 2.95)
(3) Idler pulley (8) Compressor stay T2: 22.6 (2.3, 16.6)
(4) Compressor bracket T3: 23.0 (2.35, 17.0)
(5) Compressor T4: 28.9 (2.95, 21.3)
(6) V-belt T5: 35 (3.6, 26)
AC-00335
(1)
(3)
(2)
(4)
(5)
(8)
(6)
(7)
T3
T2
T1
T5
T5
T5
T4 T4