Subaru FORESTER2001 User manual

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
3
(9,887 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V
RHD model 300 m
3
(10,593 cu ft)/h
Max air flow rate LHD model 480 m
3
(16,949 cu ft)/h 쐌Temperature control switch: FULL COLD
쐌Blower fan speed: 4th position
쐌Mode selector lever: RECIRC
RHD model 460 m
3
(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
2
FCF
3
)
[0.65±0.05 kg (1.43±0.11 lb)]
Compressor Type 5-vane rotary, fix volume (KC50G) Discharge 140 cm
3
(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
(2.74 sq ft)
Dimensions (W ×H×T) 22 ×374 ×683 mm
(0.87 ×14.72 ×26.89 in)
Radiation area 6.52 m
2
(70 sq ft)
Receiver drier Effective inner capacity 250 cm
3
(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
2
, 25.6±3.6 psi)
OFF →ON Less than 216 kPa
(2.2 kg/cm
2
, 31 psi)
High-pressure switch
operating pressure
ON →OFF 2,940±200 kPa
(29.98±2.04 kg/cm
2
, 426.3±29.0 psi)
DIFF 590±200 kPa
(6.02±2.04 kg/cm
2
, 85.6±29.0 psi)
Compressor relief valve blow-out pressure 3,600±300 kPa
(36.71±3.06 kg/cm
2
, 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
2
FCF
3
)
[0.65±0.05 kg (1.43±0.11 lb)]
Compressor Type 5-vane rotary, fix volume (KC50G) Discharge 140 cm
3
(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
(2.48 sq ft)
Dimensions (W ×H×T) 20 ×331 ×698 ×mm
(0.79 ×13.03 ×27.48 in)
Radiation area 7.2 m
2
(77 sq ft)
Receiver drier Effective inner capacity 250 cm
3
(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
2
,26±3.6 psi)
OFF →ON Less than 216 kPa
(2.2 kg/cm
2
, 31 psi)
High-pressure switch
operating pressure
ON →OFF 2,650±200 kPa
(27.02±2.04 kg/cm
2
, 384±29 psi)
OFF →ON 1,471±200 kPa
(15±2.04 kg/cm
2
, 213±29 psi)
Compressor relief valve blow-out pressure 3,600±300 kPa
(36.71±3.06 kg/cm
2
, 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)