1998 Subaru Forester Service Repair Manual

99-02 FORESTER SERVICE MANUAL

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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, reassembling, inspection and adjustment of components 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 genuine parts.

All information, illustration and specifications contained in this manual are based on the latest product information available at the time of publication approval.

FUJI HEAVY INDUSTRIES LTD.99

G8050GE6

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

AC 1.

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Page General Description.....................................................................................2 Refrigerant Pressure with Manifold Gauge Set ........................................18 Refrigerant Recovery Procedure...............................................................19 Refrigerant Charging Procedure ...............................................................20 Refrigerant Leak Check ............................................................................23 Compressor Oil .........................................................................................25 Heater Unit ................................................................................................26 Blower Motor Assembly.............................................................................27 Power Transistor (Heater Blower Resistor) ..............................................28 Heater Core...............................................................................................29 Control Unit ...............................................................................................30 Compressor ...............................................................................................32 Condenser .................................................................................................34 Receiver Drier ...........................................................................................35 Intake Unit .................................................................................................36 Flexible Hose.............................................................................................38 Relay and Fuse .........................................................................................39 Pressure Switch (Dual Switch)..................................................................40 Air Vent Grille ............................................................................................41 Heater Duct ...............................................................................................42 Heater Vent Duct.......................................................................................43 General Diagnostics ..................................................................................44

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

1. General Description A: SPECIFICATIONS 1. HEATER SYSTEM

S701001E49

S701001E4901

Item

Specifications

LHD model Heating capacity RHD model Air flow rate

LHD model RHD model LHD model

Max air flow rate RHD model Heater core size (height × length × width) Type Blower motor Fan type and size (diameter × width)

S701001

LHD model RHD model LHD model RHD model LHD model RHD model

Condition 쐌 Mode selector switch: HEAT 5.1 kW (4,386 kcal/h, 17,404 BTU/h) 쐌 Temperature control switch: FULL HOT or more 쐌 Temperature difference between hot water and inlet air: 65°C (149°F) 4.93 kW (4,240 kcal/h, 16,824 BTU/h) 쐌 Hot water flow rate: 360 (95.1 US gal, or more 79.2 Imp gal)/h 280 m3 (9,887 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V 300 m3 (10,593 cu ft)/h 쐌 Temperature control switch: FULL COLD 480 m3 (16,949 cu ft)/h 쐌 Blower fan speed: 4th position 460 m3 (16,243 cu ft)/h 쐌 Mode selector lever: RECIRC 193.5 × 152 × 35.0 mm (7.62 × 5.98 × 1.378 in) — 161.4 × 176.4 × 32 mm (6.35 × 6.94 × 1.26 in) Magnet motor 260 W or less at 12 V Magnet motor 250 W or less Sirocco fan type 150 × 75 mm (5.91 × 2.95 in) — 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

쐌 LHD Model: Item Type of air conditioner Cooling capacity Refrigerant Type Discharge Max. permissible speed Type Power consumption Type of belt Pulley dia. (effective dia.)

Pulley ratio Type Core face area

Compressor

Magnet clutch

Condenser

Dimensions (W × H × T) Radiation area Effective inner capacity Type Type

Receiver drier Expansion valve Evaporator

Dimensions (W × H × T)

Blower fan

Condenser fan (Sub fan)

Radiator fan (Main fan)

Low-pressure switch operating pressure Dual switch (Pressure switch) High-pressure switch operating pressure

Fan type Outer diameter × width Power consumption Motor type Power consumption Fan outer diameter Motor type Power consumption Fan outer diameter ON → OFF OFF → ON ON → OFF DIFF

Compressor relief valve blow-out pressure

Specifications Reheat air-mix type 5.117 kW (4,400 kcal/h, 17,459 BTU/h) HFC-134a (CH2FCF3) [0.65±0.05 kg (1.43±0.11 lb)] 5-vane rotary, fix volume (KC50G) 140 cm3 (8.54 cu in)/rev 7,000 rpm Dry, single-disc type 38 W V-Ribbed 4 PK 125 mm (4.92 in) 1.064 Corrugated fin (Multi-flow) 0.255 m2 (2.74 sq ft) 22 × 374 × 683 mm (0.87 × 14.72 × 26.89 in) 6.52 m2 (70 sq ft) 250 cm3 (15.26 cu in) Internal equalizing Single tank 60 × 224 × 235 mm (2.36 × 8.82 × 9.25 in) Sirocco fan 150 × 75 mm (5.91 × 2.95 in) 260 W at 12 V Magnet 70 W at 12 V 320 mm (12.60 in) Magnet 70 W at 12 V 320 mm (12.60 in) 177±25 kPa (1.80±0.25 kg/cm2, 25.6±3.6 psi) Less than 216 kPa (2.2 kg/cm2, 31 psi) 2,940±200 kPa (29.98±2.04 kg/cm2, 426.3±29.0 psi) 590±200 kPa (6.02±2.04 kg/cm2, 85.6±29.0 psi) 3,600±300 kPa (36.71±3.06 kg/cm2, 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)

쐌 RHD Model: Item Type of air conditioner Cooling capacity Refrigerant Type Discharge Max. permissible speed Type Power consumption Type of belt Pulley dia. (effective dia.)

Pulley ratio Type Core face area

Compressor

Magnet clutch

Condenser

Dimensions (W × H × T) Radiation area Effective inner capacity Type Type

Receiver drier Expansion valve Evaporator

Dimensions (W × H × T)

Blower fan

Condenser fan (Sub fan)

Radiator fan (Main fan)

Low-pressure switch operating pressure Dual switch (Pressure switch) High-pressure switch operating pressure

Fan type Outer diameter × width Power consumption Motor type Power consumption Fan outer diameter Motor type Power consumption Fan outer diameter ON → OFF OFF → ON ON → OFF OFF → ON

Compressor relief valve blow-out pressure

Specifications Reheat air-mix type 5.059 kW (4,350 kcal/h, 17,261 BTU/h) HFC-134a (CH2FCF3) [0.65±0.05 kg (1.43±0.11 lb)] 5-vane rotary, fix volume (KC50G) 140 cm3 (8.54 cu in)/rev 7,000 rpm Dry, single-disc type 38 W V-Ribbed 4 PK 125 mm (4.92 in) 1.064 Corrugated fin (Multi-flow) 0.231 m2 (2.48 sq ft) 20 × 331 × 698 × mm (0.79 × 13.03 × 27.48 in) 7.2 m2 (77 sq ft) 250 cm3 (15.26 cu in) Internal equalizing Single tank 60 × 224 × 235 mm (2.36 × 8.82 × 9.25 in) Sirocco fan 150 × 75 mm (5.91 × 2.95 in) 250 W at 12 V Magnet 70 W at 12 V 320 mm (12.60 in) Magnet 70 W at 12 V 320 mm (12.60 in) 177±25 kPa (1.8±0.25 kg/cm2, 26±3.6 psi) Less than 216 kPa (2.2 kg/cm2, 31 psi) 2,650±200 kPa (27.02±2.04 kg/cm2, 384±29 psi) 1,471±200 kPa (15±2.04 kg/cm2, 213±29 psi) 3,600±300 kPa (36.71±3.06 kg/cm2, 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 1. HEATER UNIT

S701001A05

S701001A0501

쐌 LHD Model:

H4M1045B

(1) (2) (3) (4) (5) (6)

Vent door DEF door DEF lever Heater core Heater case FRONT Mix door

(7) (8) (9) (10) (11) (12)

Mix lever Foot door Foot duct Heater case REAR Foot lever lower Foot lever upper

AC-5

(13) Vent lever (14) Side link Tightening torque: N·m (kgf-m, ft-lb) T: 7.35 (0.750, 5.421)

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

쐌 RHD Model:

S4M0309A

(1) (2) (3) (4) (5) (6) (7)

Heater case upper A Heater case upper B Vent door DEF door Sealing sponge DEF door lever DEF door link

(8) (9) (10) (11) (12) (13) (14)

Vent door lever Side link Foot door Mix door Heater core Heater case lower Foot door lever

AC-6

(15) Mix door lever (16) Foot duct Tightening torque: N·m (kg-m, ft-lb) T: 7.35 (0.750, 5.421)

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

2. INTAKE UNIT WITH EVAPORATOR

S701001A0505

쐌 LHD 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) (9) (10) (11) (12) (13) (14) (15)

Door (B) Intake unit case inlet Thermistor (With A/C model) Intake unit case upper Intake unit case lower Drain hose Resistor Blower motor ASSY

AC-7

(16) (17) (18) (19)

Aspirator pipe Cover Separator Rod

Tightening torque: N·m (kgf-m, ft-lb) T: 7.35 (0.750, 5.421)

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

쐌 RHD Model:

S4M0545A

(1) (2) (3) (4) (5) (6) (7) (8)

Door (A) Sealing sponge Door (B) lever Intake unit case upper Separator Cover Intake unit case lower Blower motor ASSY

(9) (10) (11) (12) (13)

Door (B) Link Door (A) lever Evaporator (With A/C model) Thermo control amplifier (With A/C model) (14) Clamp (15) Pipe (With A/C model)

AC-8

(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)

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

3. CONTROL UNIT

S701001A0503

S4M0083A

(1) (2) (3) (4) (5)

Temperature control cable Recirc control cable Clip Blower switch ASSY Harness ASSY

(6) (7) (8) (9) (10)

Bulb A/C switch ASSY Mode control cable Control dial knob A/C switch knob

AC-9

(11) Control lever knob (12) Plate (13) Base unit

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

4. AIR CONDITIONING UNIT

S701001A0504

쐌 LHD Model:

S4M0486A

(1) Condenser (2) Pipe (From condenser to receiver drier) (3) Receiver drier (4) Pipe (From receiver drier to intake unit)

(5) Hose (Low-pressure) (6) Compressor (7) Hose (High-pressure)

AC-10

Tightening torque: N·m (kgf-m, ft-lb) T1: 7.4 (0.75, 5.4) T2: 15 (1.5, 10.8)

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

쐌 RHD Model:

S4M0487A

(1) (2) (3) (4)

Compressor Hose (Low-pressure) Condenser Pipe (From receiver drier to intake unit)

(5) Receiver drier (6) Pipe (From condenser to receiver drier) (7) Hose (High-pressure)

AC-11

Tightening torque: N·m (kgf-m, ft-lb) T1: 7.4 (0.75, 5.4) T2: 15 (1.5, 10.8)

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

5. COMPRESSOR

S701001A0506

S4M0488A

(1) (2) (3) (4) (5) (6)

Idler pulley adjuster Idler pulley bracket Idler pulley Compressor bracket upper Compressor Compressor bracket lower

(7) V-belt (8) Compressor belt cover

Tightening torque: N·m (kgf-m, ft-lb) T1: 7.4 (0.75, 5.4) T2: 23 (2.3, 17) T3: 23.0 (2.35, 17.0) T4: 28.9 (2.95, 21.3) T5: 35 (3.6, 26)

AC-12

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

C: CAUTION

4. HANDLING OF REFRIGERANT

S701001A03

1. HFC-134a A/C SYSTEM

S701001A0301

쐌 Unlike the old conventional HFC-12 system components, the cooling system components for the HFC-134a system such as the refrigerant and compressor oil are incompatible. 쐌 Vehicles with the HFC-134a system can be identified by the label “A” attached to the vehicle.

Before maintenance, check which A/C system is installed in the vehicle.

S4M0547A

2. COMPRESSOR OIL

S701001A0302

쐌 HFC-134a compressor oil has no compatibility with that for R12 system. 쐌 Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use ZXL200PG. 쐌 Do not mix multiple compressor oils.

If HFC-12 compressor oil is used in a HFC-134a A/C system, the compressor may become stuck due to poor lubrication, or the refrigerant may leak due to swelling of rubber parts.

On the other hand, if HFC-134a compressor oil is used in a HFC-12 A/C system, the durability of the A/C system will be lowered. 쐌 HFC-134a compressor oil is very hygroscopic.

When replacing or installing/removing A/C parts, immediately isolate the oil from the atmosphere using a plug or tape. In order to avoid moisture, store the oil in a container with its cap tightly closed.

3. REFRIGERANT

S701001A0304

쐌 The refrigerant boils at approx. −30°C (−22°F).

When handling it, be sure to wear safety goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite.

If the refrigerant gets into your eye, avoid rubbing your eyes with your hands. Wash your eye with plenty of water, and receive medical treatment from an eye doctor. 쐌 Do not heat a service can. If a service can is directly heated, or put into boiling water, the inside pressure will become extremely high. This may cause the can to explode. If a service can must be warmed up, use hot water in 40°C (104°F) max. 쐌 Do not drop or impact a service can. (Observe the precautions and operation procedure described on the refrigerant can.) 쐌 When the engine is running, do not open the high-pressure valve of the manifold gauge. The high-pressure gas will back-flow resulting in an explosion of the can. 쐌 The refrigerant is non-toxic and harmless under normal operating circumstance, but it may change to phosgene (a noxious fume) under open flames or high temperatures (caused by a cigarette or heater). 쐌 Provide good ventilation and do not work in a closed area. 쐌 Never perform a gas leak test using a halide torch-type leak tester. 쐌 In order to avoid destroying the ozone layer, prevent HFC-134a from being released into the atmosphere. Using a refrigerant recovery system, discharge and reuse it.

S701001A0303

쐌 The HFC-12 refrigerant cannot be used in the HFC-134a A/C system. The HFC-134a refrigerant, also, cannot be used in the HFC-12 A/C system. 쐌 If an incorrect or no refrigerant is used, poor lubrication will result and the compressor itself may be damaged.

G4M0979

AC-13

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

5. O-RING CONNECTIONS

S701001A0305

쐌 Use new O-rings. 쐌 In order to keep the O-rings free of lint which will cause a refrigerant gas leak, perform operations without gloves and shop towels. 쐌 Apply the compressor oil to the O-rings to avoid sticking, then install them. 쐌 Use a torque wrench to tighten the O-ring fittings: Over-tightening will damage the O-ring and tube end distortion. 쐌 If the operation is interrupted before completing a pipe connection, recap the tubes, components, and fittings with a plug or tape to prevent contamination from entering.

쐌 Use the oil specified in the service manual to lubricate the O-rings.

Apply the oil to the top and sides of the O-rings before installation.

Apply the oil to the area including the O-rings and tube beads.

G4M0581

쐌 Visually check the surfaces and mating surfaces of O-rings, threads, and connecting points. If a failure is found, replace the applicable parts. 쐌 Install the O-rings at right angle to the tube beards.

G4M0582

G4M0583

쐌 When connecting hoses or pipes, use 2 wrenches (a torque wrench for tightening). While securing one side with a wrench, tighten the other side to the specified torque with a torque wrench.

If only one wrench is used to tighten, the tightening torque will be excessive or insufficient. This may cause a pipe distortion or gas leak, resulting in damage to hoses and pipes. 쐌 After tightening, using a clean shop towel to remove excess oil from the connections and any oil which may have run on the vehicle body or other parts. 쐌 If any leakage is suspected after tightening, do not retighten the connections, Disconnect the connections, remove the O-rings, and check the O-rings, threads, and connections.

G4M0584

AC-14

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

D: PREPARATION TOOL

S701001A17

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 compressor 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 different. The gas leak detectors for the HFC134a and CFC-12 systems must also not be interchanged.

Tool & screw type Valve type

HFC-134a Millimeter size Quick joint type

CFC-12 Inch size Screw-in type

Tools and Equipment

Description

Wrench

Various WRENCHES will be required to service any A/C system. A 7 to 40 N·m (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque wrench with various crowfoot wrenches will be needed. Open end or flare nut wrenches will be needed for back-up on the tube and hose fittings.

G4M0571

Applicator bottle

A small APPLICATOR BOTTLE is recommended to apply refrigerant oil to the various parts. They can be obtained at a hardware or drug store.

G4M0572

Manifold gauge set

A MANIFOLD GAUGE SET (with hoses) can be obtained from either a commercial refrigeration supply house or from an auto shop equipment supplier.

G4M0573

AC-15

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C) Tools and Equipment Refrigerant recovery system

Description

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.

G4M0574

Syringe

A graduated plastic SYRINGE will be needed to add oil back into the system. The syringe can be found at a pharmacy or drug store.

G4M0575

Vacuum pump

A VACUUM PUMP (in good working condition) is necessary, and may be obtained from either a commercial refrigeration supply house or an automotive equipment supplier.

G4M0576

Can tap

A CAN TAP for the 397 g (14 oz) can is available from an auto supply store.

G4M0577

AC-16

GENERAL DESCRIPTION

HVAC System (Heater, Ventilator and A/C)

Tools and Equipment

Description

Thermometer

Pocket THERMOMETERS are available from either industrial hardware store or commercial refrigeration supply houses.

G4M0578

Electronic leak detector

An ELECTRONIC LEAK DETECTOR can be obtained from either a specialty tool supply or an A/C equipment supplier.

G4M0579

Weight scale

A WEIGHT SCALE such as an electronic charging scale or a bathroom scale with digital display will be needed if a 13.6 kg (30 lb) refrigerant container is used.

G4M0580

AC-17

REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET

HVAC System (Heater, Ventilator and A/C)

2. Refrigerant Pressure with Manifold Gauge Set A: OPERATION

S701631

S701631A16

1) Place the vehicle in the shade and draftless condition.

2) Connect the manifold gauge set.

3) Open the front windows and close all doors.

4) Open the hood.

5) Increase engine rpm to 1,500.

6) Turn ON the A/C switch.

7) Turn the temperature control switch to MAX COOL. 8) Put in RECIRC position.

9) Turn the blower control switch to HI. 10) Read the gauge.

Standard: Low pressure: 127 - 196 kPa (1.3 - 2.0 kg/cm2, 18 - 28 psi) High pressure: 1,471 - 1,667 kPa (15 - 17 kg/cm2, 213 - 242 psi) Ambient temperature: 30 - 35 °C (86 - 95 °F)

B: INSPECTION

S701631A10

Symptom

High-pressure side is unusually high.

High-pressure side is unusually low.

Low-pressure side is unusually high.

Low-pressure side is unusually low.

Probable cause 쐌 Defective condenser fan motor 쐌 Clogged condenser fan 쐌 Too much refrigerant 쐌 Air inside the system 쐌 Defective receiver dryer 쐌 Defective compressor 쐌 Not enough refrigerant 쐌 Clogged expansion valve 쐌 Expansion valve frozen temporarily by moisture 쐌 Defective compressor 쐌 Defective expansion valve 쐌 Too much refrigerant 쐌 Not enough refrigerant 쐌 Clogged expansion valve 쐌 Expansion valve frozen temporarily by moisture 쐌 Saturated receiver dryer

AC-18

쐌 쐌 쐌 쐌

Repair order Replace the fan motor.

Clean the condenser fin.

Discharge refrigerant.

Replace the receiver dryer.

쐌 Replace the compressor. 쐌 Check for leaks. 쐌 Replace the expansion valve.

쐌 쐌 쐌 쐌 쐌 쐌

Replace the compressor.

Replace the expansion valve.

Discharge refigerant.

Check for leaks.

Replace the expansion valve Replace the receiver dryer.

Thank you very much for your reading.

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