2004 SUBARU FORESTER Service Repair Manual

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Page 17 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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) Tempe

Page 18 of 2870

SUBARU FORESTER 2004 Service Repair Manual AC-16
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
4. AIR CONDITIONING UNIT
LHD MODEL
(1) Condenser (5) CompressorTightening torque: N·m (kgf-m, ft-lb)
(2) High-pressure hose (6) O-

Page 19 of 2870

SUBARU FORESTER 2004 Service Repair Manual AC-17
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
RHD MODEL
(1) Condenser (5) CompressorTightening torque: N·m (kgf-m, ft-lb)
(2) High-pressure hose (6) O-ringT1: 7.4 (0.75, 5.4)
(

Page 20 of 2870

SUBARU FORESTER 2004 Service Repair Manual 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 p

Page 21 of 2870

SUBARU FORESTER 2004 Service Repair Manual AC-19
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
6. HEATER DUCT
(1) Front defroster nozzle (3) Side defroster duct (RH) (5) Side ventilation duct (RH)
(2) Side defroster duct (LH) (4

Page 22 of 2870

SUBARU FORESTER 2004 Service Repair Manual AC-20
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
C: CAUTION
1. HFC-134a A/C SYSTEM
The cooling system components for the HFC-
134a system such as the refrigerant and compres-
sor o

AC-20
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
C: CAUTION
1. HFC-134a A/C SYSTEM
The cooling system components for the HFC-
134a system such as the refrigerant and compres-
sor oil are different from the old conventional HFC-
12 system components and they are incompatible
with each other.
Vehicles with the HFC-134a system can be iden-
tified by the label (A) attached to the vehicle.
Before maintenance, check which A/C system is in-
stalled in the vehicle.
2. COMPRESSOR OIL
HFC-134a compressor oil has no compatibility
with that for R12 system.
Use only the manufacturer-authorized compres-
sor oil for the HFC-134a system; only use
ZXL200PG.
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.
HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from the atmosphere us-
ing a plug or tape. In order to avoid moisture, store
the oil in a container with its cap securely closed.
3. REFRIGERANT
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.
If an incorrect or no refrigerant is used, poor lu-
brication will result and the compressor itself may
be damaged.
4. HANDLING OF REFRIGERANT
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 refriger-
ant 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.
Do not heat a service can. If a service can is di-
rectly 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.
Do not drop or impact a service can. (Observe
the precautions and operation procedure described
on the refrigerant can.)
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 ex-
plosion of the can.
Provide good ventilation and do not work in a
closed area.
In order to prevent global warming, avoid releas-
ing HFC-134a into the atmosphere. Using a refrig-
erant recovery system, discharge and reuse it.
AC-00006
(A)
(A) Goggles
(B) Gloves
(C) Avoid open flame
(D) No direct heat on container
(E) Do not discharge
(F) Loosen
(A)
(B)
(C) (D)
(E) (F)
AC-00007

Page 23 of 2870

SUBARU FORESTER 2004 Service Repair Manual AC-21
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
5. O-RING CONNECTIONS
Use new O-rings.
In order to keep the O-rings free of lint which will
cause a refrigerant gas leak, perform

AC-21
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
5. O-RING CONNECTIONS
Use new O-rings.
In order to keep the O-rings free of lint which will
cause a refrigerant gas leak, perform operations
without gloves and shop cloths.
Apply the compressor oil to the O-rings to avoid
sticking, then install them.
Use a torque wrench to tighten the O-ring fittings:
Over-tightening will damage the O-ring and tube
end distortion.
If the operation is interrupted before completing a
pipe connection, recap the tubes, components, and
fittings with a plug or tape to prevent foreign mat-
ters from entering.
Visually check the surfaces and mating surfaces
of O-rings, threads, and connecting points. If a fail-
ure is found, replace the applicable parts.
Install the O-rings at right angle to the tube
beards. Use compressor oil specified in the service man-
ual to lubricate the O-rings.
Apply the oil to the top and sides of the O-rings be-
fore installation.
Apply compressor oil to the bead of tube.
After tightening, use a clean cloth to remove ex-
cess compressor oil from the connections and any
oil which may have run on the vehicle body or other
parts.
If any leakage is suspected after tightening, do
not retighten the connections, disconnect the con-
nections, remove the O-rings, and check the O-
rings, threads, and connections.
D: PREPARATION TOOL
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 compres-
sor 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 dif-
ferent. The gas leak detectors for the HFC-134a
and CFC-12 systems must also not be inter-
changed.(A) Seal
(A) O-ring
(B) OK
(C) NG
(D) Bead
(A)
AC-00008
AC-00009
(D) (B)
(C)
(C)
(A)
HFC-134a CFC-12
Tool & screw type Millimeter size Inch size
Valve type Quick joint type Screw-in type
AC-00010

Page 24 of 2870

SUBARU FORESTER 2004 Service Repair Manual AC-22
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
Illustration Tools and Equipment
Wrench
Va r i o u s WRENCHES will be required to service any A/C system. A 7 to
40 N·m (0.7 to 4.

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