2004 SUBARU FORESTER sensor

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-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) AspiratorTightening torque: N·m (kgf-m, ft-lb)
(8) Foot duct (17) PackingT: 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) AspiratorTightening torque: N·m (kgf-m, ft-lb)
(9) Lower case (18) PackingT: 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) PackingTightening torque: N·m (kgf-m, ft-lb)
(7) Foot duct (15) Cooling unit pipeT: 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 caseTightening torque: N·m (kgf-m, ft-lb)
(7) Defroster lever (16) PackingT: 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-44
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Ambient Sensor (Auto A/C Model)
19.Ambient Sensor (Auto A/C
Model)
A: REMOVAL
1) Open the front hood.
2) Disconnect the ground cable from battery.
3) Disconnect the ambient sensor connector.
4) Remove the ambient sensor from radiator lower
panel.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Procedure for Sensors.>
AC-00125

AC-45
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Sunload Sensor (Auto A/C Model)
20.Sunload Sensor (Auto A/C
Model)
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Disconnect the sunload sensor connector.
CAUTION:
Be careful not to damage the sensors and inte-
rior trims when removing them.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Procedure for Sensors.>
AC-00126

HVAC SYSTEM (AUTO A/C)(DIAGNOSTIC)
AC
Page
1. Basic Diagnostics Procedure ......................................................................2
2. General Description ....................................................................................3
3. Electrical Component Location ...................................................................5
4. Auto A/C Control Module I/O Signal............................................................7
5. Diagnostic Chart for Self-Diagnosis ............................................................9
6. Diagnostics for A/C System Malfunction ...................................................12
7. Diagnostic Procedure for Actuators ..........................................................21
8. Diagnostic Procedure for Sensors ............................................................32
9. General Diagnostic Table..........................................................................41