2003 forester service manual quick reference index body section
Contents
1. 5 Remove the instrument panel lt Ref to 40 REMOVAL Instrument Panel Assembly gt 6 Remove the support beam 7 Remove the blower motor unit assembly lt Ref to AC 33 REMOVAL Blower Motor Unit Assem bly gt 8 Disconnect the servo motor connectors 9 Loosen the bolt and nuts to remove the heater and cooling unit 4t Q 00055 INSTALLATION 1 Install in the reverse order of removal 2 Charge refrigerant lt Ref to AC 27 OPERA TION Refrigerant Charging Procedure gt Tightening torgue Refer to COMPONENT in General Descrip tion lt Ref to AC 7 HEATER COOLING UNIT COMPONENT General Description gt AC 41 EVAPORATOR HVAC SYSTEM HEATER VENTILATOR AND A C 15 Evaporator A REMOVAL 1 Disconnect the refrigerant recovery amp toe board area A C pipe lt Ref to AC 26 OPERATION Re frigerant Recovery Procedure gt 2 Remove the glove box 3 Remove lower motor unit assembly lt Ref to AC 33 REMOVAL Blower Motor Unit Assembly gt 4 Loosen the screws and remove evaporator cov er AC 00045 5 Remove the A C pipes in unit 6 Rotate the upper evaporator core and lower evaporator core tilt toward the front vehicle and to ward the interior respectively Then pull out the heater case to left side 7 Loosen the two bolts to remove expansion val2. n order to keep the O rings free of lint which will cause a refrigerant gas leak perform operations without gloves and shop towels 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 Ifthe operation is interrupted before completing a pipe connection recap the tubes components and fittings with a plug or tape to prevent contamination from entering AC 00008 A Seal e 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 A B 1 D C 1 0 00009 A O ring B OK C NG D Bead Use the oil specified in the service manual to lu bricate the O rings Apply the oil to the top and sides of the O rings be fore installation Apply the oil to the area including the O rings and tube beads AC 00010 After tightening use a clean shop towel to re move excess oil from the connections and any oil which may have run on the vehicle body or other parts f 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 connect
3. A INSPECTION 1 MAGNETIC CLUTCH CLEARANCE 1 Check the clearance of the entire circumference around the drive plate and pulley Standard 0 3 0 6 mm 0 0118 0 0236 in 2 MAGNETIC CLUTCH OPERATION 1 Disconnect the compressor connector 2 Connect the battery positive terminal to the No 3 terminal of the compressor connector RS OX Av AC 00048 3 Make sure the magnet clutch engages If NG replace the compressor B REMOVAL 1 Perform the compressor oil return operation lt Ref to AC 32 OPERATION Compressor Oil gt 2 Turn the A C switch OFF and stop the engine 3 Using the refrigerant recovery system dis charge refrigerant lt Ref to AC 26 OPERATION Refrigerant Recovery Procedure gt 4 Disconnect the ground cable from battery 5 Remove the V belt lt Ref to ME SOHC 41 RE MOVAL V belt gt 6 Remove the generator lt Ref to SC SOHC 15 REMOVAL Generator gt 7 Remove the low pressure hose and high pres sure hose 8 Disconnect the compressor harness from body harness HVAC SYSTEM HEATER VENTILATOR AND A C 9 Loosen the bolts to remove compressor bracket AC 00336 10 Remove the bolts and then separate compres sor and bracket AC 00051 AC 37 COMPRESSOR HVAC SYSTEM HEATER VENTILATOR AND A C C INSTALLATION 1 Install in the reverse order of removal 2 Repl
4. C INSPECTION The direction and amount of air should be adjusted smoothly The adjustment should be kept in each position AC 48 HEATER DUCT HVAC SYSTEM HEATER VENTILATOR AND A C 22 Heater Duct A REMOVAL 1 Remove the front seat lt Ref to SE 5 REMOV AL Front Seat gt 2 Remove the front side sill cover 3 Pull off the floor mat which is connected to re move the cover heater unit and heater duct and then remove the heater duct B INSTALLATION Install in the reverse order of removal AC 49 HEATER VENT DUCT HVAC SYSTEM HEATER VENTILATOR AND A C 23 Heater Vent Duct A REMOVAL 1 Remove the instrument panel lt Ref to El 40 REMOVAL Instrument Panel Assembly gt 2 Remove the screws 3 Remove the heater vent duct AC 00224 B INSTALLATION Install in the reverse order of removal AC 50 GENERAL DIAGNOSTICS HVAC SYSTEM HEATER VENTILATOR AND A C 24 General Diagnostics A INSPECTION Symptom Repair order Fuse Blower motor relay Wire harness Does not run Blower motor Blower motor Blower motor resistor Manual A C model Blower switch Abnormal noise Blower motor Refrigerant Fuse Air conditioning relay Wire harness Does not run Magnet clutch Compressor Pressure switch A C switch Blower switch V Belt Abnormal noise Magnet clutch Compressor Fuse Does not run Sub fan relay Wire harness Abnormal noise Condenser fan motor Refrigerant V Belt Magnet cl
5. HFC 134a source 13 Loosen the center hose connection on manifold gauge if applicable press a purge valve on mani fold gauge only for a couple of seconds to allow the air in the center hose to escape by the refriger ant AC 00216 14 Make sure that the high pressure valve of man ifold gauge is closed and then open the low pres sure side valve only to charge the refrigerant GW 1 Open 2 Close CAUTION Do not open the high pressure valve Be sure to open the low pressure valve 15 Close the low pressure valve when the low pressure gauge reading reaches 200 kPa 1 500 mmHg 59 1 inHg 16 Using a leak tester check the system for refrig erant leaks 17 After confirming that there are no leaks with the leak test charge the required amount of refrigerant 18 If the HFC 134a source is empty close the low pressure valve and then close the valve on can tap before replacing the empty source Restart charg ing operation after replacing the HFC 134a source with a new one and purging 19 Close the low pressure valve if the charge rate of refrigerant becomes worse 20 Confirm that both the low high pressure valves are closed Start the engine with A C switch OFF AC 28 REFRIGERANT CHARGING PROCEDURE HVAC SYSTEM HEATER VENTILATOR AND A C 21 Guickly repeat A C switch ON OFF cycles a few times to prevent initial compressor damage 22 Set up the vehicl
6. SYSTEM DIAGNOSTICS G8070GE6 m cc HVAC SYSTEM HEATER VENTILATOR AND A C OD N D GN qe ea Tore PO PO NMP AH AH AH AH AH AH AH A AB at hn O Page General Description is 2 Refrigerant Pressure with Manifold Gauge 25 Refrigerant Recovery Procedure 26 Refrigerant Charging Procedure nn L un 27 Refrigerant Leak 30 Compreseor cL 32 Blower Motor Unit 33 Blower Resistor Manual A C Model 34 Heater Core ae ina noir 35 Control UN sep en pado 36 COMPressok dtes este 37 Condensefe YY ua P Dota Fl FYR isi 39 Condenser Fan SUb FaN aa eds venues trt iden Gyw Uw 40 Heater Cooling Unit A De po an dE rid 41 Evaporatol eu eto Y o ee ae daa dde E ee 42 Hose and Tube seen 43 REE VEETEREN NN pant r 44 Pressure Switch Triple Pressure Switch 45 Ambient Sensor Auto A C Model 46 Sun load Sensor Auto A C Model 47 Ait Vent IE see DT 48 Heater DUCT cii drin ge dyre 49 Heater Vent DUCH 50 General Diagnostics ue ia pl ep wes cele lanes 51 HVAC SYSTEM HEATER VENTILATOR AND A C 1 General Description A SPECIFICATIONS 1 HEATER SYSTEM Specifications GENERAL DESCRIPTION C
7. 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 9 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C RHD MODEL WITH MANUAL A C AC 00084 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 10 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 2 BLOWER MOTOR UNIT LHD MODEL WITH AUTO A C AC 00334 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 11 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C RHD MODEL WITH AUTO A C Upper case Air inlet select actuator Air inlet select link AC 00332 4 Link lever 7 Lower case 5 Filter cover 8 Blower motor assembly 6 Cover AC 12 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C LHD MODEL W
8. cm 198 65 17 35 psi operating pressure p gp OFF o ON o 00 kPa 18 05 1 02 kg cm 256 81 14 50 psi 3 0 0 3 C Thermo control amplifier working temperature ON Evaporator outlet air 1 5 0 5 C AC 00082 AC 4 MANUAL A C MODEL GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 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 CHaFCF3 60050 g 1 32 0 11 Ib Compressor Type Vane rotary fix volume DKV 14G Discharge 140 cm 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 Ribbed 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 m 2 52 sq ft Core thickness 16 mm 0 63 in Radiation area 5 6 m 6 26 sg ft Receiver drier Effective inner capacity 220 cm 13 42 cu in Expansion valve Type External egualizing Evaporator Type Single tank Dimensions W x H x T 176 5 x 266 x 60 mm 6 95 x 10 47 x 2 36 in Blower fan Fan type Sirocco fan Outer diameter x width 150 x 75 mm 5 91 x 2 95 in Power consumption 26
9. shade and draftless condition Connect the manifold gauge set Open the front windows and close all doors Open the hood Turn ON the A C switch Turn the temperature control switch to MAX COOL 2 3 4 5 Increase the engine to 1 500 rpm 6 7 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 cm 18 28 psi High pressure 1 471 1 667 kPa 15 17 kg cm 213 242 psi Ambient temperature 30 35 C 86 95 F B INSPECTION Symptom Probable cause Repair order High pressure side is unusually high Defective condenser fan motor Clogged condenser fin Too much refrigerant Air inside the system Defective receiver dryer Replace the fan motor Clean the condenser fin Discharge refrigerant Replace the receiver dryer After reevacuating the receiver dryer charge appropriate amount of refriger ant High pressure side is unusually low Defective compressor Not enough refrigerant Clogged expansion valve Expansion valve frozen temporarily by moisture Replace the compressor Check for leaks Replace the expansion valve Fully evacuate the expansion valve Low pressure side is unusually high Defective compressor Defective expansion valve Too much refrigerant Replace the compressor Replace the expansion valve Discharge refiger
10. 0 W or less at 12 5 V Condenser fan Sub fan Motor type Magnet Power consumption 70 W at 12V Fan outer diameter 320 mm 12 6 in Radiator fan Main fan Motor type Magnet Power consumption 70 W at 12V Fan outer diameter 320 mm 12 6 in Idling speed A C ON MPFI model AC 5 800 100 rpm GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C Item Specifications 1771225 kPa ON OFF Low pressure switch i 1 80 0 25 kg cm 25 60 3 56 psi operating pressure p gp OFF gt ON 2 2 10 0 31 kg cm 29 86 4 41 psi ON gt OFF a kPa Triple switch High pressure switch 29 98 2 03 kg cm 426 32 28 87 psi Pressure switch operating pressure DIFF 590 200 kPa 6 02 2 03 kg cm 85 6 28 87 psi ON gt OFF 20 Middle pressure switch 13 97 1 22 kg cm 198 65 17 35 psi operating pressure p gp OFF gt ON o 00 kPa 18 05 1 02 kg cm 256 81 14 50 psi 3 0 0 3 C Thermo control amplifier working temperature ON Evaporator outlet air 1 5 0 5 C AC 00082 AC 6 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C B COMPONENT 1 HEATER COOLING UNIT LHD MODEL WITH AUTO A C T 17 00358 1 Evaporator cover 10 Heater core 19 O ring 2 Mode actuator 11 Drain hose 20 Expansion v
11. 2003 FORESTER SERVICE MANUAL GUICK REFERENCE INDEX BODY SECTION HVAC SYSTEM HEATER VENTILATOR AND A C HVAC SYSTEM AUTO A C DIAGNOSTICS AIRBAG SYSTEM AIRBAG SYSTEM DIAGNOSTICS 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 LIGHTING SYSTEM This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of WIPER AND WASHER SYSTEMS components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual ENTERTAINMENT fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition COMMUNICATION SYSTEM When replacement of parts during repair work is needed be sure to use SUBARU genuine parts GLASS WINDOWS MIRRORS GW SEAT BELT SYSTEM BODY STRUCTURE BS INSTRUMENTATION DRIVER INFO IDI SEATS SE SECURITY AND LOCKS SL IMMOBILIZER DIAGNOSTICS IM SUNROOF T TOP CONVERTIBLE SUNROOF All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval EXTERIOR INTERIOR TRIM El FUJI HEAVY INDUSTRIES LTD G8070GE6 bS EE r il 2003 FORESTER SERVICE MANUAL GUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CC CRUISE CONTROL
12. ATER VENTILATOR AND A C 6 Compressor Oil A OPERATION NOTE Before making repairs conduct the oil return oper ation to return the compressor oil in circulation with the refrigerant to the compressor 1 Increase engine to 1 500 rpm 2 Turn ON the A C switch 3 Turn the temperature control switch to MAX COOL 4 Put in RECIRC position 5 Turn the blower control switch to HI 6 Leave in this condition for 10 minutes B REPLACEMENT NOTE If a component is replaced add an appropriate amount of compressor oil When replacing the compressor the new com pressor will already have the specified amount of oil in it Install the new compressor after removing the same amount of oil that is remaining in the com pressor removed Replacement parts Amount of oil replenishment Approx 50 cm 1 7 US fl oz 1 8 Imp fl oz Approx 30 cm 1 0 US fl oz 1 1 Imp fl oz Approx 10 cm 0 4 US fl oz 0 4 Imp fl oz Evaporator Condenser Hose Approx 10 cm 0 4 US fl oz 0 4 Imp fl oz Receiver dryer AC 32 BLOWER MOTOR UNIT ASSEMBLY 7 Blower Motor Unit Assembly A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the glove box lt Ref to El 37 REMOV AL Glove Box gt 3 Loosen the nut to remove the support beam stay 4 Disconnect the connectors of blower motor and intake act
13. ITH MANUAL A C AC 00209 1 Upper case 4 Link rod 7 Cover 2 Air inlet select actuator b Filter cover 8 Lower case 3 Air inlet select link 6 Blower resistor 9 Blower motor ASSY AC 13 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C RHD MODEL WITH MANUAL A C AC 00085 1 Upper case 4 Air inlet select link 7 Cover 2 Air inlet select actuator b Filter cover 8 Lower case 3 Air inlet select lever 6 Blower resister 9 Blower motor assembly AC 14 3 CONTROL UNIT AUTO A C MODEL GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C AC 00210 1 Panel 2 Control dial 3 Switch 4 Control case front 7 Control case rear 5 Bulb 6 Control unit circuit AC 15 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C LHD MODEL WITH MANUAL A C AC 00211 1 Panel 5 button 9 Temperature control cable 2 Mode control dial 6 Rear defogger button 10 Mode control cable 3 Fan dial 7 Air inlet select button 11 Bulb 4 Temperature control dial 8 Switch circuit board AC 16 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C RHD MODEL WITH MANUAL A C AC 00333 1 Panel 5 A C switch 9 Mode control cable 2 Mode control dial 6 Rear defogger switch 10 Temper
14. ace the O rings on low high pressure hos es with new ones then apply compressor oil 3 When replacing compressor adjust amount of compressor oil lt Ref to AC 32 OPERATION Compressor Oil gt 4 Charge refrigerant lt Ref to AC 27 OPERA TION Refrigerant Charging Procedure gt Tightening torgue Refer to COMPONENT in General Descrip tion lt Ref to AC 18 AIR CONDITIONING UNIT COMPONENT General Description gt and lt Ref to AC 19 COMPRESSOR COMPONENT General Description gt AC 38 CONDENSER 12 Condenser A REMOVAL 1 Using the refrigerant recovery system dis charge refrigerant lt Ref to AC 26 OPERATION Refrigerant Recovery Procedure gt 2 Disconnect the ground cable from battery 3 Disconnect the pressure hose and pipe from condenser AC 00246 AC 00053 5 Remove the two bolts While lifting the condens er pull it out through the space between radiator and radiator panel AC 00091 CAUTION Be careful not to damage the radiator fins and condensor fins If a damaged fin is found repair it using a thin screwdriver If the condenser is replaced add appropriate amount of compressor oil to the compressor lt Ref to AC 32 REPLACEMENT Compressor Oil gt HVAC SYSTEM HEATER VENTILATOR AND A C B INSTALLATION 1 Install in the reverse order of removal CAUTION Replace the O rings on hoses or pipes with new ones and then apply com
15. akage about 28 g 1 0 oz per year This is not a problem 8 Starting from the connection between the low pressure pipe and evaporator check the system for leakage along the low pressure side through the compressor The following items must be checked thoroughly Connection between two parts Connection between the pipe and plate 9 Visually check the rubber area of the flexible hose for cracks Check the entire length of the flexible hose espe cially the connection with the metal hose end CAUTION Carefully check the external surface of hoses and tubes at approx 25 mm 0 98 in per sec ond AC 00036 A Flexible hose 10 Disconnect the drain hose from the heater case and check the hose end for at least 10 sec onds After the test is finished reconnect the drain hose 11 Turn the ignition Key to ON position and run the blower at high speed for 1 minute Stop the blower to check the ventilation grille on the instru ment panel While moving the tester closer to the grille run the blower for 1 or 2 seconds then stop it Check the grille at that point for atleast 10 seconds CILILIILIO CIL RJ SF 12 Check the valve in the service port AC 30 REFRIGERANT LEAK CHECK HVAC SYSTEM HEATER VENTILATOR AND A C 13 Visually check the rubber seal in the service port cap AC 00038 AC 31 COMPRESSOR OIL HVAC SYSTEM HE
16. alve 3 Mode main lever 12 Mix actuator 21 Evaporator 4 Vent door lever 13 Mix door lever 22 Evaporator lining b 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 7 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C RHD MODEL WITH AUTO A C AC 00001 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 b 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 Ib 9 Lower case 18 Packing T 7 5 0 76 5 5 AC 8 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C LHD MODEL WITH MANUAL A C AC 00359 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
17. and6 Approx 0 4 Q 3 and 4 Approx 1 1 Q 2 and 1 Approx 2 6 Q If NG replace the blower resistor AC 34 HEATER CORE HVAC SYSTEM HEATER VENTILATOR AND A C 9 Heater Core 6 Loosen the screws to remove lower case A REMOVAL 1 Remove the heater cooling unit lt Ref to AC 41 REMOVAL Heater Cooling Unit gt 2 Open the heater core pipe cover RHD model AC 00046 AC 00042 3 Loosen the screws to remove mode actuator AC 00047 B INSTALLATION Install in the reverse order of removal AC 00043 4 Loosen the screws to remove foot duct mi AC 00044 5 Loosen the screws to remove evaporator cover om AC 00045 AC 35 CONTROL UNIT HVAC SYSTEM HEATER VENTILATOR AND A C 10 Control Unit A REMOVAL 1 Disconnect the ground cable from battery 2 In case of manual A C remove the mode cable and air mix cable from links of heater unit 3 Remove the front cover El 00059 El 00102 A Clip 5 Loosen the screws on rear side of center con sole panel and then remove the control unit B INSTALLATION Install in the reverse order of removal AC 36 COMPRESSOR 11 Compressor
18. ant Low pressure side is unusually low Not enough refrigerant Clogged expansion valve Expansion valve frozen temporarily by moisture Saturated receiver dryer AC 25 Check for leaks Replace the expansion valve Replace the receiver dryer REFRIGERANT RECOVERY PROCEDURE HVAC SYSTEM HEATER VENTILATOR AND A C 3 Refrigerant Recovery Proce dure A OPERATION CAUTION During operation be sure to wear safety gog gles and protective gloves Connect the refrigerant recovery system with the manifold gauge set to discharge the refrig erant from the A C system and reuse it When reusing the discharged refrigerant keep service cans on hand Because the dis charge rate with the recovery system is approx 90 service cans are necessary to charge the refrigerant Follow the detailed operation procedure de scribed in the operation manual attached to the refrigerant recovery system 1 Perform the compressor oil return operation lt Ref to AC 32 OPERATION Compressor Oil gt 2 Stop the engine 3 Make sure the valves on low high pressure sides of manifold gauge set are fully closed AC 00146 m Low pressure gauge High pressure gauge Low pressure valve Vacuum pump valve High pressure valve For low pressure For vacuum pump For high pressure OQ Or Ew SE Oo 4 Install the low high pressure hoses to the ser vice po
19. ature control cable 3 Fan dial 7 Air inlet select switch 11 Bulb 4 Temperature control dial 8 Switch circuit board AC 17 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 4 AIR CONDITIONING UNIT AC 00243 1 Condenser 5 Compressor Tightening torque N m kgf m ft Ib 2 Hose High pressure 6 O ring Ti 7 4 0 75 5 4 3 Hose Low pressure 7 Triple pressure switch T2 15 1 5 10 8 4 Pipe AC 18 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 5 COMPRESSOR SN e AC 00335 1 Idler pulley bracket 7 Compressor belt cover Non turbo Tightening torque N m kgf m ft lb 2 Idler pulley adjuster model 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 19 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 6 HEATER DUCT FE 252 gt CA gt N AC 00212 1 Front defroster nozzle 3 Side defroster duct LH 5 Side ventilation duct LH 2 Side defroster duct RH 4 Side ventilation duct RH 6 Rear heater duct AC 20 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C C CAUTION 1 HFC 134A A C SYSTEM Unlike the old conventiona
20. dia 125 mm 4 92 in Pulley ratio 1 064 Condenser Type Corrugated fin Sub cool type Core face area 0 234 m 2 52 sq ft Core thickness 16 mm 0 63 in Radiation area 5 6 m 62 28 sq ft Receiver drier Effective inner capacity 220 cm 13 42 cu in Expansion valve Type External egualizing Evaporator Type Single tank Dimensions W x H x T 176 5 x 266 x 60 mm 6 95 x 10 47 x 2 36 in Blower fan Fan type Sirocco fan Outer diameter x width 150 x 75 mm 5 91 x 2 95 in Power consumption 230 Wat 12 5 V Condenser fan Sub fan Motor type Magnet Power consumption 70 W at 12 V Fan outer diameter 320 mm 12 6 in Radiator fan Main fan Motor type Magnet Power consumption 70 W at 12 V Fan outer diameter 320 mm 12 6 in Idling speed A C ON AC 3 800 100 rpm GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C Item Specifications 1771225 kPa ON OFF Low pressure switch i 1 80 0 25 kg cm 25 60 3 56 psi operating pressure p gp OFF gt ON er kPa 2 10 0 31 kg cm 29 86 4 41 psi ON gt OFF a kPa Triple switch High pressure switch 29 98 2 03 kg cm 426 32 28 87 psi Pressure switch operating pressure DIFF 590 200 kPa 6 02 2 03 kg cm 85 6 28 87 psi ON gt OFF ED kPa Middle pressure switch 13 97 1 22 kg
21. e to the following status A C switch ON Engine running at 1 500 rpm Blower speed setting to Hi Temperature setting to MAX COOL Air inlet setting to RECIRC Window open 23 Open the low pressure valve and charge the specified amount of refrigerant 24 Close all valves and disconnect the hoses from service port after charging the refrigerant 25 Install the cap to service port AC 29 REFRIGERANT LEAK CHECK HVAC SYSTEM HEATER VENTILATOR AND A C 5 Refrigerant Leak Check A INSPECTION 1 Operate the A C system for approx 10 minutes and confirm that the high pressure side shows at least 690 kPa 7 03 kg cm 100 psi Then stop the engine to start the leak test 2 Starting from the connection between the high pressure pipe and evaporator check the system for leaks along the high pressure side through the compressor The following items must be checked thoroughly 3 Check the joint and seam between the pressure switch triple pressure switch and high pressure pipe 4 Check the connections between the condenser and pipes and welded joints on the condenser The leak tester may detect the oil on the condenser fins as a leak 5 Check the joint between the compressor and hoses 6 Check the machined area of compressor and other joints on the compressor 7 Check the compressor shaft seal at the area near the center of compressor clutch pulley Some shaft seals show a slight amount of le
22. ensor from radiator lower panel SE AC 00125 B INSTALLATION Install in the reverse order of removal C INSPECTION Ref to AC 33 AMBIENT SENSOR Diagnostic Procedure for Sensors AC 46 SUN LOAD SENSOR AUTO A C MODEL HVAC SYSTEM HEATER VENTILATOR AND A C 20 Sun load Sensor Auto A C Model A REMOVAL 1 Disconnect the ground cable from battery 2 Disconnect the sunload sensor connector A MU II gt gt AC 00126 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 lt Ref to AC 41 SUNLOAD SENSOR Diagnostic Procedure for Sensors gt AC 47 AIR VENT GRILLE HVAC SYSTEM HEATER VENTILATOR AND A C 21 Air Vent Grille A REMOVAL 1 CENTER GRILLE 1 Disconnect the ground cable from battery 2 Remove the center console panel lt Ref to 40 REMOVAL Instrument Panel Assembly gt 3 Loosen the two screws to remove the center air vent grille 2 SIDE GRILLE 1 Remove the side vent grille by prying four points AC 00249 B INSTALLATION Install in the reverse order of removal
23. ions 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 liguid 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 HFC 134a Millimeter size Ouick joint type CFC 12 Inch size Screw in type Tool amp screw type Valve type AC 22 GENERAL DESCRIPTION Description HVAC SYSTEM HEATER VENTILATOR AND A C Tools and Eguipment AC 00213 Wrench Various WRENCHES will be reguired to service any A C system A 7 to 40 0 7 to 4 1 kgf m 5 to 30 ft Ib torque wrench with various crow foot wrenches will be needed Open end or flare nut wrenches will be needed for back up on the tube and hose fittings AC 00012 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 AC 00013 Manifold gauge set A MANIFOLD GAUGE SET with hoses can be obtained from either a commercial refrigeration supply house or from an auto shop eguipment supplier AC 00014 Refrigerant
24. l HFC 12 system com ponents the cooling system components for the HFC 134a system such as the refrigerant and com pressor oil are incompatible 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 AEE N Eg e er H L gt I o AC 00006 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 tightly 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 f an incorrect or no refrigerant is used poor lu brication will res
25. ntinuity exists 3 4 Continuity exists 3 5 No continuity While applying battery voltage to the terminal be tween 1 and 2 check continuity between 3 and 5 If no continuity exists replace the relay with a new one AC 44 PRESSURE SWITCH TRIPLE PRESSURE SWITCH HVAC SYSTEM HEATER VENTILATOR AND A C 18 Pressure Switch Triple Pres 2 Remove the pressure switch harness connector sure Switch A INSPECTION 1 Connect the manifold gauge to the service valve on the high pressure side Terminal No Operation Using a circuit tester inspect the ON OFF opera tion of the pressure switch AC 00248 Standard kPa kg cm psi High and low pressure switch 1 and 2 Turns off Pressure increases up to 2 940 200 30 012 427128 Pressure decreases down to 177225 1 8 0 3 2614 Turns on Pressure increases up to 206130 2 10 3 3014 Pressure decreases down to 2 350 200 2442 341428 Middle pressure switch Turns off Pressure decreases down to 1 370 120 1441 199114 Turns on Pressure increases up to 1 770 100 18 1 2561414 AC 45 AMBIENT SENSOR AUTO A C MODEL HVAC SYSTEM HEATER VENTILATOR AND A C 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 s
26. ondition 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 1499F Hot water flow rate 360 2 95 1 US gal 79 2 Imp gal h Air flow rate 280 m 9 888 cu ft h Heat mode FRESH FULL HOT at 12 5 V Max air flow rate 480 16 951 cu ft h Temperature control switch FULL COLD Blower fan speed 4th position Mode selector switch RECIRC Heater core size height x length x width 134 1 x 224 3 x 32 mm 5 28 x 8 83 x 1 26 in Type Blower motor Auto A C Brushless motor 230 W or less Manual A C Cylinder motor 260 W or less Fan type and size diameter x width Sirocco fan type 150 x 75 mm 5 91 x 2 95 in AC 2 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 2 A C SYSTEM AUTO A C MODEL 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 0 6 0 05 kg 1 32 0 11 Ib Compressor Type Vane rotary fix volume DKV 14G Discharge 140 cm 8 54 cu in rev Max permissible speed 7 000 rom Magnet clutch Type Dry single disc type Power consumption 38 W DC 12 V 25 C Type of belt V Ribbed 4 PK Pulley dia effective
27. pressor oil Confirm that lower guide of condenser has been fitted into holes on radiator panel k t AC 00092 2 Charge refrigerant lt Ref to AC 27 OPERA TION Refrigerant Charging Procedure gt Tightening torque Refer to COMPONENT in General Descrip tion lt Ref to AC 18 AIR CONDITIONING UNIT COMPONENT General Description gt and lt Ref to CO SOHC 5 RADIATOR AND RADIATOR FAN COMPONENT General De scription gt C INSPECTION 1 Confirm that no dust or insects are found on the condenser fins Air blow or flush fins with water as needed 2 Confirm that no oil leaks from condenser If a failure is found replace the condenser with a new one AC 39 CONDENSER FAN SUB FAN HVAC SYSTEM HEATER VENTILATOR AND A C 13 Condenser Fan Sub Fan A REMOVAL lt Ref to CO SOHC 34 REMOVAL Radiator Main Fan and Fan Motor gt B INSTALLATION lt Ref to CO SOHC 36 INSTALLATION Radiator Main Fan and Fan Motor gt AC 40 HEATER COOLING UNIT HVAC SYSTEM HEATER VENTILATOR AND A C 14 Heater Cooling Unit A REMOVAL 1 Disconnect the ground cable from battery 2 Using the refrigerant recovery system dis charge refrigerant lt Ref to AC 26 OPERATION Refrigerant Recovery Procedure gt 3 Drain LLC from the radiator 4 Remove the A C pipe of toe board Release the heater hose clamps in engine compartment to re move the hoses DD
28. recovery system 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 AC 00015 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 AC 23 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C Description Tools and Eguipment 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 eguipment supplier AC 00017 Can tap A CAN TAP for the 397 g 14 oz can is available from an auto supply store AC 00018 Thermometer Pocket THERMOMETERS are available from either industrial hard ware store or commercial refrigeration supply houses 00019 Electronic leak detector An ELECTRONIC LEAK DETECTOR can be obtained from either a specialty tool supply or an A C equipment supplier AC 00020 Weight scale A WEIGHT SCALE such as an electronic charging scale or a bath room scale with digital display will be needed if a 13 6 kg 30 Ib refrig erant container is used AC 24 REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET HVAC SYSTEM HEATER VENTILATOR AND A C 2 Refrigerant Pressure with Manifold Gauge Set A OPERATION 1 Place the vehicle in the
29. rom vehicle AC 00247 B INSTALLATION CAUTION When disconnecting connecting hoses do not apply an excessive force to them Confirm that no torsion and excessive tension exists af ter installing Seal the disconnected hose with a plug or vi nyl tape to prevent contamination from enter ing Replace the o rings for hoses and pipes with new ones and then apply compressor oil 1 Install in the reverse order of removal 2 Charge refrigerant Ref to AC 27 OPERA TION Refrigerant Charging Procedure Tightening torque Refer to COMPONENT in General Descrip tion Ref to AC 18 AIR CONDITIONING UNIT COMPONENT General Description C INSPECTION NOTE If cracking damage or swelling is found on a hose replace it with a new one AC 43 RELAY AND FUSE HVAC SYSTEM HEATER VENTILATOR AND A C 17 Relay and Fuse B INSPECTION A LOCATION E 2321235 J lla Er T F z gt 18281 rs 2 o 7 a F a s Beo 8 Bo 5 z 8 m Q 2 89 AW u 2 or o 5 s 555 0 AC 00093 ER DER AC 00255 1 2 Co
30. rts on the low high pressure sides of the vehicle respectively AC 00147 1 Low service port 2 High service port 3 Close 5 Connect the center hose to the refrigerant recov ery system 6 Follow the operation manual to activate the re frigerant recovery system AC 26 REFRIGERANT CHARGING PROCEDURE 4 Refrigerant Charging Proce 2 Install the low high pressure hoses to corre sponding service ports on vehicle dure A OPERATION CAUTION During operation be sure to wear safety gog gles and protective gloves lf air is mixed in refrigeration cycle poor cooling may result and also if moisture is mixed in refrigeration cycle clogging freezing or rust may result Before charging the refrigerant evacuate the system using vacuum pump to remove air and moisture in the system Moisture can be evapo rated and removed easily even at normal tem perature if the system is evacuated using vacuum pump 1 Close all valves of manifold gauge HVAC SYSTEM HEATER VENTILATOR AND A C AC 00147 AC 00146 1 Low service port 2 High service port 3 Close CAUTION Be sure that the hoses are securely connected 3 Connect the center hose of manifold gauge with vacuum pump 4 Activate the vacuum pump and then open the valves on low high pressure sides L Low pressure gauge H High pressure gauge 1 Low pressure val
31. uator resistor 1 5 Loosen the bolt and nut to remove blower motor unit assembly HVAC SYSTEM HEATER VENTILATOR AND A C B INSTALLATION Install in the reverse order of removal Tightening torque Refer to COMPONENT in General Descrip tion lt Ref to AC 7 HEATER COOLING UNIT COMPONENT General Description gt and lt Ref to AC 11 BLOWER MOTOR UNIT COMPONENT General Description gt C INSPECTION Inspection of Auto A C Brush less Motor Operation Connect the motor connector terminal 5 from the battery to the positive lead and terminal 2 and 1 at the same type to the negative lead Make sure the motor runs smoothly AC 00244 AC 33 BLOWER RESISTOR MANUAL A C MODEL HVAC SYSTEM HEATER VENTILATOR AND A C 8 Blower Resistor Manual A C Model A REMOVAL 1 Remove the glove box lt Ref to 37 REMOV AL Glove Box gt 2 Disconnect the blower resistor connector 3 Loosen the two screws to remove blower resis tor 00221 INSTALLATION Install in the reverse order of removal C INSPECTION 04 1 5 9 AC 00245 Measure the blower resistor resistance Terminal No Standard 3
32. ult 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 warning avoid releas ing HFC 134a into the atmosphere Using a refrig erant recovery system discharge and reuse it AC 00007 Goggles Gloves Avoid open flame D No direct heat on container Do not discharge Loosen AC 21 GENERAL DESCRIPTION HVAC SYSTEM HEATER VENTILATOR AND A C 5 O RING CONNECTIONS Use new O rings
33. utch Compressor Pressure switch Blower fan relay Blower motor A C switch Blower switch Wire harness Heater duct Heater vent duct Control unit Expansion valve Evaporator Air mix actuator Auto A C Temerature control cable Manual A C Engine coolant Aspirator hose Blower switch Air mix actuator Auto A C Temerature control cable Manual A C Heater core Wire harness Air mix actuator Auto A C Temerature control cable Manual Temperature of air from vents does not change AIC Compressor Condensor fan Cold air not emitted Warm air not emitted Temperature adjustment switch AC 51 GENERAL DIAGNOSTICS HVAC SYSTEM HEATER VENTILATOR AND A C Symptom Repair order Wire harness Unable to switch blow vents Mode actuator Auto A C Mode control cable Manual A C Mode switch Wire harness Unable to switch suction vents FRESH RECIRC actuator Air inlet select switch AC 52
34. ve r P AC 00057 CAUTION If the evaporator is replaced add appropriate amount of compressor oil to evaporator lt Ref to AC 32 REPLACEMENT Compressor Oil gt B INSTALLATION Install in the reverse order of removal NOTE Replace the o ring for refrigerant recovery amp toe board area air conditioner pipe with a new one and then apply compressor oil AC 42 HOSE AND TUBE HVAC SYSTEM HEATER VENTILATOR AND A C 16 Hose and Tube A REMOVAL CAUTION When disconnecting connecting hoses do not apply excessive force to them Confirm that no torsion and excessive tension exists after installing Seal the disconnected hose with a plug or vi nyl tape to prevent contamination from enter ing 1 Disconnect the ground cable from battery 2 Using the refrigerant recovery system dis charge refrigerant Ref to AC 26 OPERATION Refrigerant Recovery Procedure 3 Remove the evaporator unit mounting bolt A 4 Remove the low pressure hose attaching bolts B 5 Disconnect the low pressure hose from evapo rator unit 6 Disconnect the low pressure hose from com pressor 7 Remove the low pressure hose from vehicle 8 Remove the high pressure hose attaching bolts C 9 Disconnect the high pressure hose from com pressor 10 Disconnect the high pressure hose from con denser 11 Remove the high pressure tube attaching bolt D 12 Remove the high pressure tube f
35. ve 2 Vacuum pump valve AC 00148 3 High pressure valve 4 For low pressure 1 Vacuum pump B For vacuum pump 2 Open 6 For high pressure CAUTION Be sure to evacuate the system using vacuum pump AC 27 REFRIGERANT CHARGING PROCEDURE HVAC SYSTEM HEATER VENTILATOR AND A C 5 After at least 5 minutes of evacuation if the low pressure gauge reading shows 100 0 kPa 750 mmHg 29 5 inHg or higher close the valves on center hose to stop the vacuum pump 6 Leave it at least 5 to 10 minutes after closing the valves on low high pressure sides and then check the low pressure gauge reading for any changes When the gauge reading changes this is a sign of leakage Check the pipe or hose connector points and repair if necessary Repeat the procedure from 1 after repairing the faulty part 7 If there are no leaks further evacuate the sys tem 20 to 30 minutes 8 Close all valves and stop the vacuum pump 9 Following the can tap operation manual instruc tions install it to refrigerant can AC 00214 1 Tap valve 2 Connect to center hose 10 Disconnect the vacuum pump from center hose and connect the hose to tap valve 11 When a refrigerant recovery container is used measure the refrigerant amount in use using a weighting scale before connecting to center hose AC 00215 1 Refrigerant recovery container 2 Weighting scale 12 Open the valve on
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