Subaru FORESTER2001 Service Manual
Subaru FORESTER2001 Service Manual

Subaru FORESTER2001 Service Manual

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2001 FORESTER SERVICE MANUAL

BODY SECTION

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.
QUICK REFERENCE INDEX
G8050GE6

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Summary of Contents for Subaru FORESTER2001

  • Page 1: Body Section

    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.
  • Page 2: Table Of Contents

    HVAC SYSTEM (HEATER, VENTILATOR AND A/C) 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...
  • Page 3: General Description

    GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) 1. General Description S701001 A: SPECIFICATIONS S701001E49 1. HEATER SYSTEM S701001E4901 Item Specifications Condition ¼ Mode selector switch: HEAT 5.1 kW (4,386 kcal/h, 17,404 BTU/h) ¼ Temperature control switch: FULL HOT LHD model or more ¼...
  • Page 4 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) 2. A/C SYSTEM S701001E4902 ¼ LHD Model: Item Specifications Type of air conditioner Reheat air-mix type 5.117 kW Cooling capacity (4,400 kcal/h, 17,459 BTU/h) HFC-134a (CH Refrigerant [0.65±0.05 kg (1.43±0.11 lb)] Type 5-vane rotary, fix volume (KC50G) Compressor Discharge...
  • Page 5 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) ¼ RHD Model: Item Specifications Type of air conditioner Reheat air-mix type Cooling capacity 5.059 kW (4,350 kcal/h, 17,261 BTU/h) HFC-134a (CH Refrigerant [0.65±0.05 kg (1.43±0.11 lb)] Type 5-vane rotary, fix volume (KC50G) Compressor Discharge 140 cm...
  • Page 6 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) B: COMPONENT S701001A05 1. HEATER UNIT S701001A0501 ¼ LHD Model: H4M1045B (1) Vent door (7) Mix lever (13) Vent lever (2) DEF door (8) Foot door (14) Side link (3) DEF lever (9) Foot duct (4) Heater core (10) Heater case REAR...
  • Page 7 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) ¼ RHD Model: S4M0309A (1) Heater case upper A (8) Vent door lever (15) Mix door lever (2) Heater case upper B (9) Side link (16) Foot duct (3) Vent door (10) Foot door (4) DEF door (11) Mix door Tightening torque: N·m (kg-m, ft-lb)
  • Page 8 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) 2. INTAKE UNIT WITH EVAPORATOR S701001A0505 ¼ LHD Model: S4M0501A (1) Evaporator (With A/C model) (8) Door (B) (16) Aspirator pipe (2) Boot (9) Intake unit case inlet (17) Cover (3) Block expansion valve (With A/C (10) Thermistor (With A/C model) (18) Separator model)
  • Page 9 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) ¼ RHD Model: S4M0545A (1) Door (A) (9) Door (B) (16) Expansion valve (With A/C (2) Sealing sponge (10) Link model) (3) Door (B) lever (11) Door (A) lever (17) Drain hose (4) Intake unit case upper (12) Evaporator (With A/C model) Tightening torque: N·m (kgf-m, ft-lb)
  • Page 10 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) 3. CONTROL UNIT S701001A0503 S4M0083A (1) Temperature control cable (6) Bulb (11) Control lever knob (2) Recirc control cable (7) A/C switch ASSY (12) Plate (3) Clip (8) Mode control cable (13) Base unit (4) Blower switch ASSY (9) Control dial knob (5) Harness ASSY...
  • Page 11 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) 4. AIR CONDITIONING UNIT S701001A0504 ¼ LHD Model: S4M0486A (1) Condenser (5) Hose (Low-pressure) Tightening torque: N·m (kgf-m, ft-lb) (2) Pipe (From condenser to (6) Compressor 7.4 (0.75, 5.4) receiver drier) (7) Hose (High-pressure) 15 (1.5, 10.8) (3) Receiver drier (4) Pipe (From receiver drier to...
  • Page 12 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) ¼ RHD Model: S4M0487A (1) Compressor (5) Receiver drier Tightening torque: N·m (kgf-m, ft-lb) (2) Hose (Low-pressure) (6) Pipe (From condenser to 7.4 (0.75, 5.4) (3) Condenser receiver drier) 15 (1.5, 10.8) (4) Pipe (From receiver drier to (7) Hose (High-pressure) intake unit)
  • Page 13 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) 5. COMPRESSOR S701001A0506 S4M0488A (1) Idler pulley adjuster (7) V-belt Tightening torque: N·m (kgf-m, ft-lb) (2) Idler pulley bracket (8) Compressor belt cover 7.4 (0.75, 5.4) (3) Idler pulley 23 (2.3, 17) (4) Compressor bracket upper 23.0 (2.35, 17.0) (5) Compressor...
  • Page 14 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) 4. HANDLING OF REFRIGERANT C: CAUTION S701001A0304 S701001A03 ¼ The refrigerant boils at approx. −30°C (−22°F). 1. HFC-134a A/C SYSTEM S701001A0301 When handling it, be sure to wear safety goggles ¼ Unlike the old conventional HFC-12 system and protective gloves.
  • Page 15 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) ¼ Use the oil specified in the service manual to 5. O-RING CONNECTIONS S701001A0305 lubricate the O-rings. ¼ Use new O-rings. Apply the oil to the top and sides of the O-rings ¼...
  • Page 16 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 com- pressor oil is mixed, poor lubrication will result and the compressor itself may be destroyed.
  • Page 17 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) Tools and Equipment Description Refrigerant 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. G4M0574 Syringe A graduated plastic SYRINGE will be needed to add oil back into the...
  • Page 18 GENERAL DESCRIPTION HVAC System (Heater, Ventilator and A/C) Tools and Equipment Description Thermometer Pocket THERMOMETERS are available from either industrial hard- ware 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.
  • Page 19: Refrigerant Pressure With Manifold Gauge Set

    REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET HVAC System (Heater, Ventilator and A/C) 2. Refrigerant Pressure with Manifold Gauge Set S701631 A: OPERATION 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.
  • Page 20: Refrigerant Recovery Procedure

    REFRIGERANT RECOVERY PROCEDURE HVAC System (Heater, Ventilator and A/C) 3. Refrigerant Recovery 6) Follow the operation manual to activate the refrigerant recovery system. Procedure S701291 A: OPERATION S701291A16 CAUTION: ¼ During operation, be sure to wear safety goggles and protective gloves. ¼...
  • Page 21: Refrigerant Charging Procedure

    REFRIGERANT CHARGING PROCEDURE HVAC System (Heater, Ventilator and A/C) 4. Refrigerant Charging 4) Carefully open the valves on the low-/high- pressure sides to activate the vacuum pump. Procedure S701292 A: OPERATION S701292A16 CAUTION: ¼ During operation, be sure to wear safety goggles and protective gloves.
  • Page 22 REFRIGERANT CHARGING PROCEDURE HVAC System (Heater, Ventilator and A/C) 8) Leave it at least 5 minutes, and then check the 15) Carefully open the high-pressure valve with low-pressure gauge reading for any changes. the engine stopping. When a gauge indicator shows near to zero point, CAUTION: this is a sign of leakage.
  • Page 23 REFRIGERANT CHARGING PROCEDURE HVAC System (Heater, Ventilator and A/C) 19) If the HFC-134a source is empty, close the 26) Close the valve on the refrigerant source. high-pressure valve, close the valve on the can Refrigerant amount tap, and replace the HFC-134a source with a new one to restart the operation.
  • Page 24: Refrigerant Leak Check

    REFRIGERANT LEAK CHECK HVAC System (Heater, Ventilator and A/C) 5. Refrigerant Leak Check 5) Check the joint between the compressor and S701293 hoses. A: INSPECTION 6) Check the machined area of compressor and S701293A10 other joints on the compressor. 1) Operate the A/C system for approx. 10 minutes, 7) Check the thermal limiter (if equipped) on the and confirm that the high-side pressure shows at compressor housing.
  • Page 25 REFRIGERANT LEAK CHECK HVAC System (Heater, Ventilator and A/C) 12) Turn the ignition key to ON position, and run the blower at high speed for 1 minute. Stop the blower to check the ventilation grill on the instru- ment panel. While moving the tester closer to the grill, run the blower for 1 or 2 seconds, then stop it.
  • Page 26: Compressor Oil

    COMPRESSOR OIL HVAC System (Heater, Ventilator and A/C) 6. Compressor Oil B: REPLACEMENT S701294A20 S701294 NOTE: A: OPERATION S701294A16 ¼ If a component is replaced, add an appropriate NOTE: amount of compressor oil. Before making repairs, conduct the oil return ¼...
  • Page 27: Heater Unit

    HEATER UNIT HVAC System (Heater, Ventilator and A/C) 7. Heater Unit S701290 A: REMOVAL S701290A18 1) Disconnect ground cable from battery. 2) Drain engine coolant. <Ref. to CO-14, DRAIN- ING OF ENGINE, REPLACEMENT, Engine Cool- ant.> 3) Remove air cleaner case. (Non-turbo model) <Ref.
  • Page 28: Blower Motor Assembly

    BLOWER MOTOR ASSEMBLY HVAC System (Heater, Ventilator and A/C) 8. Blower Motor Assembly B: INSTALLATION S701295A11 S701295 Install in the reverse order of removal. A: REMOVAL S701295A18 1) Disconnect ground cable from battery. C: INSPECTION S701295A10 2) Remove glove box. Connect motor connector terminal 1 from the bat- tery to the positive (+) lead and terminal 2 to the negative (−) lead.
  • Page 29: Power Transistor (Heater Blower Resistor)

    POWER TRANSISTOR (HEATER BLOWER RESISTOR) HVAC System (Heater, Ventilator and A/C) 9. Power Transistor (Heater Blower Resistor) S701553 A: REMOVAL S701553A18 1) Remove glove box. <Ref. to EI-28 REMOVAL, Glove Box.> 2) Disconnect power transistor connector. 3) Loosen 2 screws to remove power transistor. B4M2305 B: INSTALLATION S701553A11...
  • Page 30: Heater Core

    HEATER CORE HVAC System (Heater, Ventilator and A/C) 10. Heater Core S701554 A: REMOVAL S701554A18 1) Remove heater unit. <Ref. AC-26 REMOVAL, Heater Unit.> 2) Remove screws to separate heater unit case. 3) Remove heater core. B4M2306 B: INSTALLATION S701554A11 Install in the reverse order of removal.
  • Page 31: Control Unit

    CONTROL UNIT HVAC System (Heater, Ventilator and A/C) 11. Control Unit 7) Remove control unit assembly from center con- S701285 sole. A: REMOVAL S701285A18 1) Disconnect GND cable from battery. 2) Set temperature control switch to “FULL HOT” and mode selector switch to “DEF” position and recirc switch to “FRESH”...
  • Page 32 CONTROL UNIT HVAC System (Heater, Ventilator and A/C) 2. A/C SWITCH S701285A1004 Check A/C switch continuity between each termi- nal. H5M1281A H4M1052 D: ADJUSTMENT S701285A01 1) Operate temperature control switch to “FULL COLD” and mode selector switch to “VENT” posi- tion and recirc switch to “RECIRC”...
  • Page 33: Compressor

    COMPRESSOR HVAC System (Heater, Ventilator and A/C) 12. Compressor 5) Disconnect low-pressure hose (A) and high- S701281 pressure hose (B). A: INSPECTION S701281A10 CAUTION: Be careful not to lose O-rings on hose. Imme- 1. MAGNETIC CLUTCH CLEARANCE diately seal hose with a plug or vinyl tape to S701281A1001 prevent the entry of contamination.
  • Page 34 COMPRESSOR HVAC System (Heater, Ventilator and A/C) C: INSTALLATION S701281A11 1) Install in the reverse order of removal. 2) Replace O-rings on low-/high-pressure hoses with new ones, then apply compressor oil. 3) When replacing compressor, adjust amount of compressor oil. <Ref. to AC-25 Compressor Oil.> 4) Charge refrigerant.
  • Page 35: Condenser

    CONDENSER HVAC System (Heater, Ventilator and A/C) 13. Condenser 5) Remove 2 bolts. While lifting condenser, pull it S701282 out through the space between the radiator and the A: REMOVAL radiator panel. S701282A18 1) Using refrigerant recovery system, discharge refrigerant. <Ref. to AC-19 OPERATION, Refriger- ant Recovery Procedure.>...
  • Page 36: Receiver Drier

    RECEIVER DRIER HVAC System (Heater, Ventilator and A/C) 14. Receiver Drier S701283 A: REMOVAL S701283A18 1) Disconnect ground cable from battery. 2) Using refrigerant recovery system, discharge refrigerant. <Ref. to AC-19 OPERATION, Refriger- ant Recovery Procedure.> 3) Disconnect pressure switch harness (A). 4) Disconnect pipe (B).
  • Page 37: Intake Unit

    INTAKE UNIT HVAC System (Heater, Ventilator and A/C) 15. Intake Unit 7) Remove intake unit mounting bolt and nut. S701632 A: REMOVAL S701632A18 1) Using refrigerant recovery system, discharge refrigerant. <Ref. to AC-19 OPERATION, Refriger- ant Recovery Procedure.> 2) Disconnect ground cable from battery. 3) LHD: Remove bolt then disconnect discharge pipe and suction pipe.
  • Page 38 INTAKE UNIT HVAC System (Heater, Ventilator and A/C) 2. RHD MODEL C: DISASSEMBLY S701632A0602 S701632A06 1) Remove some screws, then separate intake 1. LHD MODEL S701632A0601 unit case. 1) Remove thermistor (A) from intake unit case. 2) Remove some screws then separate intake unit case.
  • Page 39: Flexible Hose

    FLEXIBLE HOSE HVAC System (Heater, Ventilator and A/C) 16. Flexible Hose S701286 A: REMOVAL S701286A18 CAUTION: ¼ When disconnecting/connecting hoses, do not apply excessive force them. Confirm that no torsion and excessive tension exist after installing. ¼ Seal the disconnected hose with a plug or vinyl tape to prevent contamination from enter- S4M0217A ing.
  • Page 40: Relay And Fuse

    RELAY AND FUSE HVAC System (Heater, Ventilator and A/C) 17. Relay and Fuse B: INSPECTION S701287A10 S701287 A: LOCATION S701287A13 B4M2308A (3) — (4): Continuity exists. S4M0546A (1) — (2): No continuity While applying battery voltage to the cable A/C fuse between (3) and (4), check continuity between (1) Main fan relay and (2).
  • Page 41: Pressure Switch (Dual Switch)

    PRESSURE SWITCH (DUAL SWITCH) HVAC System (Heater, Ventilator and A/C) 18. Pressure Switch (Dual Switch) S701555 A: INSPECTION S701555A10 1) Connect the manifold gauge to the service valve on the high-pressure side. 2) Remove the pressure switch harness connec- tor. Using a circuit tester, inspect the ON-OFF operation of the pressure switch.
  • Page 42: Air Vent Grille

    AIR VENT GRILLE HVAC System (Heater, Ventilator and A/C) 19. Air Vent Grille B: INSTALLATION S701284A11 S701284 Install in the reverse order of removal. A: REMOVAL S701284A18 1. CENTER AIR VENT GRILLE C: INSPECTION S701284A1803 S701284A10 1) Remove center panel. The direction and amount of air should be adjusted 2) Loosen screw to remove grille.
  • Page 43: Heater Duct

    HEATER DUCT HVAC System (Heater, Ventilator and A/C) 20. Heater Duct S701556 A: REMOVAL S701556A18 1) Remove front seat. <Ref. to SE-5 REMOVAL, Front Seat.> 2) Remove heater unit. <Ref. AC-26 REMOVAL, Heater Unit.> 3) Remove front side sill cover. 4) Pull off floor mat to remove heater duct.
  • Page 44: Heater Vent Duct

    HEATER VENT DUCT HVAC System (Heater, Ventilator and A/C) 21. Heater Vent Duct 2) Remove screws. S701557 3) Remove heater vent duct. A: REMOVAL S701557A18 1) Remove instrument panel. <Ref. to EI-31 REMOVAL, Instrument Panel.> S4M0519 B: INSTALLATION S701557A11 Install in the reverse order of removal. AC-43...
  • Page 45: General Diagnostics

    GENERAL DIAGNOSTICS HVAC System (Heater, Ventilator and A/C) 22. General Diagnostics S701278 A: INSPECTION S701278A10 Symptom Repair order Fuse Blower motor relay Blower motor Doesn’t move. Blower motor Blower motor resister Blower switch Wire harness Strange noise. Blower motor Refrigerant Fuse Air conditioning relay Magnet clutch...

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