FUJI HEAVY INDUSTRIES LTD. G8080GE7
03-04 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
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, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance 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 specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTIC)
AC
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTIC) AB
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEM WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOW/MIRROR GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEAT SE
SECURITY AND LOCK SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANEL EB
03-04 FORESTER SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G8080GE7
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4SO)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4DOTC)
CRUISE CONTROL SYSTEM
(DIAGNOSTIC)
CC(H4DOTC 2.5)
IMMOBILIZER (DIAGNOSTIC) IM
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-2
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
1. General Description
A: SPECIFICATION
1. HEATER SYSTEM
2. A/C SYSTEM
• AUTO A/C MODEL
Item Specifications Condition
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 (149°F)
• Hot water flow rate: 3602 (95.1 US gal, 79.2
Imp gal)/h
Air flow rate
280 m
3
(9,888 cu ft)/h
Heat mode (FRESH), FULL HOT at 12.5 V
Max air flow rate
480 m
3
(16,951 cu ft)/h
• Temperature control switch: FULL COLD
• Blower fan speed: 4th position
• Mode selector lever: RECIRC
Heater core size
(height×length×width)
134.1×224.3×32 mm
(5.28×8.83×1.26 in)
—
Blower motor
Type
Auto A/C (Brushless motor)
230 W or less
12.5 V
Manual A/C (Cylinder motor)
260 W or less
12.5 V
Fan type and size
(diameter×width)
Sirocco fan type
150×75 mm (5.91×2.95 in)
—
Item 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 (CH
2
FCF
3
)
[0.6±0.05 kg (1.32±0.11 lb)]
Compressor
Type Vane rotary, fix volume (DKV-14G)
Discharge
140 cm
3
(8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Magnet clutch
Type Dry, single-disc type
Power consumption 38 W (DC 12 V-25°C)
Type of belt V-belt 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
(2.52 sq ft)
Core thickness 16 mm (0.63 in)
Radiation area
5.6 m
2
(62.28 sq ft)
Receiver drier Effective inner capacity
220 cm
3
(13.42 cu in)
Expansion valve Type External equalizing
Evaporator
Type Single tank
Dimensions (W×H×T)
176.5×266×60 mm
(6.95×10.47×2.36 in)
Blower fan
Fan type Sirocco fan
Outer diameter×width 150×75 mm (5.91×2.95 in)
Power consumption 230 W or less at 12.5 V
AC-3
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• MANUAL A/C MODEL
Condenser fan (Sub fan)
Motor type Magnet
Power consumption
2.5 L turbo model and turbo AT model for EC and
EK:
120 W at 12 V
Other model than above:
70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
Radiator fan (Main fan)
Motor type Magnet
Power consumption
2.5 L turbo model and turbo AT model for EC and
EK:
120 W at 12 V
Other model than above:
70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
Idling speed (A/C ON) MPFI model 800±100 rpm
Triple switch
(Pressure switch)
Low-pressure switch
operating pressure
ON → OFF
177±25 kPa
(1.80±0.25 kg/cm
2
, 25.60±3.56 psi)
OFF → ON
206±30 kPa
(2.10±0.31 kg/cm
2
, 29.86±4.41 psi)
High-pressure switch
operating pressure
ON → OFF
2,940±200 kPa
(29.98±2.03 kg/cm
2
, 426.32±28.87 psi)
OFF → ON
590±200 kPa
(6.02±2.03 kg/cm
2
, 85.6±28.87 psi)
Middle pressure switch
operating pressure
ON → OFF
1370±120 kPa
(13.97±1.22 kg/cm
2
, 198.65±17.35 psi)
OFF → ON
1,770±100 kPa
(18.05±1.02 kg/cm
2
, 256.81±14.50 psi)
Thermo control amplifier working temperature
(Evaporator outlet air)
Item 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 (CH
2
FCF
3
)
[600±50 g (1.32±0.11 lb)]
Compressor
Type Vane rotary, fix volume (DKV-14G)
Discharge
140 cm
3
(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-belt 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Item Specifications
AC-00082
OFF
ON
3.0 0.3
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Subaru Forester 2003 2004 Service Repair Workshop Manual
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Description
- This workshop service repair manual covers all repairs, both mechanical and electrical, for all models and engine types for the specified years.
- It includes detailed pictures, diagrams, and specific information such as routine maintenance, tune-up procedures, engine specifications, and more.
- Professionals and DIY enthusiasts can benefit from the knowledge contained within this manual to easily perform their own servicing and repairs.
- Delivery of this manual is instant upon payment, with no shipping involved, allowing you to start fixing the vehicle right away.
- By using this manual, you can save a significant amount of money by avoiding overpriced mechanic services for jobs you can easily do yourself.
- The manual is user-friendly and compatible with any PC/MAC computer using Microsoft Windows, making it accessible to all.
FAQ:
- Why should I purchase this Service Repair Workshop Manual?
This manual provides an easy layout format covering all repair procedures in great detail, enabling better understanding of vehicle parts and repair procedures. - What models are covered in this manual?
All models for the specified years and all engine types are included, making it specific to the stated model and equivalent to the type of manual used by local dealers/mechanics. - What type of information is covered?
The manual covers a wide range of information including engine repair, electrical systems, safety precautions, tightening torques, and more. - How long for delivery?
Delivery is instant upon payment, with no shipping involved, allowing immediate access to the manual. - How much money will I save?
This manual can help save thousands by enabling DIY repairs and avoiding overpriced mechanic services. - Is this manual hard to use?
No, it is user-friendly and compatible with various PC/MAC computers using Microsoft Windows, making it simple to use.
