Air Conditioning System: Other Subaru Forester SF рестайлинг

Compressor Oil

Do not use any compressor oil that is not specifically designated for the HFC-134a air conditioning system; only use ZXL200PG. Also, do not use HFC-134a compressor oil in the CFC-12 air conditioning system. If compression oils are mixed, poor lubrication will result and the compressor itself may be damaged.

Because HFC-134a compressor oil is very hygroscopic (easily absorbs moisture), when parts of the air conditioning system are being removed, quickly install a blind plug to prevent contact with the outside air. Also, always make sure that the service container for compressor oil is tightly closed except when in use. Store compressor oil in a tightly closed steel container.

Refrigerant

Do not put CFC-12 refrigerant into a HFC-134a air conditioning system. Also, do not put HFC-134a refrigerant into a CFC-12 air conditioning system. If the wrong refrigerant is used, poor lubrication will result and the compressor itself may be destroyed.

Handling Of Refrigerant

Because refrigerant boils at approx. -30°C (-22°F) at sea level, it is cold enough to give you severe frostbite. Always wear goggles to protect your eyes and gloves to protect your hands. Also, even under the pressures normally found in CFC-12 containers, refrigerant will boil with the addition of heat. This could raise the pressure inside the container to a dangerous level.

Never expose a can of HFC-134a to direct sunlight, or to temperatures over 40°C (104°F). One more thing to remember about HFC-134a is that when it is exposed to an open flame or to hot metal, it forms phosgene, a deadly gas. Do not discharge HFC-134a into the atmosphere on purpose. Always read and follow the precautions on the HFC-134a bottle.

Identifying Handling & Precaution Labels. Scheme 32

Scheme 33

1. The combination of moisture and refrigerant forms acid, therefore, moisture should not be allowed to enter the refrigerant.
2. Refrigerant oil readily absorbs moisture, therefore, keep refrigerant oil containers tightly capped.
3. The process of evacuating the system is performed to remove small amounts of moisture. This is accomplished by lowering the pressure inside the system, which allows the moisture to boil off, in much the same way that a pot of water will boil away to nothing given enough time. The evacuation process does not suck the moisture out of the system.
4. A minimum level of vacuum must be reached to satisfactorily evacuate the system. This minimum level of vacuum depends on the temperature inside the system. The chart below shows the level of vacuum required to boil water at various temperatures. Additionally, the vacuum level shown on a gauge will read approx. 3.3 kPa (25 mmHg, 1 inHg) less for each 304.8 m (1,000 ft) above sea level, due to the decrease in atmospheric pressure at altitude. (Scheme 33): Chart Showing Level Of Vacuum Required To Boil Water At Various Temperatures

TOOLS AND EQUIPMENT

The following section provides information about the tools and equipment that will be necessary to properly service the A/C system.

Since equipment may vary slightly depending on the manufacturer, it is important to always read and follow the manufacturer's instructions.

Tools & Equipment Used To Properly Service A/C System (1 Of 4). Scheme 34

Tools & Equipment Used To Properly Service A/C System (2 Of 4). Scheme 35

Tools & Equipment Used To Properly Service A/C System (3 Of 4). Scheme 36

Tools & Equipment Used To Properly Service A/C System (4 Of 4). Scheme 37

General

The following points should be kept in mind when assembling O-ring connections

1. Avoid unnecessary handling and contact of O-rings with your hands, since even clean fingers contain body acids, which can contaminate the O-ring surface.
2. Do not handle O-rings with gloves, shop towels, etc., since lint particles may cling to the O-ring, possibly causing a leak upon assembly.
3. Always lubricate O-rings before assembly to allow the O-ring to seat itself properly.
4. Be certain to use torque wrenches when tightening O-ring fittings, because overtightening can not only damage the O-ring, but it can distort the tube end as well.

Scheme 38

Scheme 39

1. Just prior to making the connection, remove the protective seals (A). CAUTION: If for any reason you have to stop before making a connection, recap the tube, component or fitting. (Scheme 38): Identifying Protective Seals (A)
2. Visually inspect the O-ring surface, the O-ring mating surface, the threads and the connection points. If a defective part is found, replace it. The O-ring must sit square against the tube bead. If necessary, slide the O-ring into proper position with clean hands. (Scheme 39): Identifying O-Ring's Proper Position Against Tube Bead

DISCHARGE THE SYSTEM

Note. Refer to the relevant refrigerant recovery system instruction manual for operating procedures.

Scheme 40

Scheme 41

1. Close the high and low side manifold valves. (Scheme 40): Identifying High & Low Side Manifold Valves
2. Turn the A/C system ON and turn the IG switch OFF.
3. Attach the high and low-pressure manifolds to the high and low services port on the vehicle. (Scheme 41): Identifying High & Low Services Port On Vehicle

Prepare For Discharging

Connect center manifold hose to refrigerant recovery system to recycle refrigerant.

EVACUATING AND CHARGING

The following points should be kept in mind when evacuating and charging with a manifold gauge set

1. Be certain that goggles and gloves are worn.
2. If bulk refrigerant [13.6 kg (30 lb) canister] is used, be certain to weight the charge amount carefully, using the correct equipment, to avoid overcharging the system.
3. The charging procedure described in this section begins by charging liquid refrigerant into the high-pressure side of the system with the engine off. The procedure is completed by charging refrigerant vapor into the low-pressure side of the system with the engine running. CAUTION: Never open the high-pressure manifold valve when the engine is running.

Scheme 42

Scheme 43

Scheme 44

1. Close the high and low-pressure manifold valves. (Scheme 42): Closing High & Low-Pressure Manifold Valve
2. Attach the low-pressure manifold hose to the low-pressure service port on the vehicle. Check the low-pressure gauge. If more than 68.6 kPa (0.70 kg/cm 2, 10 psi) is indicated, discharge the system prior to charging.
3. Attach the high-pressure manifold hose to the high-pressure service port on the vehicle.
4. Connect the center hose from the manifold to the vacuum pump.
5. Turn on the vacuum pump.
6. Slowly open the low-pressure manifold valve. (Scheme 43): Identifying Set-Up; Gauge Set Manifold To Vacuum Pump
7. When the low-pressure gauge reaches approximately 66.43 kPa (498.3 mmHg, 19.62 inHg), slowly open the high-pressure manifold valve.
8. Maintain a minimum vacuum level of 100.56 kPa (754.4 mmHg, 29.70 inHg) for a minimum of 15 minutes on a new system or 30 minutes for an in-service system. NOTE: The gauge will read 3.3 kPa (25 mmHg, 1 inHg) less for every 304.8 m (1,000 ft) above sea level. (Scheme 44): Reading Gauges Under Vacuum

Scheme 45

Scheme 46

Scheme 47

Scheme 48

1. After 15 minutes (or more) of evacuation, close the high-pressure manifold valve.
2. Close the low-pressure manifold valve. (Scheme 45): Performing A Vacuum Leak Test
3. Turn off the vacuum pump.
4. Note the low side gauge reading. (Scheme 46): Noting Low Side Gauge Reading
5. After 5 minutes, re-check the low-pressure gauge reading. If the vacuum level has changed more than 3.3 kPa (25 mmHg, 1 inHg), perform an HFC-134a leak test. If the vacuum reading is about the same as noted in step 4), continue on to next step.
6. Carefully attach the can tap to the refrigerant can by following the can tap manufacturer's instructions. (Scheme 47): Attaching Can Tap To Refrigerant Can
7. Disconnect the center manifold hose from the vacuum pump and connect the hose to the tap valve.
8. If a 13.6 kg (30 lb) container of refrigerant is used a weight scale will be needed. This scale is to determine the amount of refrigerant that is used. Connect the center hose from the manifold to the valve. Place the 13.6 kg (30 lb) container on the scale, valve end down. (Scheme 48): Identifying Weight Scale

Purge The Center Hose

Scheme 49

1. Verify that all three hose connections are tight at the manifold gauge set. (Scheme 49): Purging Gauge Set Center Hose
2. Open the valve on the HFC-134a source.
3. Loosen the center hose connection at the manifold and allow the HFC-134a to escape for no more than two or three seconds, then quickly retighten the hose fitting at the manifold.

Scheme 50

1. Connect a tachometer to the engine.
2. With the engine off, start charging by slowly opening the high-pressure manifold valve. NOTE: The initial charge rate can be increased by immersing the can in lukewarm [Below 38°C (100°F)] water for a short time. (Scheme 50): Initially Charging Through High Side

Check The Gauge Readings

When both the high and low-pressure gauge readings are about equal, or the HFC-134a source is empty, or the system has been filled to specifications, close the high-pressure manifold valve.

Checking Gauge Set Readings Are About Equal. Scheme 51

Add Additional Cans

If the HFC-134a source is exhausted, first close the high-pressure manifold valve, second, close the can tap valve, then slowly purge the refrigerant from the service hose by loosening the fitting at the can tap.

Scheme 52

Scheme 53

1. Verify that the high-pressure manifold valve is closed (should have already been closed).
2. Verify that the low-pressure manifold valve is closed (should have already been closed). (Scheme 52): Verifying High & Low Pressure Manifold Valves Are Closed
3. With the A/C switch off and the windows rolled down, START the engine and run at idle RPM.
4. Set the A/C controls on maximum cool and set the blower speed on the highest setting.
5. Quickly turn the A/C switch on-off-on-off a few times to prevent initial compressor damage due to "load shock". Finish this operation with the A/C switch in the ON position. (Scheme 53): Sequence of Low Side Charge
6. Raise engine RPM to approximately 1,500 RPM.

Scheme 54

Scheme 55

1. With the refrigerant source connected and the service hose purged, slowly open the low-pressure manifold valve, while checking the low-pressure gauge reading. CAUTION: The refrigerant source must be positioned for vapor (valve up). (Scheme 54): Reading Low-Side Pressure Gauge
2. Keep the low side pressure below 276 kPa (2.81 kg/cm 2, 40 psi) by using the low-pressure manifold valve to regulate the flow of refrigerant into the system.
3. When the system is fully charged, close the low-pressure manifold valve.
4. Close the valve at the refrigerant source. (Scheme 55): Refrigerant Capacity Chart

Complete All System Checks

1. Evaluate the system performance, see «PERFORMANCE TEST»(ref-175292-S11848640042005042000000) .
2. Perform leak detection test, see «LEAK TESTING»(ref-175292-S42299444462005042000000) . CAUTION: Always perform leak checking in an environment free of refrigerant pollution.

Note. Do not disconnect the high or low-pressure hoses from the vehicle before leak checking.

Disconnect The Manifold Gauge Set

1. Remove the high or low-pressure hoses from the service ports and install the service port caps.

Check The System Pressure

With gauges connected to the A/C system, operate the A/C and confirm that the high side pressure is above 690 kPa (7.03 kg/cm 2 , 100 psi). If not, evacuate and charge the system before leak checking. See EVACUATING AND CHARGING .

Checking A/C System Pressure. Scheme 56

Check The Service Port Caps

Visually inspect the inside of the service port caps. Make sure the rubber seal is in place on the inside of the caps. Disconnect the gauges from the vehicle and install the service port caps.

Checking Service Port Caps For Rubber Seal. Scheme 57

System Oil Stabilization

1. Prior to opening the refrigerant system for repairs (except compressor seizure) the system must be stabilized for correct oil replenishment.
2. Follow these procedures: Engine speed set to 1,500 rpm A/C "ON" Air source to recirculate Blower 4th or high speed position Make sure the air entering the evaporator is above 26.7°C (80°F). The discharge (high) side pressure must be above 588 kPa (6 kg/cm 2 , 85 psi). Operate the A/C for 10 minutes.

System Discharge

Slowly, discharge the system starting with the high-pressure side until the pressure drops below 345 kPa (3.52 kg/cm 2 , 50 psi), then open the low-pressure side.

Scheme 58

1. After stabilization and discharge, replace the component, adding the appropriate amount of oil (ZXL200PG) to the new component before installation. (Scheme 58): Refrigerant Oil Capacity Chart
2. If the compressor is replaced (after stabilization): Drain and measure the oil from the original compressor. Drain the oil from the replacement compressor and refill with the same amount that was drained from the original [20 ml (0.7 US fl oz, 0.7 Imp fl oz) minimum]. Always use ZXL200PG for the replacement oil.

Vehicle Set Up

In order to obtain meaningful test results, the vehicle must be set up to meet the following conditions

1. Vehicle in shade
2. No wind
3. All vehicle doors closed
4. Front windows open
5. Hood open
6. Engine speed set at 1,500 rpm.
7. A/C ON
8. Temperature control lever - Maximum cold
9. Air source - Recirculation
10. Blower speed - 4th position (High)
11. Operate A/C for 10 minutes (Minimum) before taking measurement.

Measurements

After 10 minutes (Minimum) of A/C operation and using accurate test equipment, take the following measurements (in order)

1. Evaporator intake air temperature at recirculation door.
2. Evaporator discharge air temperature at center grill.
3. Condenser (Ambient) intake air temperature measured 0.9 m (3 ft) in front and in line with the center of the condenser
4. Suction (Low) side pressure
5. Discharge (High) side pressure

Note. If only one thermometer is available; 1) take the ambient measurement first; then 2) the intake air; and 3) discharge air temperature.

Compressor Clutch

Note. Compressor clutch trouble is often caused by clutch slippage and noise. Check and take corrective measures, as required.

Scheme 59

Scheme 60

1. Remove belt cover. (Scheme 59): Removing Belt Cover
2. Check the clearance between drive plate and pulley over the entire perimeter is within specifications. Clearance: 0.45+/-0.15 mm (0.0177+/-0.0059 in) (Scheme 60): Checking Compressor Clutch Clearance Between Drive Plate & Pulley
3. Check that voltage applied to magnetic coil is at least 10.5 volts.
4. When noise is noted, check that it originates in either compressor or pulley bearing.

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

1. Disconnect ground cable from battery.
2. Discharge refrigerant using refrigerant recovery system, see «DISCHARGE THE SYSTEM»(ref-175292-S13290396852005042000000). Fully close low-pressure valve of manifold gauge. Connect low-pressure charging hose of manifold gauge to low-pressure service valve. Open low-pressure manifold gauge valve slightly, and slowly discharge refrigerant from system. CAUTION: Do not allow refrigerant to rush out. Otherwise, compressor oil will be discharged along with refrigerant. (Scheme 61): Connecting Hoses Of Manifold Gauge Set
3. Remove low-pressure hose (A) and high-pressure hose (B). CAUTION: Be careful not to lose O-ring of low-pressure hose. Plug the opening to prevent foreign matter from entering. (Scheme 62): Identifying Low-Pressure Hose (A) & High-Pressure Hose (B)
4. Compressor belt cover and generator belt cover: Remove bolts which secure belt covers. (Scheme 63): Locating Compressor Belt Cover & Generator Belt Cover
5. Remove generator V-belt: Loosen lock bolt (A) on generator bracket. Turn adjusting bolt (B) and remove V-belt. (Scheme 64): Removing Generator V-Belt
6. Remove compressor V-belt: Loosen lock nut (A) on idler pulley. Turn adjusting bolt (B) and remove V-belt. (Scheme 65): Removing Compressor V-Belt
7. Disconnect generator harness. (Scheme 66): Identifying Generator Harness Connector
8. Disconnect compressor harness: Disconnect compressor harness from body harness.
9. Remove lower bracket: Remove bolts which secure lower compressor bracket. (Scheme 67): Identifying Lower Compressor Bracket Bolts
10. Remove compressor: Remove bolts which secure compressor. Remove compressor from bracket. (Scheme 68): Removing Upper Compressor Bracket Bolts

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

1. Install compressor: Install compressor on bracket. (Scheme 69): Installing Compressor
2. Install lower bracket. (Scheme 70): Installing Lower Bracket
3. Connect compressor harness.
4. Connect generator harness.
5. Install compressor V-belt (Rear): After adjusting belt tension, tighten tension pulley lock nut (A) securely. (Scheme 71): Identifying Tension Pulley Lock Nut (A)
6. Install generator V-belt: After adjusting V-belt tension, tighten generator bracket lock bolt (A) securely. (Scheme 72): Identifying Generator Bracket Lock Bolt (A)
7. Check drive belt tension and adjust it if necessary by changing generator position and/or idler pulley position. CAUTION: Ensure that the V-belt is aligned correctly. If it is not, check for loose bolts. The V-belt should not be too tight or too loose. A belt which is too tight may break bearing or cause gas to leak from the shaft seal. A belt which is too loose slips, thereby causing the belt cut. After completing the compressor installation and testing the system operation, check and adjust the tension of both V-belts again. (Scheme 73): Checking V-Belt Alignment (Scheme 74): Checking & Adjusting Tension Of Both V-Belts
8. Install high-pressure hose (B) and low-pressure hose (A). CAUTION: Be sure to apply compressor oil to the periphery of O-ring. (Scheme 75): Installing Low-Pressure Hose (A) & High-Pressure Hose (B)
9. Install belt cover. CAUTION: After installing belt cover, make sure it is not misaligned or twisted. After installing belt cover, check the clearance between pulley and belt cover.
10. Connect ground cable to negative terminal of battery.
11. Charging refrigerant. See «EVACUATING AND CHARGING»(ref-175292-S25885800222005042000000).

Scheme 76

Scheme 77

Scheme 78

1. Disconnect battery negative terminal.
2. Discharge refrigerant using refrigerant recovery system, see «DISCHARGE THE SYSTEM»(ref-175292-S13290396852005042000000).
3. Remove front grille, see «FRONT GRILLE»(ref-175292-S04405763472005051000000).
4. Disconnect high-pressure hose (A) and high-pressure pipe (B) from condenser. (Scheme 76): Disconnecting High-Pressure Hose (A) & High-Pressure Pipe (B) From Condenser
5. Remove the radiator bracket (A) and then remove the two bolts which secure condenser. While lifting condenser, remove it through space between radiator and radiator panel. (Scheme 77): Remove Radiator Bracket (A) & Removing Condenser
6. The condenser should be installed in the reverse order in which it was removed. When installing the condenser, pay attention to the following: CAUTION: Before connecting the pipe, be sure to apply oil to the periphery of O-ring. NOTE: After installing condenser, ensure that guide (A) on lower side of condenser is inserted into hole in radiator panel (B). Tighten attaching bolts. (Scheme 78): Installing Condenser, Align Guide Pin (A) Into Hole In Radiator Panel (B).
7. Charge refrigerant. See «EVACUATING AND CHARGING»(ref-175292-S25885800222005042000000).

FLEXIBLE HOSE

Scheme 79

1. Disconnect battery negative terminal.
2. Discharge refrigerant using refrigerant recovery system, see «DISCHARGE THE SYSTEM»(ref-175292-S13290396852005042000000).
3. Remove low-pressure hose (A): CAUTION: Plug the opening to prevent foreign matter from getting in. Remove hose attaching bolts (C). Remove the hose assembly from evaporator unit. Disconnect the low-pressure hose (A) from the hose assembly (E).
4. Remove high-pressure hose (B): CAUTION: Plug the opening to prevent foreign matter from getting in. Remove hose attaching bolt (D). Remove high-pressure hose (B). (Scheme 79): Removing High-Pressure Hose (B)
5. Install in the reverse order of removal.
6. Charge refrigerant. See «EVACUATING AND CHARGING»(ref-175292-S25885800222005042000000).