HVAC: Removal & Installation Subaru Forester SG

REPLACEMENT

Note. If a component is replaced, add an appropriate amount of compressor oil. When replacing the compressor, the new compressor 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 compressor removed.

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1. Disconnect the ground cable from battery.
2. Remove the glove box. Refer to «REMOVAL»(ref-200811-S42774016482005102300000) , Glove Box.
3. Loosen the nut to remove the support beam stay.
4. Disconnect the connectors of blower motor and intake actuator resistor.
5. Loosen the bolt and nut to remove blower motor unit assembly.

INSTALLATION

Install in the reverse order of removal.

Tightening torque

1. Refer to «HEATER COOLING UNIT»(ref-200802-S00897147722005102300000) , COMPONENT, General Description and «BLOWER MOTOR UNIT»(ref-200802-S18982624232005102300000) , COMPONENT, General Description.

Install in the reverse order of removal.

Scheme 43

Measure the blower resistor resistance.

Scheme 44

If NG, replace the blower resistor.

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Scheme 50

1. Remove the heater cooling unit. Refer to «REMOVAL»(ref-200802-S32134914022005102300000) , Heater Cooling Unit.
2. Open the heater core pipe cover.
3. Loosen the screws to remove mode actuator.
4. Loosen the screws to remove foot duct.
5. Loosen the screws to remove evaporator cover.
6. Loosen the screws to remove lower case.
7. Remove the heater core.

Install in the reverse order of removal.

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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.
4. Remove the center console panel.
5. Loosen the screws on rear side of center console panel, and then remove the control unit.

Install in the reverse order of removal.

1. Install in the reverse order of removal.
2. Replace the O-rings on low-/high-pressure hoses with new ones, then apply compressor oil.
3. When replacing compressor, adjust amount of compressor oil. Refer to «OPERATION»(ref-200802-S42441765782005102300000) , Compressor Oil.
4. Charge refrigerant. Refer to «OPERATION»(ref-200802-S23315326842005102300000) , Refrigerant Charging Procedure. Tightening torque: Refer to «AIR CONDITIONING UNIT»(ref-200802-S38630260042005102300000) , COMPONENT, General Description and «COMPRESSOR»(ref-200802-S10758109822005102300000) , COMPONENT, General Description.

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1. Using the refrigerant recovery system, discharge refrigerant. Refer to «OPERATION»(ref-200802-S28881992342005102300000) , Refrigerant Recovery Procedure.
2. Disconnect the ground cable from battery.
3. Disconnect the pressure hose and pipe from condenser.
4. Remove the radiator bracket (A).
5. Remove the two bolts. While lifting the condenser, pull it out through the space between radiator and radiator panel. CAUTION: Be careful not to damage the radiator fins and condenser 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. Refer to «REPLACEMENT»(ref-200802-S03250812552005102300000) , Compressor Oil.

Scheme 56

1. Install in the reverse order of removal. CAUTION: Replace the O-rings on hoses or pipes with new ones, and then apply compressor oil. Confirm that lower guide of condenser has been fitted into holes on radiator panel.
2. Charge refrigerant. Refer to «OPERATION»(ref-200802-S23315326842005102300000) , Refrigerant Charging Procedure. Tightening torque: Refer to «AIR CONDITIONING UNIT»(ref-200802-S38630260042005102300000) , COMPONENT, General Description and «RADIATOR AND RADIATOR FAN»(ref-200790-S34145038662005102300000) , COMPONENT, General Description.

REMOVAL

Refer to REMOVAL , Radiator Main Fan and Fan Motor.

Refer to INSTALLATION , Radiator Main Fan and Fan Motor.

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1. Disconnect the ground cable from battery.
2. Using the refrigerant recovery system, discharge refrigerant. Refer to «OPERATION»(ref-200802-S28881992342005102300000) , Refrigerant Recovery Procedure.
3. Drain LLC from the radiator.
4. Remove the bolt securing expansion valve and pipe in engine compartment. Release the heater hose clamps in engine compartment to remove the hoses.
5. Remove the instrument panel. Refer to «REMOVAL»(ref-200811-S29558660072005102300000) , Instrument Panel Assembly.
6. Remove the support beam.
7. Remove the blower motor unit assembly. Refer to «REMOVAL»(ref-200802-S17112986852005102300000) , Blower Motor Unit Assembly.
8. Disconnect the servo motor connectors.
9. Loosen the bolt and nuts to remove the heater and cooling unit.

1. Install in the reverse order of removal.
2. Charge refrigerant. Refer to «OPERATION»(ref-200802-S23315326842005102300000) , Refrigerant Charging Procedure. Tightening torque: Refer to «HEATER COOLING UNIT»(ref-200802-S00897147722005102300000) , COMPONENT, General Description.

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Scheme 60

1. Disconnect the refrigerant recovery & toe board area A/C pipe. Refer to «OPERATION»(ref-200802-S28881992342005102300000) , Refrigerant Recovery Procedure.
2. Remove the glove box.
3. Remove lower motor unit assembly. Refer to «REMOVAL»(ref-200802-S17112986852005102300000) , Blower Motor Unit Assembly.
4. Loosen the screws and remove evaporator cover.
5. Remove the A/C pipes in unit.
6. Rotate the upper evaporator core and lower evaporator core tilt toward the front vehicle and toward the interior, respectively. Then pull out the heater case to left side.
7. Loosen the two bolts to remove expansion valve. CAUTION: If the evaporator is replaced, add appropriate amount of compressor oil to evaporator. Refer to «REPLACEMENT»(ref-200802-S03250812552005102300000) , Compressor Oil.

Install in the reverse order of removal.

Note. Replace the o-ring for refrigerant recovery & toe board area air conditioner pipe with a new one, and then apply compressor oil.

Scheme 61

1. Disconnect the ground cable from battery.
2. Using the refrigerant recovery system, discharge refrigerant. Refer to «OPERATION»(ref-200802-S28881992342005102300000) , 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 evaporator unit.
6. Disconnect the low-pressure hose from compressor.
7. Remove the low-pressure hose from vehicle.
8. Remove the high-pressure hose attaching bolts (C).
9. Disconnect the high-pressure hose from compressor.
10. Disconnect the high-pressure hose from condenser.
11. Remove the high-pressure tube attaching bolt (D).
12. Remove the high-pressure tube from vehicle.

1. Install in the reverse order of removal.
2. Charge refrigerant. Refer to «OPERATION»(ref-200802-S23315326842005102300000) , Refrigerant Charging Procedure. Tightening torque: Refer to «AIR CONDITIONING UNIT»(ref-200802-S38630260042005102300000) , COMPONENT, General Description.

Install in the reverse order of removal.

Install in the reverse order of removal.

Install in the reverse order of removal.

1. Remove the front seat.
2. Remove the front side sill cover.
3. Pull off the floor mat, which is connected to remove the cover heater unit and heater duct, and then remove the heater duct.

Install in the reverse order of removal.

Scheme 62

1. Remove the instrument panel. Refer to «REMOVAL»(ref-200811-S29558660072005102300000) , Instrument Panel Assembly.
2. Remove the screws.
3. Remove the heater vent duct.

Install in the reverse order of removal.

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