Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Subaru Forester 1999-2004 Approved Subaru Forester 2004 5 - Body HVAC SYSTEM (AUTO AC) (DIAGNOSTICS) Diagnostic Procedure for Actuators
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DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
7. Diagnostic Procedure for Actuators
A: INTAKE DOOR ACTUATOR
TROUBLE SYMPTOM:
FRESH/RECIRC mode is not changed.
WIRING DIAGRAM:
IGNITION
SWITCH BATTERY
F/B NO.17 SBF-4 SBF-1
i49 AUTO A/C CONTROL
MODULE
18
20
19
i41
14
13
12
B202
4
2
1
3
B91
INTAKE DOOR
ACTUATOR
B91 i49 (GRAY) B202
1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11
11 12 13 14 15 16 17 18 19 20 12 13 14 15 16 17 18 19 20 21 22 23 24
AC-00800
AC-21
DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
Step Check Yes No
1 CHECK POWER SUPPLY TO INTAKE DOOR Is the voltage more than 7 V Go to step 2. Check the harness
ACTUATOR. (At normal temperature)? for open or short
1) Turn the ignition switch to OFF. between intake
2) Disconnect the intake door actuator con- door actuator and
nector. fuse.
3) Turn the ignition switch to ON.
4) Measure the voltage between intake door
actuator connector and chassis ground.
Connector & terminal
(B91) No. 4 (+) -- Chassis ground (-):
2 CHECK HARNESS BETWEEN A/C CON- Is the resistance less than 1 Go to step 3. Repair the open
TROL MODULE AND INTAKE DOOR ACTU- ? circuit in harness
ATOR. between auto A/C
1) Turn the ignition switch to OFF. control module
2) Disconnect the auto A/C control module and intake door
connector. actuator.
3) Measure the resistance between intake
door actuator connector and auto A/C control
module connector.
Connector & terminal
(i49) No. 18 -- (B91) No. 2:
(i49) No. 20 -- (B91) No. 1:
(i49) No. 19 -- (B91) No. 3:
3 CHECK INTAKE DOOR ACTUATOR OPERE- Is the intake door actuator Go to step 4. Replace the intake
TION. moved to FRESH? door actuator.
1) Connect the intake door actuator connec-
tor.
2) Ground the auto A/C control module con-
nector with a suitable wire.
3) Turn the ignition switch to ON and check
movement of intake door actuator.
Connector & terminal
(i49) No. 20 -- Chassis ground:
4 CHECK INTAKE DOOR ACTUATOR OPERA- Is the intake door actuator Replace the auto Replace the intake
TION. moved to RECIRC? A/C control mod- door actuator.
1) Turn the ignition switch to OFF. ule.
2) Ground the auto A/C control module con-
nector with a suitable wire.
3) Turn the ignition switch to ON and check
movement of intake door actuator.
Connector & terminal
(i49) No. 18 -- Chassis ground:
AC-22
DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
B: MODE DOOR ACTUATOR
TROUBLE SYMPTOM:
Air flow outlet is not changed.
WIRING DIAGRAM:
AUTO A/C CONTROL
A: i48 B: i49
MODULE
A13
A12
A16
B9
B8
A4
A5
i41
15
10
11
8
6
7
9 B202
10
1
2
4
7
5
6
9
8
B77
MODE ACTUATOR
B77 (BROWN) i48 (GRAY) i49 (GRAY) B202
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 9 10
9 10 11 12 13 14 15 16 12 13 14 15 16 17 18 19 20 21 22 23 24
11 12 13 14 15 16 17 18 19 20
AC-00801
AC-23
DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
Step Check Yes No
1 CHECK POWER SUPPLY FOR AUTO A/C Is the voltage more than 12 V? Go to step 2. Replace the auto
CONTROL MODULE SIDE. A/C control mod-
1) Turn the ignition switch to ON. ule.
2) Turn the mode control dial to VENT posi-
tion.
3) Press the DEF switch and measure the
voltage between auto A/C control module and
chassis ground when VENT is changed to DEF
position.
Connector & terminal
(i49) No. 9 (+) -- Chassis ground (-):
2 CHECK POWER SUPPLY FOR ACTUATOR Is the voltage more than 7 V Go to step 3. Repair the open
SIDE. (At normal temperature)? circuit in harness
1) Turn the mode control dial to VENT posi- between auto A/C
tion. control module
2) Press the DEF switch and measure the and mode door
voltage between mode door actuator harness actuator.
connector terminal and chassis ground when
VENT is changed to DEF position.
Connector & terminal
(B77) No. 1 (+) -- Chassis ground (-):
3 CHECK POWER SUPPLY FOR AUTO A/C Is the voltage more than 12 V? Go to step 4. Replace the auto
CONTROL MODULE SIDE. A/C control mod-
1) Press the DEF switch. ule.
2) Turn the mode control dial to VENT position
and measure the voltage between auto A/C
control module and chassis ground when DEF
is changed to VENT position.
Connector & terminal
(i49) No. 8 (+) -- Chassis ground (-):
4 CHECK POWER SUPPLY FOR ACTUATOR Is the voltage more than 7 V Go to step 5. Repair the open
SIDE. (At normal temperature)? circuit in harness
1) Press the DEF switch. between auto A/C
2) Turn the mode control dial to VENT position control module
and measure the voltage between mode door and mode door
actuator harness connector terminal and chas- actuator.
sis ground when DEF is changed to VENT
position.
Connector & terminal
(B77) No. 2 (+) -- Chassis ground (-):
5 CHECK ACTUATOR. Does the motor operate nor- Go to step 6. Replace the mode
1) Turn the ignition switch to OFF. mally? door actuator.
2) Disconnect the connector from mode door
actuator.
3) Connect the battery positive (+) terminal to
terminal No. 1 and ground (-) terminal to termi-
nal No. 2 of mode door actuator to make sure
that actuator operates.
4) Connect the battery positive (+) terminal to
terminal No. 2 and ground (-) terminal to termi-
nal No. 1 of mode door actuator to make sure
that actuator operates.
AC-24
DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
Step Check Yes No
6 CHECK AUTO A/C CONTROL MODULE SIG- Is the voltage the value shown Go to step 9. Go to step 7.
NAL VOLTAGE. in the followings?
1) Turn the ignition switch to ON. HEAT, D/H, DEF: Approx. 5 V,
2) Turn the mode control dial and measure VENT, BI-LEVEL: Approx. 0 V
voltage between auto A/C control module har-
ness connector terminal and chassis ground
for each mode.
Connector & terminal
(i48) No. 4 (+) -- Chassis ground (-):
7 CHECK AUTO A/C CONTROL MODULE SIG- Is the voltage approx. 5 V? Go to step 9. Go to step 8.
NAL POWER SUPPLY.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from mode door
actuator.
3) Turn the ignition switch to ON.
4) Measure the voltage between mode door
actuator harness connector terminal and chas-
sis ground.
Connector & terminal
(B77) No. 5 (+) -- Chassis ground (-):
8 CHECK HARNESS BETWEEN AUTO A/C Is the resistance less than 1 Replace the auto Repair the open
CONTROL MODULE AND MODE DOOR AC- ? A/C control mod- circuit in harness
TUATOR. ule. between auto A/C
1) Turn the ignition switch to OFF. control module
2) Disconnect the connectors from auto A/C and mode door
control module and mode door actuator. actuator.
3) Measure the resistance of harness
between auto A/C control module and mode
door actuator.
Connector & terminal
(i48) No. 4 -- (B77) No. 5:
9 CHECK AUTO A/C CONTROL MODULE SIG- Is the voltage the value Go to step 12. Go to step 10.
NAL VOLTAGE. shown in the followings?
1) Turn ignition switch to ON. VENT, D/H: Approx. 5 V, BI-
2) Turn the mode control dial and measure LEVEL, HEAT, DEF: Approx.
voltage between auto A/C control module har- 0V
ness connector terminal and chassis ground
for each mode.
Connector & terminal
(i48) No. 12 (+) -- Chassis ground (-):
10 CHECK AUTO A/C CONTROL MODULE SIG- Is the voltage approx. 5 V? Go to step 12. Go to step 11.
NAL POWER SUPPLY.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from mode door
actuator.
3) Turn the ignition switch to ON.
4) Measure the voltage between mode door
actuator harness connector terminal and chas-
sis ground.
Connector & terminal
(B77) No. 6 (+) -- Chassis ground (-):
(B77) No. 9 (+) -- Chassis ground (-):
AC-25
DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
Step Check Yes No
11 CHECK HARNESS BETWEEN AUTO A/C Is the resistance less than 1 Replace the auto Repair the open
CONTROL MODULE AND MODE DOOR AC- ? A/C control mod- circuit in harness
TUATOR. ule. between auto A/C
1) Turn the ignition switch to OFF. control module
2) Disconnect the connectors from auto A/C and mode door
control module and mode door actuator. actuator.
3) Measure the resistance of harness
between auto A/C control module and mode
door actuator.
Connector & terminal
(i48) No. 12 -- (B77) No. 6:
(i48) No. 12 -- (B77) No. 9:
12 CHECK AUTO A/C CONTROL MODULE SIG- Is the voltage the value shown Go to step 15. Go to step 13.
NAL VOLTAGE. in the followings?
1) Turn ignition switch to ON. BI-LEVEL, DEF: Approx. 5 V,
2) Turn the mode control dial and measure VENT, HEAT, D/H: Approx. 0 V
voltage between auto A/C control module har-
ness connector and chassis ground for each
mode.
Connector & terminal
(i48) No. 5 (+) -- Chassis ground (-):
13 CHECK AUTO A/C CONTROL MODULE SIG- Is the voltage approx. 5 V? Go to step 15. Go to step 14.
NAL POWER SUPPLY.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from mode door
actuator.
3) Turn the ignition switch to ON.
4) Measure the voltage between mode door
actuator harness connector terminal and chas-
sis ground.
Connector & terminal
(B77) No. 4 (+) -- Chassis ground (-):
(B77) No. 7 (+) -- Chassis ground (-):
14 CHECK HARNESS BETWEEN AUTO A/C Is the resistance less than 1 Replace the auto Repair the open
CONTROL MODULE AND MODE DOOR AC- ? A/C control mod- circuit in harness
TUATOR. ule. between auto A/C
1) Turn the ignition switch to OFF. control module
2) Disconnect the connectors from auto A/C and mode door
control module and mode door actuator. actuator.
3) Measure the resistance of harness
between auto A/C control module and mode
door actuator.
Connector & terminal
(i48) No. 5 -- (B77) No. 4:
(i48) No. 5 -- (B77) No. 7:
15 CHECK AUTO A/C CONTROL MODULE SIG- Is the voltage the value shown Go to step 19. Go to step 16.
NAL VOLTAGE. in the followings?
1) Turn ignition switch to ON. VENT, BI-LEVEL, HEAT:
2) Turn the mode control dial and measure Approx. 5V D/H, DEF: Approx.
voltage between auto A/C control module har- 0V
ness connector terminal and chassis ground
for each mode.
Connector & terminal
(i48) No. 13 (+) -- Chassis ground (-):
AC-26
DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
Step Check Yes No
16 CHECK AUTO A/C CONTROL MODULE SIG- Is the voltage approx. 5 V? Go to step 18. Go to step 17.
NAL POWER SUPPLY.
1) Turn the ignition switch to OFF.
2) Disconnect the connector from mode door
actuator.
3) Turn the ignition switch to ON.
4) Measure the voltage between mode door
actuator harness connector and chassis
ground.
Connector & terminal
(B77) No. 8 (+) -- Chassis ground (-):
17 CHECK HARNESS BETWEEN AUTO A/C Is the resistance less than 1 Replace the auto Repair the open
CONTROL MODULE AND MODE DOOR AC- ? A/C control mod- circuit in harness
TUATOR. ule. between auto A/C
1) Turn the ignition switch to OFF. control module
2) Disconnect the connectors from auto A/C and mode door
control module and mode door actuator. actuator.
3) Measure the resistance of harness
between auto A/C control module and mode
door actuator.
Connector & terminal
(i48) No. 13 -- (B77) No. 8:
18 CHECK ACTUATOR GROUND CIRCUIT. Is the resistance less than 1 Replace the mode Repair the open
1) Turn the ignition switch to OFF. ? door actuator. circuit in harness
2) Disconnect the connector from auto A/C between auto A/C
control module. control module
3) Measure the resistance of harness and mode door
between auto A/C control module and mode actuator.
door actuator.
Connector & terminal
(i48) No. 16 -- (B77) No. 10:
19 CHECK POOR CONTACT. Is there poor contact in con- Repair the con- Repair the poor
Check poor contact in auto A/C control module nector? nector. contact in auto A/C
connector. control module.
AC-27
DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
C: AIR MIX DOOR ACTUATOR
TROUBLE SYMPTOM:
Outlet air temperature is not changed.
WIRING DIAGRAM:
AUTO A/C CONTROL
A: i48 B: i49
MODULE
A16
B1
B7
A7
B6
1
2
6
3
4
i65
AIR MIX DOOR
ACTUATOR
i65 A: i48 (GRAY) B: i49 (GRAY)
1 2 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
3 4 5 6 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20
AC-00802
AC-28
DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
Step Check Yes No
1 CHECK POWER SUPPLY TO AIR MIX DOOR Is the voltage approx. 5 V? Go to step 2. Replace the auto
ACTUATOR PBR. A/C control mod-
1) Turn the ignition switch to OFF. ule.
2) Disconnect the air mix door actuator con-
nector.
3) Turn the ignition switch and AUTO switch to
ON.
4) Measure the voltage between A/C control
module connector terminals.
Connector & terminal
(i48) No. 7 (+) -- (i48) No. 16 (-):
2 CHECK POWER SUPPLY TO AIR MIX DOOR Is the voltage more than 7 V Go to step 3. Replace the auto
ACTUATOR. (At normal temperature)? A/C control mod-
Measure the voltage between auto A/C control ule.
module connector terminal and chassis ground
when setting temperature control dial to FULL
COOL.
Connector & terminal
(i49) No. 6 (+) -- Chassis ground (-):
3 CHECK POWER SUPPLY TO AIR MIX DOOR Is the voltage more than 7 V Go to step 4. Replace the auto
ACTUATOR. (At normal temperature)? A/C control mod-
Measure the voltage between auto A/C control ule.
module connector terminal and chassis ground
when setting temperature control dial to FULL
HOT.
Connector & terminal
(i49) No. 7 (+) -- Chassis ground (-):
4 CHECK HARNESS BETWEEN AUTO A/C Is the resistance less than 1 Go to step 5. Repair the open
CONTROL MODULE AND AIR MIX DOOR ? circuit in harness
ACTUATOR. between auto A/C
1) Turn the A/C and ignition switch to OFF. control module
2) Disconnect the auto A/C control module and air mix door
connector. actuator.
3) Measure the resistance between auto A/C
control module and air mix door actuator con-
nector.
Connector & terminal
(i65) No. 1 -- (i49) No. 1:
(i65) No. 2 -- (i49) No. 7:
(i65) No. 3 -- (i48) No. 16:
(i65) No. 4 -- (i48) No. 7:
(i65) No. 6 -- (i49) No. 6:
5 CHECK AIR MIX DOOR ACTUATOR PBR Is the voltage 0.5 V (FULL Go to step 6. Replace the air
SIGNAL. COOL) -- 4.5 V (FULL HOT)? mix door actuator.
1) Connect the auto A/C control module and
air mix door actuator connector.
2) Turn the ignition switch and AUTO switch to
ON.
3) Change the set temperature between FULL
COOL and FULL HOT, check voltage between
auto A/C control module connector terminals.
Connector & terminal
(i49) No. 1 (+) -- (i48) No. 16 (-):
6 CHECK POOR CONTACT. Is there poor contact in the Repair the con- Replace the auto
Check poor contact in the auto A/C control connector? nector. A/C control mod-
module connector. ule.
AC-29
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