2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
Contents
1. AC 00935 B INSTALLATION Install in the reverse order of removal AC 46 Heater Cock Solenoid Valve 27 Heater Cock Solenoid Valve A REMOVAL 1 Drain the engine coolant lt Ref to CO H4SO 2 0 13 DRAINING OF ENGINE COOLANT RE PLACEMENT Engine Coolant gt 2 Disconnect the harness connector A of the heater cock solenoid valve 3 Remove the two bolts to remove the heater cock solenoid from the bracket 4 Pull out the heater cock solenoid Loosen the hose clamp and disconnect the two heater hoses B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Remove the heater cock solenoid valve lt Ref to AC 47 REMOVAL Heater Cock Solenoid Valve gt 2 Connect the positive terminal of battery to No 1 terminal of heater cock solenoid valve and the ground terminal to No 2 terminal Check that the heater cock solenoid valve opens and closes nor mally S AC 00888 If any failure is found replace the heater cock sole noid valve AC 47 HVAC SYSTEM HEATER VENTILATOR AND A C General Diagnostic Table HVAC SYSTEM HEATER VENTILATOR AND A C 28 General Diagnostic Table A INSPECTION Symptom Repair order Fuse Blower motor relay Blower motor Blower motor resistor Blower switch Wire harness Blower motor Refrigerant Fuse Air conditioning relay Magnet clutch Doesn t operate Compressor Pressur2. AC 00021 A Low pressure gauge Compound pressure gauge B High pressure gauge C Close 4 Install the low high pressure hoses to the ser vice ports on the low high pressure sides of the vehicle respectively AC 00022 A Low pressure gauge Compound pressure gauge High pressure gauge Close Low pressure side service port High pressure side service port B C D E 5 Connect the center hose to the refrigerant recov ery system 6 Follow the operation manual to activate the re frigerant recovery system AC 20 Refrigerant Charging Procedure HVAC SYSTEM HEATER VENTILATOR AND A C 4 Refrigerant Charging Proce dure A PROCEDURE CAUTION e During operation be sure to wear protective goggles and protective gloves e Before charging the refrigerant evacuate the system to remove small amounts of moisture remaining in the system The moisture in the system can be completely evacuated only under the minimum vacuum level The minimum vacuum level affects the temperature in the system e The list below shows the vacuum values nec essary to boil water in various temperature In addition the vacuum levels indicated on the gauge are approx 3 3 kPa 25 mmHg 0 98 inHg lower than those measured at 304 8 m 1 000 ft above sea level Vacuum level required to boil water at sea level Temperature 1 7 C 35 F 7 2 C 45 F
3. 2 SIDE GRILLE Remove the two pawls to remove side air vent grill b ES B INSTALLATION Install in the reverse order of removal C INSPECTION 1 Check the direction and amount of air can be ad justed smoothly 2 Check the adjustment can be kept in each posi tion V AC 00932 AC 44 Heater Duct HVAC SYSTEM HEATER VENTILATOR AND A C 25 Heater Duct A REMOVAL 1 FRONT HEATER DUCT 1 Remove the instrument panel lower cover lt Ref to El 50 REMOVAL Instrument Panel Lower Cov er gt 2 Remove the screws and detach the front heater duct A AC 00933 2 REAR HEATER DUCT 1 Remove the heater cooling unit lt Ref to AC 36 REMOVAL Heater and Cooling Unit gt 2 Remove the front seats lt Ref to SE 7 REMOV AL Front Seat gt 3 Remove the front side sill cover 4 Pull off the floor mat to remove the rear center heater duct A and rear heater duct LH RH B ST AC 00934 B INSTALLATION Install in the reverse order of removal AC 45 Heater Vent Duct HVAC SYSTEM HEATER VENTILATOR AND A C 26 Heater Vent Duct A REMOVAL 1 Remove the instrument panel lt Ref to El 50 REMOVAL Instrument Panel Lower Cover gt 2 Remove the screws and detach the center vent duct A 3 Remove the screws and detach the center vent duct B 4 Remove the insulator remove the screws and detach the defroster duct
4. Wal AC 00026 A Low pressure gauge Compound pressure gauge B High pressure gauge C Close D Vacuum pump turn off AC 21 Refrigerant Charging Procedure HVAC SYSTEM HEATER VENTILATOR AND A C 7 Note the low pressure gauge reading Biri 8 Leave it at least 5 minutes and then check the low pressure gauge reading for any changes When a gauge indicator shows near to zero point it is a sign of leakage Check pipe connector points repair them make sure there is no leakage by air bleeding 9 Following the can tap operation manual instruc tions install it to the refrigerant can AC 00027 lt AC 00028 A Tap valve B Center manifold hose 10 Disconnect the center manifold hose from the vacuum pump and connect the hose to the tap valve 11 When a 13 6 kg 30 Ib refrigerant container is used measure the refrigerant amount in use using a weight scale B AC 00029 A Refrigerant container HFC 134a B Weight scale 12 Confirm that all the 3 hoses are tightly connect ed to the manifold gauge set AC 00030 A Low pressure gauge Compound pressure gauge B High pressure gauge C Close 13 Open the valve on the HFC 134a source 14 Loosen the center hose connection on the manifold gauge
5. AC 13 General Description HVAC SYSTEM HEATER VENTILATOR AND A C C CAUTION 1 HFC 134a A C SYSTEM e The cooling system components for the HFC 134a system such as the refrigerant and compres sor oil are different from the conventional CFC 12 system components and they are incompatible with each other e Vehicles with the HFC 134a system can be iden tified by the label A attached to the vehicle Before maintenance check which A C system is in stalled to the vehicle AC 00762 2 COMPRESSOR OIL e HFC 134a compressor oil has no compatibility with that of CFC 12 system e Use only Denso Oil 8 which is a manufacturer authorized compressor oil for HFC 134a system Do not mix multiple compressor oils If CFC 12 compressor oil is used in the HFC 134a A C system the compressor may become stuck due to poor lubrication or the refrigerant may leak due to swelling of rubber parts On the other hand if HFC 134a compressor oil is used in a CFC 12 A C system the durability of the A C system will be lowered e HFC 134a compressor oil is very hygroscopic When replacing or installing removing A C parts immediately isolate the oil from atmosphere using a plug or tape In order to avoid moisture store the oil in a container with its cap tightly closed 3 REFRIGERANT e The CFC 12 refrigerant cannot be used in the HFC 134a A C system The HFC 134a refrigerant also
6. 1 Install in the reverse order of removal 2 Replace the O rings on low high pressure hos es with new ones then apply compressor oil 3 When replacing the compressor adjust amount of compressor oil lt Ref to AC 25 PROCEDURE Compressor Oil gt 4 Charge refrigerant lt Ref to AC 21 PROCE DURE Refrigerant Charging Procedure gt Tightening torque Refer to COMPONENT of General Descrip tion lt Ref to AC 10 AIR CONDITIONING UNIT COMPONENT General Description gt lt Ref to AC 11 COMPRESSOR COMPO NENT General Description gt AC 34 Condenser 15 Condenser A REMOVAL 1 Using the refrigerant recovery system dis charge refrigerant lt Ref to AC 20 PROCEDURE Refrigerant Recovery Procedure gt 2 Disconnect the ground cable from battery 3 Disconnect the pressure hose and pipe from condenser ee H AC 00775 4 Remove the radiator bracket A and hood stay B AC 00776 5 Remove the front grille lt Ref to El 24 REMOV AL Front Grille gt 6 Remove two bolts While lifting condenser pull it out through the space between radiator and radia tor panel LL AC 00777 CAUTION e Be careful not to damage the condenser fins If a damaged fin is found repair it using a thin screwdriver HVAC SYSTEM HEATER VENTILATOR AND A C
7. HVAC SYSTEM HEATER VENTILATOR AND A C 22 Sunload Sensor Auto A C Model A REMOVAL 1 Disconnect the ground cable from battery 2 Disconnect the connector and remove the sun load sensor e TT AC 00930 CAUTION Be careful not to damage the interior trims when removing the sensor B INSTALLATION Install in the reverse order of removal C INSPECTION lt Ref to AC diag 36 SUNLOAD SENSOR Diag nostic Procedure for Sensors gt AC 42 In Vehicle Sensor Auto A C Model HVAC SYSTEM HEATER VENTILATOR AND A C 23 In Vehicle Sensor Auto A C Model A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the instrument panel lower cover lt Ref to El 50 REMOVAL Instrument Panel Lower Cov er gt 3 Disconnect the connector and aspirator hose remove the pawl and remove the in vehicle sensor A from instrument lower cover AC 00790 CAUTION Be careful not to damage the sensors and inte rior trims when removing B INSTALLATION Install in the reverse order of removal C INSPECTION lt Ref to AC diag 32 IN VEHICLE SENSOR Di agnostic Procedure for Sensors gt AC 43 Air Vent Grille HVAC SYSTEM HEATER VENTILATOR AND A C 24 Air Vent Grille A REMOVAL 1 CENTER GRILLE 1 Disconnect the ground cable from battery 2 Remove the three pawls and connector to re move center air vent grill FY TE
8. AC 9 General Description HVAC SYSTEM HEATER VENTILATOR AND A C 4 AIR CONDITIONING UNIT AC 00911 1 Condenser 5 Compressor Tightening torque N m kgf m ft lb 2 Hose High pressure 6 O ring T1 7 5 0 76 5 5 3 Hose Low pressure 7 Clamp T2 10 1 0 7 4 4 Bracket 8 Tube T3 5 0 5 3 7 AC 10 General Description HVAC SYSTEM HEATER VENTILATOR AND A C 5 COMPRESSOR H4 model AC 00760 1 Idler pulley bracket 5 Compressor Tightening torque N m kgf m ft lb 2 Idler pulley adjuster 6 Compressor lower bracket T1 23 0 2 35 17 0 3 Idler pulley 7 V Belt T2 28 9 2 95 21 3 4 Compressor upper bracket T3 36 3 7 26 6 AC 11 General Description HVAC SYSTEM HEATER VENTILATOR AND A C H6 model AC 00912 1 2 3 Compressor upper bracket Compressor Compressor lower bracket AC 12 T1 28 9 2 95 21 3 T2 36 3 7 26 6 Tightening torque N m kgf m ft lb General Description HVAC SYSTEM HEATER VENTILATOR AND A C 6 HEATER DUCT AC 00913 1 Front defroster nozzle 3 Side ventilation duct RH 5 Rear heater duct LH 2 Side ventilation duct LH 4 Center ventilation duct 6 Rear heater duct RH
9. Motor type Magnet Power consumption 90 W Fan outer diameter 300 mm 11 8 in Idling speed A C ON MPFI model 800 100 rpm Low pressure switch operating pressure ON gt OFF 196 20 kPa 2 00 0 20 kg cm 28 4 2 9 psi OFF 3 ON 225 kPa 2 29 0 25 30 kg cm 32 636 gt psi Triple switch High pressure switch Pressure switch operating pressure ON gt OFF 3 140 559 kPa 32 02 051 44 kg em 455 4 7 9 psi OFF ON 2 550 200 kPa 26 00 2 04 kg cm 369 8 29 0 psi Middle pressure switch operating pressure ON gt OFF 1 370 120 kPa 13 97 1 22 kg cm 198 65 17 35 psi OFF ON 1 770 100 kPa 18 05 1 02 kg cm 256 81 14 50 psi Thermo control amplifier working temperature Evaporator outlet air AC 4 AC 00601 General Description HVAC SYSTEM HEATER VENTILATOR AND A C B COMPONENT 1 HEATER COOLING UNIT Auto A C model AC 00906 1 Foot duct RH 8 Mix actuator 15 Foot duct LH 2 Evaporator center 9 Mode actuator 16 Unit ASSY 3 Pipe cover 10 Heater pipe clamp 17 Drain hose 4 Evaporator cover 11 Heater core 5 Expansion valve 12 Heater core cover Tightening torque N m kgf m ft lb 6 Packing 13 Aspirator T 7 5 0 76 5 5 7 Evaporator 14 Aspirator hose AC 5 General Description HVAC SYSTEM HEATER VENTILAT
10. 12 8 C 55 F Vacuum 100 9 kPa 757 mmHg 29 8 inHg 100 5 kPa 754 mmHg 29 7 inHg 99 8 kPa 749 mmHg 29 5 inHg 99 2 kPa 744 mmHg 29 3 inHg 98 5 kPa 739 mmHg 29 1 inHg 18 3 C 65 F 23 9 C 75 F 29 4 C 85 F 35 C 95 F 97 2 kPa 729 mmHg 28 7 inHg 95 8 kPa 719 mmHg 28 3 inHg 1 Close the valves on low high pressure sides of the manifold gauge Ce AC 00023 A Low pressure gauge Compound pressure gauge High pressure gauge Close E 2 Install the low high pressure hoses to the corre sponding service ports on the vehicle respectively 3 Connect the center hose of the manifold gauge set with the vacuum pump Q 4 Carefully open the valves on the low high pres sure sides to activate the vacuum pump 9 AC 00024 gt Low pressure gauge Compound pressure gauge B High pressure gauge C Slowly open D Vacuum pump turn on 5 After the low pressure gauge reaches 100 0 kPa 750 mmHg 29 5 inHg or higher evacuate the system for approx 15 minutes Continue evacua tion Je NS 6 After 15 minutes of evacuation if the reading shows 100 0 kPa 750 mmHg 29 5 inHg or higher close the valves on the both sides to stop the vac uum pump AC 00025
11. 186 m 2 002 sq ft Core thickness 16 mm 0 63 in Radiation area 5 49 m 59 09 sq ft Receiver drier Effective inner capacity 190 cm 11 6 cu in Expansion valve Type Internal equalizing Type Single tank pyaporaint Dimensions W x H x T haga x GE Fan type Sirocco fan Blower fan Outer diameter x width 150 x 75 mm 5 91 x 2 95 in Power consumption 220 W AC 2 General Description HVAC SYSTEM HEATER VENTILATOR AND A C Motor type Magnet H4 model 90 W H6 model 160 W H4 model 300 mm 11 8 in H6 model 320 mm 12 6 in Motor type Magnet H4 model 90 W H6 model 160 W Condenser fan Sub fan Power consumption Fan outer diameter Radiator fan Main fan Power consumption H4 model 300 mm 11 8 in H6 model 320 mm 12 6 in Idling speed A C ON MPFI model 800 100 rpm Fan outer diameter 196 20 kPa Kierch 2 00 0 20 kg cm 28 4 2 9 psi operating pressure BEE 225 9 59 kPa CS 0 25 2 3 6 2 29 025 ag kg em 32 6 6 gt psi 3 14050 259 kPa Triple switch ON gt OPF 0 51 2 7 25 riple switch High pressure switch 32 02 gt _ gt 94 kg em 455 47 zen psi Pressure switch operating pressure SEN 2 550 200 kPa 26 00 2 04 kg cm 369 8 29 0 psi 1 370 120 kP ON gt OFF ee b Middle pressure switch 13 97 1 22 kg cm 198 65 17 35 psi operating pressure 1 770 100 kP E AP OFF gt ON 2 a 18 05 1 02 kg cm
12. 256 81 14 50 psi ON gt OFF Thermo control amplifier working temperature Evaporator outlet air AC 00601 e Manual A C model Specification Type of air conditioner Reheat air mix type Cooling capacity 5 3 kW 4 557 kcal h 18 084 BTU h HFC 134a CH gt FCF3 0 4 0 03 kg 0 88 0 07 Ib Type Scroll constant volume SCSA 08C Compressor Discharge 74 5 cc 4 55 cu in rev Max permissible speed 9 000 rpm Type Dry single disc type Power consumption 35 W Magnet clutch Type of belt V belt 4 PK Pulley dia effective dia 93 mm 3 7 in Pulley ratio 1 43 Refrigerant AC 3 General Description HVAC SYSTEM HEATER VENTILATOR AND A C Condenser Type Corrugated fin Sub cool type Core face area 0 186 m 2 002 sq ft Core thickness 16 mm 0 63 in Radiation area 5 49 m 59 09 sq ft Receiver drier Effective inner capacity 250 cm 15 26 cu in Expansion valve Type Externally equalizing Evaporator Type Single tank Dimensions W x H x T 298 6 x 151 x 38 mm 11 7 x 5 94 x 1 50 in Blower fan Fan type Sirocco fan Outer diameter x width 150 x 75 mm 5 91 x 2 95 in Power consumption 220 W Condenser fan Sub fan Motor type Magnet Power consumption 90 W Fan outer diameter 300 mm 11 8 in Radiator fan Main fan
13. Triple Pressure Switch HVAC SYSTEM HEATER VENTILATOR AND A C 20 Pressure Switch Triple Pressure Switch A INSPECTION 1 Connect the manifold gauge to the service valve on the high pressure side 2 Remove the pressure switch harness connector Using a circuit tester inspect the ON OFF operation of pressure switch EG Vy N AC 00788 Terminal Operation Standard No H kPa kg cm2 psi Turns OFF Increasing to 214050 0202 3 g4 AGS A 29 0 D ing to 196 20 2 00 0 20 28 4 2 9 High and low pressure switch 1 and 2 dd O Turns ON Increasing to E EEN Decreasing to 2 550 200 26 00 2 04 369 8 29 0 Middle or r switch 3 and4 Turns OFF Decreasing to 1 370 120 14 1 199 14 Se ane Turns ON Increasing to 1 770 100 1841 256 14 AC 40 Ambient Sensor Auto A C Model 21 Ambient Sensor Auto A C Model A REMOVAL 1 Open the front hood 2 Disconnect the ground cable from battery 3 Disconnect the ambient sensor connector 4 Remove the ambient sensor from the radiator lower panel Z Vee AC 00125 B INSTALLATION Install in the reverse order of removal C INSPECTION lt Ref to AC diag 30 AMBIENT SENSOR Diag nostic Procedure for Sensors gt HVAC SYSTEM HEATER VENTILATOR AND A C AC 41 Sunload Sensor Auto A C Model
14. e If a component has been replaced add an ap propriate amount of compressor oil same as the amount of remaining oil in removed component e When replacing the compressor the new com pressor 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 com pressor removed AC 25 Blower Motor Unit Assembly HVAC SYSTEM HEATER VENTILATOR AND A C 7 Blower Motor Unit Assembly A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the glove box lt Ref to El 51 REMOV AL Glove Box gt 3 Disconnect the connectors of A C control mod ule intake door actuator blower motor power tran sistor and blower resistor 4 Loosen the bolt and nut to remove blower motor unit assembly AC 00914 B INSTALLATION Install in the reverse order of removal Tightening torque Refer to COMPONENT of General Descrip tion lt Ref to AC 5 HEATER COOLING UNIT COMPONENT General Description gt lt Ref to AC 7 BLOWER MOTOR UNIT COM PONENT General Description gt AC 26 Blower Motor HVAC SYSTEM HEATER VENTILATOR AND A C 8 Blower Motor A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the glove box lower cover lt Ref to El 51 REMOVAL Glove Box gt 3 Disconnect the connector of blower motor 4 Loosen the screw to r
15. e If the condenser is replaced add an appropri ate amount of compressor oil to the compres sor lt Ref to AC 25 REPLACEMENT Compressor Oil gt B INSTALLATION 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 A has been fit ted into holes on radiator panel r AC 00631 2 Charge refrigerant lt Ref to AC 21 PROCE DURE Refrigerant Charging Procedure gt A Tightening torque Refer to COMPONENT of General Descrip tion lt Ref to AC 10 AIR CONDITIONING UNIT COMPONENT General Description gt lt Ref to CO H4SO 2 0 5 RADIATOR AND RADIATOR FAN COMPONENT General De scription gt C INSPECTION 1 Check no dust or insects are found on the con denser fins Air blow or flush fins with water as needed 2 Inspect for oil leakage from condenser If a fail ure is found replace the condenser with a new one AC 35 Heater and Cooling Unit HVAC SYSTEM HEATER VENTILATOR AND A C 16 Heater and Cooling Unit A REMOVAL 1 Disconnect the ground cable from battery 2 Using the refrigerant recovery system dis charge refrigerant lt Ref to AC 20 PROCEDURE Refrigerant Recovery Procedure gt 3 Drain coolant from the radiator 4 Remove the bolts securing expansion valve and pipe in engine compartme
16. 0 45 0 15 mm 0 0177 0 0059 in 2 MAGNETIC CLUTCH OPERATION 1 Disconnect the compressor connector 2 Connect the battery positive terminal to ter minal No 1 of compressor connector and negative terminal to terminal No 2 3 Check the magnet clutch engagement If NG replace the compressor B REMOVAL 1 Perform the compressor oil return operation lt Ref to AC 25 PROCEDURE Compressor Oil gt 2 Turn the A C switch to OFF and stop the engine 3 Using the refrigerant recovery system dis charge refrigerant lt Ref to AC 20 PROCEDURE Refrigerant Recovery Procedure gt 4 Disconnect the ground cable from battery 5 Remove the V belts lt Ref to ME H4SO 2 0 38 REMOVAL V belt gt lt Ref to ME H4DOTC 39 REMOVAL V belt gt lt Ref to ME H6DO 33 RE MOVAL V belt gt 6 Remove the generator lt Ref to SC H4SO 2 0 14 REMOVAL Generator gt lt Ref to SC H6DO 14 REMOVAL Generator gt HVAC SYSTEM HEATER VENTILATOR AND A C 7 Remove the bolt and remove the low pressure hose and high pressure hose AC 00772 8 Disconnect the compressor harness from body harness 9 Remove the bolts and remove compressor bracket e H4 model AC 00920 10 Remove the bolts and then remove the bracket from compressor AC 00774 AC 33 Compressor HVAC SYSTEM HEATER VENTILATOR AND A C C INSTALLATION
17. 13 6 kg 30 Ib refrig erant container is used AC 00020 AC 18 Refrigerant Pressure with Manifold Gauge Set HVAC SYSTEM HEATER VENTILATOR AND A C 2 Refrigerant Pressure with Manifold Gauge Set A PROCEDURE 1 Place the vehicle in the shade and windless condition Connect the manifold gauge set Open the front windows and close all doors Open the front hood Turn on the A C switch Turn the temperature control switch to MAX COOL 2 3 4 5 Increase the engine to 1 500 rpm 6 7 8 Put in RECIRC position 9 Turn the blower control switch to HI 10 Read the gauge Standard Low pressure 127 196 kPa 1 3 2 0 kg cm 1 Lins 28 psi High pressure 1 471 1 667 kPa 15 17 kg cm 213 242 psi Ambient temperature 30 35 C 86 95 F INSPECTION Symptom Probable cause Repair order High pressure side is unusually high Defective condenser fan motor Clogged condenser fin Too much refrigerant Air inside the system Defective receiver dryer e Replace the fan motor e Clean the condenser fin e Discharge refrigerant e Replace the receiver dryer e After evacuating again charge an appropriate amount of refrigerant High pressure side is unusually low Defective compressor Not enough refrigerant Clogged expansion valve Expansion valve frozen temporarily by moisture Replace the compress
18. 2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION HVAC SYSTEM AC HEATER VENTILATOR AND A C HVAC SYSTEM AUTO A C ETC ET DIAGNOSTICS AIRBAG SYSTEM AB AIRBAG SYSTEM DIAGNOSTICS AB diag This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair COU revels LIGHTING SYSTEM LI This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of WIPER AND WASHER SYSTEMS components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual ENTERTAINMENT fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition COMMUNICATION SYSTEM When replacement of parts during repair work is needed be sure to use SUBARU genuine parts GLASS WINDOWS MIRRORS GW SEAT BELT SYSTEM SB BODY STRUCTURE BS INSTRUMENTATION DRIVER INFO IDI SEATS SE SECURITY AND LOCKS SL SUNROOF T TOP CONVERTIBLE TOP cp SUNROOF EXTERIOR INTERIOR TRIM EI All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval EXTERIOR BODY PANELS FUJI HEAVY INDUSTRIES LTD G2320GE7 2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CC CRUI
19. 23 Refrigerant Leak Check HVAC SYSTEM HEATER VENTILATOR AND A C 5 Refrigerant Leak Check A INSPECTION 1 Operate the A C system for approx 10 minutes and confirm that the high side pressure shows at least 690 kPa 7 03 kg cm 100 psi Then stop the engine to start the leak test 2 Starting from the connection between high pres sure pipe and evaporator check the system for leaks along the high pressure side through the compressor The following items must be checked thoroughly 3 Check the joint and seam between pressure switch dual switch and high pressure pipe 4 Check the connections between condenser and pipes and welded joints on the condenser The leak tester may detect the oil on the condenser fins as a leak 5 Check the joint between compressor and hoses 6 Check the machined area of compressor and other joints on the compressor 7 Check the compressor shaft seal at the area near the center of compressor clutch pulley Some shaft seals show a slight amount of leakage about 3 g 0 1 oz per year This is not a problem 8 Starting from the connection between low pres sure pipe and evaporator check the system for leakage along the low pressure side through the compressor The following items must be checked thoroughly Connection between 2 parts Connection between pipe and plate AC 00035 9 Visually check the rubber area of the flexible hose for cracks Check the e
20. AC SYSTEM HEATER VENTILATOR AND A C 11 Heater Core A REMOVAL 1 Remove the heater and cooling unit lt Ref to AC 36 REMOVAL Heater and Cooling Unit gt 2 Remove the screws and remove the heater core cover and pipe clamp AC 00917 3 Remove the heater core B INSTALLATION Install in the reverse order of removal AC 30 Control Unit Manual A C Model HVAC SYSTEM HEATER VENTILATOR AND A C 12 Control Unit Manual A C Model A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the glove box lt Ref to El 51 REMOV AL Glove Box gt 3 Remove the control wires AC 00918 4 Remove the integrated panel lt Ref to ET 5 REMOVAL Audio gt 5 Loosen the screw to remove the control unit from bracket B INSTALLATION Install in the reverse order of removal AC 31 Control Unit Auto A C Model HVAC SYSTEM HEATER VENTILATOR AND A C 13 Control Unit Auto A C Model A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the glove box lt Ref to El 51 REMOV AL Glove Box gt 3 Remove the screw disconnect the connector and remove the control unit AC 00919 B INSTALLATION Install in the reverse order of removal AC 32 Compressor 14 Compressor A INSPECTION 1 MAGNETIC CLUTCH CLEARANCE Check the clearance of entire circumference around the drive plate and pulley Standard
21. OR AND A C e Manual A C model AC 00907 1 Foot duct RH 8 Clip 15 Unit ASSY 2 Thermo amplifier 9 Air mix door linkage 16 Drain hose 3 Pipe cover 10 Mode actuator 4 Evaporator cover 11 Heater pipe clamp Tightening torque N m kgf m ft Ib 5 Expansion valve 12 Heater core T 7 5 0 76 5 5 6 Packing 13 Heater core cover 7 Evaporator 14 Foot duct LH AC 6 General Description HVAC SYSTEM HEATER VENTILATOR AND A C 2 BLOWER MOTOR UNIT AC 00908 1 Upper case 6 Control unit Auto A C model Tightening torque N m kgf m ft lb 2 Intake door actuator 7 Power transistor Auto A C model T 7 5 0 76 5 5 3 Filter Auto A C model Blower resistor Manual A C 4 Filter cover model 5 Blower motor ASSY AC 7 General Description HVAC SYSTEM HEATER VENTILATOR AND A C 3 CONTROL PANEL Auto A C model WEA f 1 AC 00909 A For integrated audio B For Mcintosh audio 1 Temperature control dial 3 Board 4 Heater control base 2 Control panel assembly AC 8 General Description HVAC SYSTEM HEATER VENTILATOR AND A C e Manual A C model Je AC 00910 1 Dial 5 Heater control panel 8 Valve 2 A C switch 6 Heater control base 9 Fan switch ASSY 3 FRESH RECIRC switch 7 Temperature control cable 10 Switch base 4 Rear window defogger switch
22. SE CONTROL SYSTEM CC diag DIAGNOSTICS IMMOBILIZER DIAGNOSTICS LUC IEN LAN SYSTEM DIAGNOSTICS LAN diag G2320GE7 SSS Ses HVAC SYSTEM HEATER VENTILATOR AND A C O CO IRON O Se PO PO PO POP PP PND M AH sch ch sch SBNAARSGSSPSOHBNAAR YAS Page General a PN ner nnn nennen nenne 2 Refrigerant Pressure with Manifold Gauge Set 19 Refrigerant Recovery Procedure ss 20 Refrigerant Charging Procedure geseet 21 Refrigerant Leak TEE 24 Compressor EE 25 Blower Motor Unit Assembly 26 Blower e TEEN 27 Power Transistor Auto A C Model ccccceeeeeeeeeeeeeeeeeeeeeeeeeeenaeeeeeneeas 28 Blower Resistor Manual A C Model 29 Heater GE ae 30 Control Unit Manual A C Model AAA 31 Control Unit Auto A C Mod lisme tement en 32 COMPr SS EE 33 Condenser EE 35 Heater and Cooling E EE 36 CEA LE 0 10 L 2 LOSC 37 ele nd BAR Te 38 Relay and EE 39 Pressure Switch Triple Pressure Switch 40 Ambient Sensor Auto A C Model 41 Sunload Sensor Auto A C Model 42 In Vehicle Sensor Auto A C Model 43 Air Vent GUNG cad tate te sa etre na EEE 44 Heater DUCH misici nn et thet tnt tete Rte rte ni 45 Heater Vent Ke t ee rt dede nr ete 46 Heater Cock Solenoid Valve EEN 47 General Diagnostic TIDE wie situent tendent an te 48 General Description HVAC SYSTEM HEATER VENTILATOR AND A C 1 General Description A SPECIFICATION 1 HEATER SYSTEM Specification On conditio
23. cannot be used in the CFC 12 A C system e If an incorrect or no refrigerant is used it will re sult in poor lubrication and the compressor itself may be damaged 4 HANDLING OF REFRIGERANT e The refrigerant boils at approx 30 C 22 F When handling it be sure to wear protective gog gles and protective gloves Direct contact of the re frigerant with skin may cause frostbite If the refrigerant gets into your eye avoid rubbing your eyes with your hands Wash your eye with plenty of water and receive medical treatment from an eye doctor Do not heat a service can If a service can is di rectly heated or put into boiling water the inside pressure will become extremely high This may cause the can to explode If a service can must be warmed up use hot water in 40 C 104 F max Do not drop or impact a service can Observe the precautions and operation procedure described on the refrigerant can e When the engine is running do not open the high pressure valve of manifold gauge The high pressure gas will back flow resulting in an explo sion of the can e Provide good ventilation and do not work in a closed area In order to prevent global warming avoid releas ing HFC 134a into the atmosphere Using a refrig erant recovery system discharge and reuse it gt A ES D F aa E Si X AC 00007 N Goggles Gloves Avoid open flame No direct h
24. e switch A C switch Blower switch Wire harness V Belt Magnet clutch Compressor Refrigerant V Belt Magnet clutch Compressor Pressure switch A C switch Blower switch Wire harness Heater duct Heater vent duct Engine coolant Blower switch Heater core Heater cock solenoid valve Engine coolant Air mix actuator Auto A C Wire harness Auto A C Temperature control cable Manual A C Mode actuator Auto A C Air flow switch Auto A C Wire harness Auto A C Mode cable Manual A C Air inlet select switch Auto A C FRESH RECIRC actuator Auto A C Wire harness Auto A C Intake cable Manual A C Doesn t operate Blower motor Compressor Cold air not emitted Warm air not emitted Temperature of air from vents does not change Unable to switch blow vents Unable to switch suction vents AC 48
25. e the screws and clip to remove the evap orator cover AC 00927 7 Pull out the evaporator A in the direction of ar row ANAL AC 00928 CAUTION If the evaporator is replaced add an appropri ate amount of compressor oil to evaporator lt Ref to AC 25 REPLACEMENT Compressor Oil gt B INSTALLATION Install in the reverse order of removal AC 37 Hose and Tube HVAC SYSTEM HEATER VENTILATOR AND A C 18 Hose and Tube A REMOVAL CAUTION e When disconnecting connecting hoses do not apply an excessive force to them Confirm that no torsion and excessive tension is charged after installing e Seal the disconnected hose with a plug or vi nyl tape to prevent foreign matter from enter ing 1 Disconnect the ground cable from battery 2 Using the refrigerant recovery system dis charge refrigerant lt Ref to AC 20 PROCEDURE Refrigerant Recovery Procedure gt 3 Remove the evaporator unit mounting bolt A and low pressure hose bracket bolt B 4 Remove the low pressure hose attaching bolts C 5 Disconnect the low pressure hose from evapo rator unit 6 Disconnect the low pressure hose from com pressor 7 Remove the low pressure hose from vehicle 8 Remove the high pressure hose attaching bolt D 9 Disconnect the high pressure hose from com pressor 10 Disconnect the high pressure hose from con denser 11 Remove the high pressure h
26. eat on container Do not discharge Loosen 5 O RING CONNECTIONS Always use a new O ring In order to keep the O rings free of lint which will cause a refrigerant gas leak perform operations without gloves and cloth AC 14 General Description HVAC SYSTEM HEATER VENTILATOR AND A C Apply compressor oil to O rings to avoid sticking before installation e Use a torque wrench to tighten the O ring fittings Over tightening will result in damage of O ring and tube end distortion e Ifthe operation is interrupted before completing a pipe connection recap the tubes components and fittings with a plug or tape to prevent foreign matter from entering AC 00008 A Seal e Visually check the surfaces and mating surfaces of O rings threads and connecting points If a fail ure is found replace the applicable parts Install the O rings at right angle to tube beads A B y D C C I GS en I AC 00009 e Use compressor oil specified in the service man ual to lubricate the O rings Apply oil to the top and sides of O rings before in stallation Apply compressor oil to the bead of tube AC 00010 e After tightening use a clean cloth to remove ex cess compressor oil from the connections and any oil which may have run on the vehicle body or other parts e If any leakage is suspected after tightening d
27. emove blower motor B INSTALLATION Install in the reverse order of removal C INSPECTION Connect the battery positive terminal to terminal No 2 of blower motor and negative terminal to terminal No 1 Check the blower motor for smooth rotation AC 00915 AC 27 Power Transistor Auto A C Model HVAC SYSTEM HEATER VENTILATOR AND A C 9 Power Transistor Auto A C Model A REMOVAL 1 Remove the glove box lower cover on passen ger side lt Ref to El 51 REMOVAL Glove Box gt 2 Disconnect the power transistor connector 3 Remove two screws and then remove the pow Bg Cc AC 00916 B INSTALLATION Install in the reverse order of removal AC 28 Blower Resistor Manual A C Model HVAC SYSTEM HEATER VENTILATOR AND A C 10 Blower Resistor Manual A C Model A REMOVAL 1 Remove the glove box lower cover on passen ger side lt Ref to El 51 REMOVAL Glove Box gt 2 Disconnect the blower resistor connector 3 Remove two screws and then remove the blow er resistor AC 00916 B INSTALLATION Install in the reverse order of removal C INSPECTION LE d AC 00766 Measure the See resistor resistance Terminal No Standard 4 and 2 Approx 0 44 Q 4 and 3 Approx 1 12 Q 4 and 1 Approx 2 92 Q If NG replace the blower resistor AC 29 Heater Core HV
28. ew one to restart the operation CT Le TC 7 od ili A Low pressure gauge Compound pressure gauge B High pressure gauge C Close l Q C AC 00033 23 While reading the low pressure gauge careful ly open the low pressure valve with the refrigerant source connected and the service hose purged CAUTION Never open the high pressure valve with the en gine running The high pressure gas will back flow resulting in an explosion of the can AC 00034 24 Adjust the refrigerant flow to maintain the pres sure on the low pressure side at 276 kPa 2 81 kg cm 40 psi max 25 After the system is fully charged close the low pressure valve 26 Close the valve on the refrigerant source Refrigerant amount Minimum 370 g 0 82 Ib Maximum 430 g 0 95 Ib Refrigerant HFC 134a 27 Disconnect the hose from the service port and install the service port cap 20 Confirm that both the low high pressure valves can be closed Start the engine with the A C switch OFF 21 Quickly repeat ON OFF cycles a few times to prevent initial compressor damage 22 Set up the vehicle to the following status e A C switch ON Engine running at 1 500 rom Blower speed setting to HI Temperature setting to MAX COOL Air inlet setting to RECIRC Window open AC
29. n Heating capacity 5 2 KW 4 471 kcal h 17 743 BTU h or more e Mode selector switch HEAT e Temperature control switch FULL HOT e Temperature difference between hot water and inlet air 65 C 149 F e Hot water flow rate 360 2 95 1 US gal 79 2 Imp gal h Air flow rate 370 m 13 066 cu ft h Heat mode FRESH FULL HOT at 12 5 V Max air flow rate 460 m 16 245 cu ft h e Temperature control switch FULL COLD e Blower fan speed Auto A C 6th position Manual A C 4th position e Mode selector lever RECIRC Heater core size height x length x width 264 x 110 x 27 mm 10 4 x 4 33 x 1 06 in Type Magnet motor 220 W or less Blower motor Fan type and size diameter x width 2 A C SYSTEM Auto A C model Sirocco fan type 150 x 75 mm 5 91 x 2 95 in Item Specification Type of air conditioner Reheat air mix type Cooling capacity 5 3 kW 4 557 kcal h 18 084 BTU h Refrigerant HFC 134a CHsFCF3 0 4 0 03 kg 0 88 0 07 Ib Type Scroll constant volume SCSA 08C Compressor Discharge 74 5 cc 4 55 cu in rev Max permissible speed 9 000 rpm Type Dry single disc type Power consumption 35 W Magnet clutch H4 model V belt 4 PK ENEE H6 model V belt 6 PK Pulley dia effective dia 93 mm 3 7 in Pulley ratio 1 43 Condenser Type Corrugated fin Sub cool type Core face area 0
30. nt Release the heater hose clamps in engine compartment to remove the hoses AC 00921 5 Remove the instrument panel lt Ref to El 56 REMOVAL Instrument Panel Assembly gt 6 Remove the support beam 7 Remove the blower motor unit assembly lt Ref to AC 26 REMOVAL Blower Motor Unit Assem bly gt 8 Disconnect the actuator connector 9 Remove the bolt and nuts to remove the heater and cooling unit AC 00922 B INSTALLATION 1 Install in the reverse order of removal 2 Charge refrigerant lt Ref to AC 21 PROCE DURE Refrigerant Charging Procedure gt Tightening torque Refer to COMPONENT of General Descrip tion lt Ref to AC 5 HEATER COOLING UNIT COMPONENT General Description gt AC 36 Evaporator 17 Evaporator A REMOVAL 1 Remove the blower motor unit assembly lt Ref to AC 26 REMOVAL Blower Motor Unit Assem bly gt 2 Disconnect the connector remove the screw and then remove the air mix door actuator and mode door actuator 3 Disconnect the connector remove the screw and remove the pipe cover and evaporator sensor t AC 00924 4 Remove the bolts securing expansion valve and pipe in engine compartment AC 00925 HVAC SYSTEM HEATER VENTILATOR AND A C 5 Remove the bolt which holds the pipe to evapo rator 6 Remov
31. ntire length of the flexible hose espe cially the connection with the metal hose end CAUTION Carefully check the external surface of hoses and tubes at approx 25 mm 0 98 in per sec ond 7 Y AC 00036 A Flexible hose 10 Disconnect the drain hose from heater case and check the hose end for at least 10 seconds After the test is finished reconnect the drain hose 11 Turn the ignition key to ON position and run the blower at high speed for approx 1 minute Stop the blower to check the ventilation grille on the in strument panel While moving the tester closer to the grille run the blower for 1 or 2 seconds then stop it Check the grille at that point for at least 10 seconds AC 00037 12 Check the valve in the service port 13 Visually check the rubber seal in the service port cap AC 00038 AC 24 Compressor Oil HVAC SYSTEM HEATER VENTILATOR AND A C 6 Compressor Oil A PROCEDURE NOTE Before making repairs perform the oil return oper ation to return the compressor oil in circulation with the refrigerant to the compressor 1 Increase the engine to 1 500 rpm 2 Turn ON the A C switch 3 Turn the temperature control switch to MAX COOL 4 Put in RECIRC position 5 Turn the blower control switch to HI 6 Leave in this condition for 10 minutes B REPLACEMENT NOTE
32. o not further tighten the connections but disconnect the connections remove the O rings and check the O rings threads and connections AC 15 General Description HVAC SYSTEM HEATER VENTILATOR AND A C D PREPARATION TOOL CAUTION When working on vehicles with HFC 134a system only use HFC 134a specified tools and parts Do not mix with those of CFC 12 If HFC 134a and CFC 12 refrigerant or compressor oil is mixed it will result in poor lubrication and the compressor itself may be destroyed In order to prevent the mixture of HFC 134a and CFC 12 parts and liquid the tool and screw type and the type of service valves used are different The gas leak detectors for the HFC 134a and CFC 12 systems must also not be interchanged HFC 134a CFC 12 Tool amp screw type Millimeter size Inch size Valve type Quick joint type Screw in type ILLUSTRATION Tools and Equipment Wrench Various WRENCHES will be required to service any A C system 7 to 40 N m 0 7 to 4 1 kgf m 5 to 30 ft lb torque wrench and various crow foot wrenches will be needed Open end or flare nut wrenches will be needed to hold the tube and hose fittings AC 00213 Applicator bottle A small APPLICATOR BOTTLE is recommended to apply compressor oil to the various parts It can be available at a hardware or drug store AC 00012 Manifold gauge set A MANIFOLD GAUGE SET with hoses can be available at either a refrigerant supplier o
33. or Check for leaks Replace the expansion valve Fully evacuate the expansion valve Low pressure side is unusually high Defective compressor Defective expansion valve Too much refrigerant Replace the compressor Replace the expansion valve Discharge refrigerant Low pressure side is unusually low Not enough refrigerant Clogged expansion valve Expansion valve frozen temporarily by moisture e Saturated receiver dryer AC 19 Check for leaks Replace the expansion valve Replace the receiver dryer Refrigerant Recovery Procedure HVAC SYSTEM HEATER VENTILATOR AND A C 3 Refrigerant Recovery Proce dure A PROCEDURE CAUTION e During operation be sure to wear protective goggles and protective gloves e Connect the refrigerant recovery system with the manifold gauge set to discharge the refrig erant from the A C system and reuse it e When reusing the discharged refrigerant keep service cans on hand Because the dis charge rate with the recovery system is approx 90 service cans are necessary to charge the refrigerant e Follow the detailed operation procedure de scribed in the operation manual attached to the refrigerant recovery system 1 Perform the compressor oil return operation lt Ref to AC 25 PROCEDURE Compressor Oil gt 2 Stop the engine 3 Make sure the valves on low high pressure sides of manifold gauge set are fully closed
34. ose from vehicle 12 Remove the high pressure attaching bolt E 13 Remove the high pressure tube from vehicle AC 00929 B INSTALLATION CAUTION e When disconnecting or connecting the hos es do not apply excessive force to them Con firm that no torsion and excessive tension is charged after installing e Seal the disconnected hose with a plug or vi nyl tape to prevent foreign matter from enter ing 1 Install in the reverse order of removal 2 Charge refrigerant lt Ref to AC 21 PROCE DURE Refrigerant Charging Procedure gt Tightening torque Refer to COMPONENT of General Descrip tion lt Ref to AC 10 AIR CONDITIONING UNIT COMPONENT General Description gt C INSPECTION Check the hoses for cracks damage and expan sion If any fault is found replace them with new ones AC 38 Relay and Fuse HVAC SYSTEM HEATER VENTILATOR AND A C 19 Relay and Fuse B INSPECTION A LOCATION AC 00641 3 4 Continuity exists 1 Joint b 1 2 Continuity does not exist oint box 2 Main fuse box While applying battery voltage to the terminal be tween 3 and 4 check continuity between 1 and Main Fan Relay 1 2 Main Fan Relay 2 If no continuity exists replace the relay with a new Sub Fan Relay one A C Relay A C Fuse AC 39 Pressure Switch
35. r an automotive equipment supplier AC 00013 AC 16 ILLUSTRATION General Description HVAC SYSTEM HEATER VENTILATOR AND A C Tools and Equipment AC 00014 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 HD AC 00015 Syringe A graduated plastic SYRINGE will be needed to add oil back into the system syringe can be available at a pharmacy or drug store AC 00016 Vacuum pump A VACUUM PUMP is necessary for a good working condition and may be available at either a refrigerant supplier or an automotive equipment supplier AC 00017 Can tap A CAN TAP for the 397 g 14 oz can is available at an automotive equipment supplier AC 17 General Description HVAC SYSTEM HEATER VENTILATOR AND A C ILLUSTRATION Tools and Equipment Temperature gauge A Pocket THERMOMETER is available at either a industrial hardware S store or a refrigerant suppliers AC 00018 Electronic leak detector An ELECTRONIC LEAK DETECTOR can be available at either a spe cialty tool supplier or an A C equipment supplier AC 00019 Weight scale A WEIGHT SCALE such as an electronic charging scale or a bath room scale with digital display will be needed if a
36. set if applicable press a purge valve on the manifold gauge set only for a couple of seconds to allow the air in the center hose to es cape by the refrigerant 15 Carefully open the high pressure valve with the engine stopping CAUTION Do not open the low pressure valve D ITU A Low pressure gauge Compound pressure gauge High pressure gauge Close Ignition switch OFF Slowly open CAUTION Never run the engine during charging from the high pressure side 16 Close the high pressure valve when the low pressure gauge reaches 98 kPa 1 kg cm 14 psi Using a leak tester check the system for leaks If any leakage is found after the refrigerant recov ery is completed repair the applicable area AC 22 Refrigerant Charging Procedure HVAC SYSTEM HEATER VENTILATOR AND A C 17 After confirming that there are no leaks with the leak test charge the required amount of refrigerant CAUTION Never run the engine during charging from the high pressure side 18 Close the high pressure valve when e the readings of low high pressure gauges be come almost equal after the charging speed is re duced e the HFC 134a source becomes empty or the system is filled with the gas gt cane 19 If the HFC 134a source is empty close the high pressure valve close the valve on the can tap and replace the HFC 134a source with a n
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