Subaru R-12 User's Manual
Contents
1. Subaru Ar Conditioning System Oil Refill Fill the compressor with the proper amount of the correct type refrigerant oil Use of the incorrect type of compressor oil may result in damage to the com pressor Refer to Subaru Service Bulletin number 10 37 84 dated 12 12 84 for compressor oil specifications for Matsushita Panasonic Hitachi Lone Star and other compressor types Always manually rotate the compressor several turns to confirm proper operation after filling with refrigerant oil Note The variable displacement Calsonic and DIESEL KIKI compressors may only be filled with special V 5 compressor oil D 9OPX Any contamination with other types of compressor oils will cause compressor damage Never substitute or cross contaminate R 12 compatible compressor oil with R 134a compatible compressor oil Refer to the Oil Charge Table found in Section 4 7 of the appropriate model year Service Manual This can be a useful tool to determine the proper procedure to follow and to determine the amount of refrigerant oil to add or replace to the compressor after servicing repairing or replacing major system components Always manually rotate the compressor several turns to confirm proper operation Performance Testing Test Conditions e The vehicle must be indoors or in the shade e Doors should be closed all windows open e Hood open e Connect the manifold gauge e Set the mode switch to the A C MAX position On variable2. Lower than normal pressure indicates Remarks Install on 4EAT Addendum to Service Bulletin 02 70 89 Compressor Oil Legacy V 5 Compressor amp A C System Service Information A C System Servicing Discontinued Shorting Loop For A C Cut Relay Number Date 10 58 90 10 59 90 10 60 90 10 61 91 10 62 91 10 63 93 10 64 93 10 65 94 10 66 94 10 67 94 05 30 90 07 06 90 08 14 90 07 02 91 09 20 91 04 12 93 11 08 93 03 08 94 06 17 94 11 11 94 10 68 96R 07 01 98 System is undercharged or Compressor is NOT changing to minimum stroke Switch system ON and OFE If high and low side pressures remain equal Extreme System undercharge or Defective compressor Note The clutches on the variable displacement Calsonic and DIESEL KIKI compressors are not serviceable Always refer to the current Subaru Service Bulletins for possible future changes to this procedure Title 10 57 90 05 29 90 A C Compressor Inspection Thermoprotector Service Procedure Thermoprotector Testing Procedure Clarification Automatic Climate Control Diagnostic Information Removal and Recycling of Refrigerant R 1 2 Wynn s Justy A C SOA329A110 amp SOA329A112 R 134a Refrigerant Handling Procedures Heater Vent Door Binding Or Leaking Air Proper Oils For Subaru A C Systems R 12 and R 134a Air Conditioning System Handling Procedures Clicking Noise F
3. ary Avr Conditioning Systems ver the years Subaru air conditioning systems have taken many different shapes and sizes from full manual cable and vacuum controlled systems like those found on Loyale models to the fully automatic electronically controlled systems employed by the SVX and some Legacy models Because of this great diversity in Subaru air conditioning systems it would be impossible to tell you everything there is to know about every single Subaru air conditioning system in this edition of The End Wrench Introduction What we will do instead is to give you a cross section summary of recent Subaru air conditioning systems We ll show you what s unique and different about each system and describe the best troubleshooting and repair strategies for these systems In compliance with government requirements all Subaru vehicles manufactured within the past few years are equipped with R 134a air conditioning systems But there are still a large percentage of Subaru vehicles on the road with R 12 refrigerant in their A C sytems We ll explain how to safely handle R 12 and R 134a refrigerants and we ll also explain your repair and retrofit options when a Subaru equipped with an R 12 air conditioning system comes to your shop for repairs SUBARU Air Flow System The purpose of the air flow system is to provide air to the heating ventilation defroster and air conditioning systems Control of the air flow is accompl
4. displacement compressor system set the A C controls to high blower and normal A C Note When servicing variable displacement compressors refer to Service Bulletin 10 52 89 dated 07 28 89 for complete compressor diagnostic information e Set the temperature control to COLD e Start the engine and idle at 1 500 RPM e Operate for approximately 10 minutes then observe the high and the low pressure levels An essential step of the performance test is measuring the temperature of the inlet air at the blower and the temperature of the outlet air at the vent grills The temperature difference should be within specifications for the system System temperatures will vary with changing conditions such as high ambient air temperature humidity and altitude Temperature M easurement J pogo 4 24 Senice Bulletins oning Related Air Conditi Subaru Ar Conditioning System Performance Test Results Standard Compressor Systems System performs to specifications test complete Higher than normal pressures indicate Restriction of air across condenser Defective cooling fan s Refrigerant overcharge Kestriction in system Air in system Moisture in system Lower than normal pressures indicate System is undercharged Compressor is defective Variable Displacement Compressor Systems System performs to Lower than normal pressures indicate Compressor has shifted to minimum str
5. ditioning System Bypass Adjusting Screw ECVT Fast Idle Control Device A C Idle Air Control On manual transaxle equipped Justy vehicles the FICD is incorporated in the idle up system Proper adjustment and operation is outlined in Service Bulletins 02 70 89 and 02 72 89 On ECVT equipped carbureted vehicles an air fuel bypass control system performs the FICD function The ECVT air bypass control system consists of an air bypass valve an adjusting screw and an air bypass solenoid The system is designed to increase idle speed whenever the A C relay is activated by supplying additional air fuel into the intake manifold Bypass air enters through the air horn on the secondary side The airflow is regulated by an adjusting screw When the bypass valve opens bypass air fuel enters the manifold below the secondary throttle plate When the adjusting screw is turned clockwise bypass air fuel is reduced and the idle speed is lowered When the adjusting screw is turned counter clockwise bypass air fuel is increased and the idle speed is increased Note Always refer to the appropriate Justy model year Subaru Service Manual sections 2 2 and 2 6 for the proper ECVT FICD adjustment procedures and specifications TBI system equipped Loyale vehicles control the FICD function through the ECM the idle air control valve IAC and the A C switch The air conditioning ON OFF switch is an input to the ECM The ECM operates the idle air cont
6. g System Charging Charging the system is required after servicing repair or replacement of system components or to locate a leak when there is no refrigerant in the system Follow the steps listed below to charge the system e Leak detection of a pressurized system is required to locate an otherwise unidentifiable leak in a discharged system or when the system was dicharged evacuated for repairs The proper procedure is to Connect the manifold gauges or ACR 4 to the system Attach the center charging hose to the refrigerant source Charge the system initially with 5 75 Ibs 0 226 0 34 kg Note Refer to the appropriate model year Subaru Service Manual or air conditioning manufacturer s instructions for charging details pressures and system capacities Use an electronic leak detector such as a pump style halogen dual gas type Ifa leak is detected recover the remaining refrigerant and repair the leak If no leak is detected continue charging the system When charging of the system has been completed close the manifold gauge valves and manually rotate the compressor several turns to distribute any trapped refrigerant oil before the clutch is engaged Check again for refrigerant leaks with an approved leak detector Conduct a performance test Upon successful completion of the performance test disconnect the high and low pressure hoses from the service valves Replace the valve caps to the service val
7. g and components may be hot enough to cause minor burns Do not touch or hold for extended periods of time Note If a component on the high side of the system located before the Thermal Expansion Valve is cool or cold this is an indication of a restriction Servicing Manifold Gauges The manifold gauges measure the pressures of the low side or suction side and the high side or discharge side of the system The gauges are calibrated in psi for pressure and inches of mercury for vacuum Note that zero 0 psi is equal to sea level or 14 7 psi or the pressure at the altitude level at which the gauge is being used The gauge set consists of the valve body the connectors for the low pressure charge or evacuation and high pressure hoses and the gauges The service valves are infinitely adjustable between fully open and fully closed Manifold Gauges sens To connect the manifold gauge set to the system Fully close both of the manifold valves Remove the compressor service valve caps Connect the high and low pressure hoses to the service valves Note Some refrigerant gas will be discharged as the hoses are connected to the service valves This is normal however you should attempt to connect the hoses as quickly as possible to prevent excess refrigerant loss and air from entering the system Note Start vehicle engine and follow the directions concerning idle speed etc contained in the appropriate model
8. ished by four types of systems which are Subaru model specific Manual cable Justy Manual cable vacuum Loyale Manual cable electric Legacy Impreza and XT Automatic electric SVX The mode selector controls the rout ing of air to the defroster heater core air conditioning evaporator and the outlet ducts The temperature control lever adjusts the temperature of the air admitted to the passenger compart ment and regulates the flow of air through the heater core via the air mix doors The fan switch controls the speed of the fan and thus the volume of air that flows through the evaporator and heater cores Loyale vehicles have vent control levers which are not a part of the mode selector switch These are manually adjusted by the driver and passenger to admit or restrict the flow of outside air through side vent outlets The Legacy and the Impreza have eight position mode panels while the Loyale and XT have six button panels The additional VENT mode supplies 5 a ae ee A outside air to the passenger compartment through the dash vents The flow ni of vent air may be increased by using the fan and heated by increasing the temperature control setting The DEF HEAT mode switches the A C com pressor ON and supplies air flow to the defrost and floor outlets The remaining mode switches operate similar to other Subaru A C system controls The air flow unit used on Legacy vehicles equipped with manual A C systems is similar t
9. mpressor oil in system 6 7 10 Note Do not introduce compressed air into R 134a components B 74N Se General Preparations Always conduct a visual inspection of the air conditioning system to identify any damage excessive wear refrigerant leaks oil residue improper belt adjust ment improper pulley alignment and plugged condenser cooling fins Note Never use water to clean the condenser or radiator fins Using compressed air is the approved method Observe the refrigerant flow through the receiver dryer sight glass if equipped use the correct gauges to check all systems verify all system compo nents and controls are operable check for loose fittings replace defective worn or damaged drive belts and repair system leaks Note The use of the sight glass alone to determine system charge level can be misleading Normally operating and correctly charged variable displacement compressors and R 134a systems will have bubbles showing in the sight glass under certain conditions Discharging Caution Refrigerant R 12 has been identified as a compound which causes damage to the ozone layer It is unlawful to discharge R 12 into the atmosphere Subaru of America encourages you to handle R 12 in a responsible and safe manner and according to Federal EPA guidelines and any local and state regulations Always follow approved recovery recycling procedures and utilize approved recovery recycli
10. ng equipment Discharging and recovery of the system refrigerant is required before replacement of major components of the system It is also required when the system has a leak or for the replacement of refrigerant oil Discharging and recovery of the system refrigerant is the first step in preparing for major servicing repair or replacement of components the second step is evacuation Evacuating Evacuating the system removes air and moisture from the system Discharge and recover the system refrigerant first then follow the steps listed below to evacuate the system e Fully close both valves of the manifold gauge set e Connect a vacuum pump to the center charging hose of the manifold gauge set e Start the vacuum pump e Open the low and high pressure valves slowly e When the pressure reading has reached approximately 29 00 in Hg fully close both valves Evacuating The System e Stop the vacuum pump e Wait 10 minutes the pressure reading should not change Elevation Vacuum of System If it changes there is a leak in the system m ft mm Hg in Hg Note Certain types of system leaks such as loose fittings may not 0 0 WM 2795 be discovered using this method Always recheck the system with a leak detector after the system is charged 300 1 000 685 26 97 600 2 000 660 25 98 900 3 000 635 25 00 Note Values show readings of the low pressure gauge Elevation Pressure Relationship Subaru Ar Conditionin
11. o the unit used on Automatic Climate Control equipped vehicles Loyale Vacuum System Mode Control Legacy Impreza M ode Panel Only Loyale vehicles use a manually actuated vacuum operated system to control the position of the mode and circulation shutter actuators The vacuum system operates the air flow shutters in all Loyale vehicles Check vacuum to the shutter actuators if the defroster floor vents or fresh air vents do not operate properly The vacuum system also provides vacuum to the FICD diaphragm based upon FICD solenoid signal if so equipped XT Mode Control System In XT vehicles the electrical mode control system operates the various mode shutters and doors Electric motors control the operation of the air flow shutters in the XT The motors operate the shutter actuators through a gear drive and linkage assembly If the flow of air through the defroster floor vents or other vents is insufficient check operation of the shutter actuators and switches A C Cut System This system is installed on many 1987 and later model year automatic transaxle equipped Subaru vehicles The purpose of the A C cut system is to improve engine performance during full throttle acceleration Refer to the chart to determine component application for the various models listed M odel KTTO a n i Legacy SVX usty Impreza Note All sequential MFI equipped vehicles feature hey AIC cut systems A C Cut System Subaru Ar Con
12. oke e Stop engine e Wait ten 10 minutes retest System is undercharged e Clunking sound is normal while charging system Compressor is defective Control Valve Testing Variable Displacement Compressor Bring compressor to the minimum stroke position Open hood and windows Set engine speed to fast idle Set blower speed to low Set A C control to A C MAX 2 specifications test complete Higher than normal pressures indicate Restriction of air across condenser Defective cooling fan s Refrigerant overcharge Kestriction in system Air in system Moisture in system Number Date 15 42 87 15 44 87 02 70 89 02 72 89 10 49 88 10 50 89 10 51 89 10 52 89 10 53 89 10 55 90 10 56 90 05 18 87 05 26 87 08 24 89 05 07 86 08 04 88 05 29 89 05 29 89 07 28 89 10 18 89 01 29 90 01 29 90 Heater Gears 87 to 89 L Series amp XT Models Title Accessory A C Justy SOA332A105 Accessory AC SOA332A1 05 Idle Speed Adjustment Procedure for MT ECVT Idle Speed Adjustment Procedure for MT ECVT Fresh Circ Air Lever Not Holding Position Heater Gears 87 89 T Series Suction pressure should pe 25285 pa Note When inlet air temperature to evaporator is LOW the discharge pressure may appear to be excessively LOW and bubbles may be seen in sight glass This condition is normal
13. problem Operational check Check that the problem does exist Are components inoperable or malfunctioning Determine related symptoms Operational check Identify other symptoms that exist Are other circuits and components affected Do the related symptoms always occur with the primary symptom Isolate the problem Use the split half technique the wiring diagrams the troubleshooting trees appropriate model year service manuals and manufacturer s manuals to locate the problem Identify the cause of the problem Is a circuit grounded Proper vacuum not available Belt alignment and or tension improperly adjusted or is a component defective Repair and or replace Defective wiring vacuum lines and components as required Confirm proper adjustment of components as required Verify operation Check the system to verify that the problem has been solved Ensure that all system components operate properly under standard operating conditions according to technical specifications Also check related systems for proper operation Quick Touch Method An important step in troubleshooting air conditioning systems is to use the quick touch method Very briefly touch the components and tubing on the high side and the low side of the system High side components should feel warm or hot to touch while the low side components should feel cool to the touch Exercise caution when performing this procedure on high side of the system The tubin
14. rol valve IAC to adjust the idle speed to compensate for the increased compressor load No adjustment is required On all model year Loyale and XT MFI vehicles an FICD solenoid incorporated in the throttle body provides the increase in idle speed The throttle body includes an adjustment screw for adjusting the FICD specification All Legacy SVX and XT 6 vehicles use an idle air control valve to provide the FICD function The valve opens a port during A C operation which admits additional air into the induction system Impreza vehicles use a solenoid which initially compensates for the increased compressor load when the air conditioning system is switched ON The A C IAC then compensates to maintain engine speed at target RPM Note The Impreza FICD solenoid is set at the factory and should not require adjustment Any changes to the adjustment can affect driveability and vehicle emissions during cold engine operation Justy MFI vehicles increase idle speed by admitting additional air into the air collector assembly through the FICD solenoid which is opened by a signal from the MFI control unit Impreza FICD SUBARU Troubleshooting and Servicing Six Step Troubleshooting The following six step method of troubleshooting will save time and effort in the diagnosis and analysis of air conditioning problems It provides a logical approach to solving the problem not just treating the symptoms The steps are as follows O Verify the
15. rom The Heater Mode Door Actuator Air Conditioning Retrofit Procedures R 12 to R 134a
16. ves Refrigerant is colorless and odorless You must use a leak detector to locate a leak and determine the size of the problem Use of a halogen pump style electronic leak detector is recommended over other types of detectors Electronic leak detectors usually buzz or squeal in the presence of refrigerant Always follow the leak detector manufacturer s instruc tions for proper use It is Subaru policy to not use flame type detectors because harmful gasses may be emitted when using these types of detectors Oil Discharging and Refill Procedure Discharge the compressor oil when the quality of the refrigerant oil is unsatis factory or for repair of the compressor Turn the compressor upside down and pour the oil out of the compressor Most compressors drain oil from both the inlet and outlet ports The DIESEL KIKI variable dis placement compressor drains and fills oil through a drain plug hole located in the center of the case Always refer to the appropriate model year Subaru Service Manuals and the A C manufacturer s instructions Be sure to record the amount of oil discharged Note New compressors contain enough oil for a complete dry system When replacing a new compressor on an existing system the old compressor must be drained and the oil quantity measured Then drain the new compressor and measure the amount of oil Oil Discharging Refill the new compressor with the same quantity of oil as was removed from old compressor
17. year Subaru Service Manual Note Federal Law requires that all AIC service hoses be equipped with check valves at or near the service hose connections These check valves prevent refrigerant in the hoses from escaping to the atmosphere To disconnect the gauge set from service valves Quickly disconnect the charging hoses from the service valves Always disconnect the low side while the engine is running Disconnect the high side with the engine OFF and after the pressure has stabilized Manifold gauge interpretation takes some practice and must be completed with consideration of the other symptoms and potential problems that have been identified in the system Precautions Wear protective clothing and eyewear do not allow skin to come in direct contact with refrigerant Do not store or allow refrigerant containers to exceed 52 degrees C 126 degrees F Do not use refrigerant in confined spaces with poor ventilation Do not use R 12 refrigerant in the presence of an open flame Do not steam clean system Do not drop refrigerant containers or otherwise cause the container to rupture Follow proper procedure while connecting disconnecting hoses of manifold gauges vacuum pump oil separator and charging systems Open and close manifold gauge valves carefully Exercise caution while working around drive belts pulleys and other moving components of an operating air conditioning system Ensure the proper level and type of co
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