Subaru 2004 LEGACY Manuel utilisateur

FUJI HEAVY INDUSTRIES LTD. G2320GE7

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

BODY SECTION

This service manual has been prepared

to provide SUBARU service personnel

with the necessary information and data

for the correct maintenance and repair

of SUBARU vehicles.

This manual includes the procedures

for maintenance, disassembling, reas-

sembling, inspection and adjustment of

components and diagnostics for guid-

ance of experienced mechanics.

Please peruse and utilize this manual

fully to ensure complete repair work for

satisfying our customers by keeping

their vehicle in optimum condition.

When replacement of parts during

repair work is needed, be sure to use

SUBARU genuine parts.

All information, illustration and specifi-

cations contained in this manual are

based on the latest product information

available at the time of publication

approval.

HVAC SYSTEM

(HEATER, VENTILATOR AND A/C) AC

HVAC SYSTEM (AUTO A/C)

(DIAGNOSTICS) AC(diag)

AIRBAG SYSTEM AB

AIRBAG SYSTEM (DIAGNOSTICS) AB(diag)

SEAT BELT SYSTEM SB

LIGHTING SYSTEM LI

WIPER AND WASHER SYSTEMS WW

ENTERTAINMENT ET

COMMUNICATION SYSTEM COM

GLASS/WINDOWS/MIRRORS GW

BODY STRUCTURE BS

INSTRUMENTATION/DRIVER INFO IDI

SEATS SE

SECURITY AND LOCKS SL

SUNROOF/T-TOP/CONVERTIBLE TOP

(SUNROOF) SR

EXTERIOR/INTERIOR TRIM EI

EXTERIOR BODY PANELS EB

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

BODY SECTION

G2320GE7

CRUISE CONTROL SYSTEM CC

CRUISE CONTROL SYSTEM

(DIAGNOSTICS) CC(diag)

IMMOBILIZER (DIAGNOSTICS) IM(diag)

LAN SYSTEM (DIAGNOSTICS) LAN(diag)

HVAC SYSTEM

(HEATER, VENTILATOR AND A/C)

Page

1. General Description ....................................................................................2

2. Refrigerant Pressure with Manifold Gauge Set.........................................19

3. Refrigerant Recovery Procedure...............................................................20

4. Refrigerant Charging Procedure ...............................................................21

5. Refrigerant Leak Check ............................................................................24

6. Compressor Oil .........................................................................................25

7. Blower Motor Unit Assembly .....................................................................26

8. Blower Motor .............................................................................................27

9. Power Transistor (Auto A/C Model) ..........................................................28

10. Blower Resistor (Manual A/C Model) ........................................................29

11. Heater Core...............................................................................................30

12. Control Unit (Manual A/C Model) ..............................................................31

13. Control Unit (Auto A/C Model)...................................................................32

14. Compressor...............................................................................................33

15. Condenser.................................................................................................35

16. Heater and Cooling Unit............................................................................36

17. Evaporator.................................................................................................37

18. Hose and Tube..........................................................................................38

19. Relay and Fuse .........................................................................................39

20. Pressure Switch (Triple Pressure Switch).................................................40

21. Ambient Sensor (Auto A/C Model) ............................................................41

22. Sunload Sensor (Auto A/C Model) ............................................................42

23. In-Vehicle Sensor (Auto A/C Model) .........................................................43

24. Air Vent Grille ............................................................................................44

25. Heater Duct ...............................................................................................45

26. Heater Vent Duct.......................................................................................46

27. Heater Cock Solenoid Valve .....................................................................47

28. General Diagnostic Table..........................................................................48

AC-2

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

General Description

1. General Description

A: SPECIFICATION

1. HEATER SYSTEM

2. A/C SYSTEM

• Auto A/C model

Item Specification On condition

Heating capacity 5.2 kW (4,471 kcal/h,

17,743 BTU/h) or more

• Mode selector switch: HEAT

• Temperature control switch: FULL HOT

• Temperature difference between hot water

and inlet air: 65!C (149!F)

• Hot water flow rate: 360 2(95.1 US gal,

79.2 Imp gal)/h

Air flow rate 370 m3(13,066 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V

Max air flow rate 460 m3(16,245 cu ft)/h

• Temperature control switch: FULL COLD

• Blower fan speed:

Auto A/C: 6th position

Manual A/C: 4th position

• Mode selector lever: RECIRC

Heater core size

(height "length "width)

264 "110 "27 mm

(10.4 "4.33 "1.06 in) —

Blower motor

Type Magnet motor 220 W or less 12 V

Fan type and size

(diameter "width)

Sirocco fan type

150 "75 mm (5.91 "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 (CH2FCF3)

[0.4#0.03 kg (0.88#0.07 lb)]

Compressor

Type Scroll, constant volume (SCSA 08C)

Discharge 74.5 cc (4.55 cu in)/rev

Max. permissible speed 9,000 rpm

Magnet clutch

Type Dry, single-disc type

Power consumption 35 W

Type of belt H4 model: V-belt 4 PK

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 0.186 m2(2.002 sq ft)

Core thickness 16 mm (0.63 in)

Radiation area 5.49 m2(59.09 sq ft)

Receiver drier Effective inner capacity 190 cm3(11.6 cu in)

Expansion valve Type Internal equalizing

Evaporator

Type Single tank

Dimensions (W "H "T) 298.6 "151 "38 mm

(11.76 "5.94 "1.50 in)

Blower fan

Fan type Sirocco fan

Outer diameter "width 150 "75 mm (5.91 "2.95 in)

Power consumption 220 W

AC-3

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

General Description

• Manual A/C model

Condenser fan (Sub fan)

Motor type Magnet

Power consumption H4 model: 90 W

H6 model: 160 W

Fan outer diameter H4 model: 300 mm (11.8 in)

H6 model: 320 mm (12.6 in)

Radiator fan (Main fan)

Motor type Magnet

Power consumption H4 model: 90 W

H6 model: 160 W

Fan outer diameter H4 model: 300 mm (11.8 in)

H6 model: 320 mm (12.6 in)

Idling speed (A/C ON) MPFI model 800#100 rpm

Triple switch

(Pressure switch)

Low-pressure switch

operating pressure

ON $OFF 196#20 kPa

(2.00#0.20 kg/cm2, 28.4#2.9 psi)

OFF $ON 225+25%29 kPa

(2.29+0.25%0.30 kg/cm2, 32.6+3.6%4.2 psi)

High-pressure switch

operating pressure

ON $OFF 3,140+50%200 kPa

(32.02+0.51%2.04 kg/cm2, 455.4+7.25%29.0 psi)

OFF $ON 2,550#200 kPa

(26.00#2.04 kg/cm2, 369.8#29.0 psi)

Middle-pressure switch

operating pressure

ON $OFF 1,370#120 kPa

(13.97#1.22 kg/cm2, 198.65#17.35 psi)

OFF $ON 1,770#100 kPa

(18.05#1.02 kg/cm2, 256.81#14.50 psi)

Thermo-control amplifier working temperature

(Evaporator outlet air)

(1) ON

(2) OFF

(3) 1#0.5!C (33.8#0.9!F)

(4) 4+1.50!C (39.2+2.70!F)

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 (CH2FCF3)

[0.4#0.03 kg (0.88#0.07 lb)]

Compressor

Type Scroll, constant volume (SCSA 08C)

Discharge 74.5 cc (4.55 cu in)/rev

Max. permissible speed 9,000 rpm

Magnet clutch

Type Dry, single-disc type

Power consumption 35 W

Type of belt V-belt 4 PK

Pulley dia. (effective dia.) 93 mm (3.7 in)

Pulley ratio 1.43

AC-0060

(1)

(2)

(3)

(4)

AC-4

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

General Description

Condenser

Type Corrugated fin (Sub cool type)

Core face area 0.186 m2(2.002 sq ft)

Core thickness 16 mm (0.63 in)

Radiation area 5.49 m2(59.09 sq ft)

Receiver drier Effective inner capacity 250 cm3(15.26 cu in)

Expansion valve Type Externally equalizing

Evaporator

Type Single tank

Dimensions (W "H "T) 298.6 "151 "38 mm

(11.7 "5.94 "1.50 in)

Blower fan

Fan type Sirocco fan

Outer diameter "width 150 "75 mm (5.91 "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)

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

Triple switch

(Pressure switch)

Low-pressure switch

operating pressure

ON $OFF 196#20 kPa

(2.00#0.20 kg/cm2, 28.4#2.9 psi)

OFF $ON 225+25%29 kPa

(2.29+0.25%0.30 kg/cm2, 32.6+3.6%4.2 psi)

High-pressure switch

operating pressure

ON $OFF 3,140+50%200 kPa

(32.02+0.51%2.04 kg/cm2, 455.4+7.25%29.0 psi)

OFF $ON 2,550#200 kPa

(26.00#2.04 kg/cm2, 369.8#29.0 psi)

Middle-pressure switch

operating pressure

ON $OFF 1,370#120 kPa

(13.97#1.22 kg/cm2, 198.65#17.35 psi)

OFF $ON 1,770#100 kPa

(18.05#1.02 kg/cm2, 256.81#14.50 psi)

Thermo control amplifier working temperature

(Evaporator outlet air)

(1) ON

(2) OFF

(3) 1#0.5!C (33.8#0.9!F)

(4) 4+1.50!C (39.2+2.70!F)

AC-0060

(1)

(2)

(3)

(4)

AC-5

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

General Description

B: COMPONENT

1. HEATER COOLING UNIT

• Auto A/C model

(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-00906

(16)

(13)

(17)

(15)

(10)

(9)

(11)

(12)

(14)

(8)

(7)

(4)

(5)

(3)

(2)

(1)

(6)

AC-6

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

General Description

• Manual A/C model

(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-lb)

(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-00907

(4)

(5)

(6)

(11)

(12)

(13)

(16)

(15)

(10)

(9)

(14)

(8)

(7)

(3)

(2)

(1)

AC-7

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

General Description

2. BLOWER MOTOR UNIT

(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

model)

(4) Filter cover

(5) Blower motor ASSY

(1)

(2)

(7)

(5)

(3)

(4)

(6)

AC-00908

AC-8

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

General Description

3. CONTROL PANEL

• Auto A/C model

(A) For integrated audio (B) For Mclntosh audio

(1) Temperature control dial (3) Board (4) Heater control base

(2) Control panel assembly

AC-00909

(1)

(2)

(1)

(2)

(3)

(4)

(A) (B)

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