Subaru Legacy 04 SERVICE MANUAL.pdf

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2004 LEGACY SERVICE MANUAL
BODY SECTION
QUICK REFERENCE INDEX
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTICS)
AIRBAG SYSTEM
AIRBAG SYSTEM (DIAGNOSTICS)
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.
SEAT BELT SYSTEM
LIGHTING SYSTEM
WIPER AND WASHER SYSTEMS
ENTERTAINMENT
COMMUNICATION SYSTEM
GLASS/WINDOWS/MIRRORS
BODY STRUCTURE
INSTRUMENTATION/DRIVER INFO
SEATS
SECURITY AND LOCKS
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
EXTERIOR/INTERIOR TRIM
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
AC
AC(diag)
AB
AB(diag)
SB
LI
WW
ET
COM
GW
BS
IDI
SE
SL
SR
EI
EB
EXTERIOR BODY PANELS
G2320GE7
2003 LEGACY SERVICE MANUAL
BODY SECTION
QUICK REFERENCE INDEX
CRUISE CONTROL SYSTEM
CRUISE CONTROL SYSTEM
(DIAGNOSTICS)
IMMOBILIZER (DIAGNOSTICS)
LAN SYSTEM (DIAGNOSTICS)
CC
CC(diag)
IM(diag)
LAN(diag)
G2320GE7
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
AC
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Page
General Description ....................................................................................2
Refrigerant Pressure with Manifold Gauge Set.........................................19
Refrigerant Recovery Procedure...............................................................20
Refrigerant Charging Procedure ...............................................................21
Refrigerant Leak Check ............................................................................24
Compressor Oil .........................................................................................25
Blower Motor Unit Assembly .....................................................................26
Blower Motor .............................................................................................27
Power Transistor (Auto A/C Model) ..........................................................28
Blower Resistor (Manual A/C Model) ........................................................29
Heater Core...............................................................................................30
Control Unit (Manual A/C Model) ..............................................................31
Control Unit (Auto A/C Model)...................................................................32
Compressor...............................................................................................33
Condenser.................................................................................................35
Heater and Cooling Unit............................................................................36
Evaporator.................................................................................................37
Hose and Tube..........................................................................................38
Relay and Fuse .........................................................................................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 Grille ............................................................................................44
Heater Duct ...............................................................................................45
Heater Vent Duct.......................................................................................46
Heater Cock Solenoid Valve .....................................................................47
General Diagnostic Table..........................................................................48
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
1. General Description
A: SPECIFICATION
1. HEATER SYSTEM
Item
Specification
On condition
• 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
Heat mode (FRESH), FULL HOT at 12.5 V
• Temperature control switch: FULL COLD
• Blower fan speed:
Auto A/C: 6th position
Manual A/C: 4th position
• Mode selector lever: RECIRC
—
12 V
—
Heating capacity
5.2 kW (4,471 kcal/h,
17,743 BTU/h) or more
Air flow rate
370 m
3
(13,066 cu ft)/h
Max air flow rate
460 m
3
(16,245 cu ft)/h
Heater core size
(height
"
length
"
width)
Type
Blower motor
Fan type and size
(diameter
"
width)
264
"
110
"
27 mm
(10.4
"
4.33
"
1.06 in)
Magnet motor 220 W or less
Sirocco fan type
150
"
75 mm (5.91
"
2.95 in)
2. A/C SYSTEM
• Auto A/C model
Item
Type of air conditioner
Cooling capacity
Refrigerant
Type
Discharge
Max. permissible speed
Type
Power consumption
Type of belt
Pulley dia. (effective dia.)
Pulley ratio
Type
Condenser
Core face area
Core thickness
Radiation area
Receiver drier
Expansion valve
Evaporator
Effective inner capacity
Type
Type
Dimensions (W
"
H
"
T)
Fan type
Outer diameter
"
width
Power consumption
Specification
Reheat air-mix type
5.3 kW
(4,557 kcal/h, 18,084 BTU/h)
HFC-134a (CH
2
FCF
3
)
[0.4#0.03 kg (0.88#0.07 lb)]
Scroll, constant volume (SCSA 08C)
74.5 cc (4.55 cu in)/rev
9,000 rpm
Dry, single-disc type
35 W
H4 model: V-belt 4 PK
H6 model: V-belt 6 PK
93 mm (3.7 in)
1.43
Corrugated fin (Sub cool type)
0.186 m
2
(2.002 sq ft)
16 mm (0.63 in)
5.49 m
2
(59.09 sq ft)
190 cm
3
(11.6 cu in)
Internal equalizing
Single tank
298.6
"
151
"
38 mm
(11.76
"
5.94
"
1.50 in)
Sirocco fan
150
"
75 mm (5.91
"
2.95 in)
220 W
Compressor
Magnet clutch
Blower fan
AC-2
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Motor type
Condenser fan (Sub fan)
Power consumption
Fan outer diameter
Motor type
Radiator fan (Main fan)
Power consumption
Fan outer diameter
Idling speed (A/C ON)
Low-pressure switch
operating pressure
MPFI model
ON
$
OFF
OFF
$
ON
ON
$
OFF
OFF
$
ON
ON
$
OFF
OFF
$
ON
Magnet
H4 model: 90 W
H6 model: 160 W
H4 model: 300 mm (11.8 in)
H6 model: 320 mm (12.6 in)
Magnet
H4 model: 90 W
H6 model: 160 W
H4 model: 300 mm (11.8 in)
H6 model: 320 mm (12.6 in)
800#100 rpm
196#20 kPa
(2.00#0.20 kg/cm
2
, 28.4#2.9 psi)
225
+25
%29
kPa
(2.29
+0.25
%0.30
kg/cm
2
, 32.6
+3.6
%4.2
psi)
3,140
+50
%200
kPa
(32.02
+0.51
%2.04
kg/cm
2
, 455.4
+7.25
%29.0
psi)
2,550#200 kPa
(26.00#2.04 kg/cm
2
, 369.8#29.0 psi)
1,370#120 kPa
(13.97#1.22 kg/cm
2
, 198.65#17.35 psi)
1,770#100 kPa
(18.05#1.02 kg/cm
2
, 256.81#14.50 psi)
Triple switch
High-pressure switch
(Pressure switch) operating pressure
Middle-pressure switch
operating pressure
(3)
(1)
Thermo-control amplifier working temperature
(Evaporator outlet air)
(2)
(4)
AC-00601
(1) ON
(2) OFF
(3) 1#0.5!C (33.8#0.9!F)
(4) 4
+1.50
!C
(39.2
+2.70
!F)
• Manual A/C model
Item
Type of air conditioner
Cooling capacity
Refrigerant
Type
Discharge
Max. permissible speed
Type
Power consumption
Type of belt
Pulley dia. (effective dia.)
Pulley ratio
Specification
Reheat air-mix type
5.3 kW (4,557 kcal/h, 18,084 BTU/h)
HFC-134a (CH
2
FCF
3
)
[0.4#0.03 kg (0.88#0.07 lb)]
Scroll, constant volume (SCSA 08C)
74.5 cc (4.55 cu in)/rev
9,000 rpm
Dry, single-disc type
35 W
V-belt 4 PK
93 mm (3.7 in)
1.43
Compressor
Magnet clutch
AC-3

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