SUBARU LEGACY 1995 Service Repair Manual

11. Compressor
Compressor is a swash plate type. When trouble occurs,
replace compressor as a single unit.
B4M0090
A: COMPRESSOR CLUTCH INSPECTION
Compressor clutch trouble is often caused by clutch slip-
page and noise. Check and take corrective measures, as
required.
1) Remove belt cover.
2) Check that clearance between drive plate and pulley
over the entire perimeter is within specifications.
Clearance:
0.3 — 0.6 mm (0.012 — 0.024 in)
B4M0091
3) Check that voltage applied to magnetic coil is at least
10.5 volts.
4) When noise is noted, check that it originates in either
compressor or pulley bearing.
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4-7SERVICE PROCEDURE
11. Compressor

B4M0092A
B: REMOVAL
1) Disconnect ground cable from battery.
2) Discharge refrigerant using refrigerant recovery system.
<Ref. to 4-7 [W601].>
(1) Fully close low-pressure valve of manifold gauge.
(2) Connect low-pressure charging hose of manifold
gauge to low-pressure service valve.
(3) Open low-pressure manifold gauge valve slightly,
and slowly discharge refrigerant from system.
CAUTION:
Do not allow refrigerant to rush out. Otherwise, com-
pressor oil will be discharged along with refrigerant.
B4M0093A
3) Remove low-pressure hose
1(Flexible hose Ps) and
high-pressure hose

2(Flexible hose Pd).
CAUTION:
Be careful not to lose O-ring of low-pressure hose.
Plug the opening to prevent foreign matter from
entering.
G4M0624
4) Remove compressor belt cover and alternator belt
cover.
Remove bolts which secure belt covers.
G4M0625
5) Remove alternator V-belt.
Loosen lock bolt on alternator bracket. Turn adjusting bolt
and remove V-belt.
32
4-7SERVICE PROCEDURE
11. Compressor

G4M0626
6) Remove compressor V-belt.
Loosen lock nut on idler pulley. Turn adjusting bolt and
remove V-belt.
G4M0627
7) Disconnect alternator harness.
G4M0628
8) Disconnect compressor harness.
Disconnect compressor harness from body harness.
9) Lower bracket.
Remove bolts which secure lower compressor bracket.
G4M0629
10) Remove compressor.
Remove bolt which secure compressor. Remove compres-
sor from bracket.
G4M0630
C: INSTALLATION
1) Install compressor.
Install compressor on bracket.
33
4-7SERVICE PROCEDURE
11. Compressor

2) Connect compressor harness.
3) Connect alternator harness.
4) Install compressor V-belt (Rear).
After adjusting belt tension, tighten tension pulley lock nut
securely.
G4M0632
5) Install alternator V-belt.
After adjusting V-belt tension, tighten alternator bracket
lock bolt securely.
6) Check drive belt tension and adjust it if necessary by
changing alternator position and/or idler pulley position.
Pulley arrangement Tension mm (in)/98N (10 kg, 22 lb)
G4M0939
AB
*New belt:
7.0—9.0
(0.276—0.354)
Existing belt:
9.0—11.0
(0.354—0.433)*New belt:
7.5—8.5
(0.295—0.335)
Existing belt:
9.0—10.0
(0.354—0.394)
* When replacing belts with new ones, adjust tensions to
specification and then readjust to the same specification
after running engine for 5 minutes.
Figures in table refer to the number of grooves in pulleys.
C/P : Crankshaft pulley
ALT : Alternator pulley
P/S : Power steering oil pump pulley
A/C : Air conditioner compressor pulley
I/P : Idler pulley
34
4-7SERVICE PROCEDURE
11. Compressor

G4M0634
CAUTION:
Ensure that the V-belt is aligned correctly. If it is not,
check for loose bolts.
The V-belt should not be too tight or too loose.
A belt which is too tight may break bearing or cause
gas to leak from the shaft seal. A belt which is too
loose slips, thereby causing the belt cut.
After completing the compressor installation and
testing the system operation, check and adjust the ten-
sion of both V-belts again.
G4M0635
7) Install high-pressure hose (Flexible hose Pd).
Connect high-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periphery of
O-ring.
B4M0094A
8) Install low-pressure hose
1(Flexible hose Ps).
Connect low-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periphery of
O-ring.
9) Install belt cover.
10) Connect ground cable to negative terminal of battery.
11) Charge refrigerant. <Ref. to 4-7 [W708].>
35
4-7SERVICE PROCEDURE
11. Compressor

B4M0095
12. Condenser
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery system.
<Ref. to 4-7 [W601].>
3) Remove front grille.
G2M0375
4) Remove canister from bracket.
CAUTION:
Do not disconnect hose from canister.
Insert air vent hose of canister into the hole on body.
B4M0096A
5) Remove the radiator upper bracket of both side.
6) Disconnect high-pressure hose

1and high-pressure
pipe

2from condenser.
B4M0097
7) Remove the two bolts which secure condenser. While
lifting condenser, remove it through space between radia-
tor and radiator panel.
B4M0098A
8) The condenser should be installed in the reverse order
in which it was removed.
When installing the condenser, pay attention to the follow-
ing:
CAUTION:
Before connecting the pipe, be sure to apply oil to the
periphery of O-ring.
36
4-7SERVICE PROCEDURE
12. Condenser

NOTE:
After installing condenser, ensure that guide on lower side
of condenser is inserted into hole in radiator panel. Tighten
attaching bolts.
9) Charge refrigerant. <Ref. to 4-7 [W708].>
B: INSPECTION
1) Make sure the condenser fins are free from dust and
insects. If the fins are clogged, clean by blowing air or
water through them.
NOTE:
To prevent dust and water from getting into the condenser,
this work must be done when the condenser is installed in
an actual vehicle.
2) Check the condenser to see if it shows any sign of oil.
Should oil ooze or gas leak from the condenser replace it
with a new one.
G4M0640
13. Receiver Drier
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery system.
<Ref. to 4-7 [W601].>
3) Disconnect pressure switch harness

1.
4) Disconnect pipes

2.
5) Remove mounting bolt

3and remove receiver drier.
CAUTION:
The receiver drier contains a desiccant. Be sure to put
a blind plug in the detached receiver drier to protect it
from moisture.
6) Install the receiver drier in the reverse order of removal.
7) Charge refrigerant. <Ref. to 4-7 [W708].>
37
4-7SERVICE PROCEDURE
12. Condenser - 13. Receiver Drier

NOTE:
After installing condenser, ensure that guide on lower side
of condenser is inserted into hole in radiator panel. Tighten
attaching bolts.
9) Charge refrigerant. <Ref. to 4-7 [W708].>
B: INSPECTION
1) Make sure the condenser fins are free from dust and
insects. If the fins are clogged, clean by blowing air or
water through them.
NOTE:
To prevent dust and water from getting into the condenser,
this work must be done when the condenser is installed in
an actual vehicle.
2) Check the condenser to see if it shows any sign of oil.
Should oil ooze or gas leak from the condenser replace it
with a new one.
G4M0640
13. Receiver Drier
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery system.
<Ref. to 4-7 [W601].>
3) Disconnect pressure switch harness

1.
4) Disconnect pipes

2.
5) Remove mounting bolt

3and remove receiver drier.
CAUTION:
The receiver drier contains a desiccant. Be sure to put
a blind plug in the detached receiver drier to protect it
from moisture.
6) Install the receiver drier in the reverse order of removal.
7) Charge refrigerant. <Ref. to 4-7 [W708].>
37
4-7SERVICE PROCEDURE
12. Condenser - 13. Receiver Drier

G4M0641
14. Evaporator Module
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery system.
<Ref. to 4-7 [W601].>
3) Disconnect discharge pipe, suction pipe and grommets.
B5M0025
4) Remove glove box and pocket back panel. <Ref. to 5-4
[W1A0].>
G4M0642
5) Disconnect the harness connector from evaporator.
6) Disconnect drain hose.
7) Remove evaporator mounting bolt and nut.
8) Install the evaporator in the reverse order of removal.
9) Charge refrigerant. <Ref. to 4-7 [W708].>
B4M0099A
B: DISASSEMBLY AND ASSEMBLY
1) Remove resistor assembly
1and remove six screws
from evaporator case.
B4M0100A
2) Remove thermostat
1from upper case. (Thermistor
2
is inserted into specified evaporator fin position.) When
installing thermostat, be sure to insert thermistor into speci-
fied fin position.
38
4-7SERVICE PROCEDURE
14. Evaporator Module

B4M0101A
3) Disconnect the connection between the expansion
valve and pipe from receiver drier.
4) Remove the expansion valve from pipes.
5) To install expansion valve, reverse removal procedures.
Properly wrap capillary tube of expansion valve with seal.
6) Check to see if the evaporator fins are clogged. If they
are, clean them with compressed air.
CAUTION:
Water must never be used to clean the evaporator.
7) Check parts that have been removed for cracks or
scratches, and repair or replace them with new ones, if
necessary.
8) Reassemble the evaporator in the reverse order of dis-
assembly.
NOTE:
Confirm that the O-ring is inserted in the specified position.
B4M0102A
15. Condenser Fan Assembly
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Disconnect harness connector from fan motor.
3) Remove condenser fan bolt from radiator.
4) Pull condenser fan assembly.
5) Install the condenser fan assembly in the reverse order
of removal.
Tightening torque:
T: 7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
39
4-7SERVICE PROCEDURE
14.Evaporator - 15. Condenser Fan Assembly