SUBARU LEGACY 1999 Service Repair Manual

11. Compressor
A: INSPECTION
1. COMPRESSOR CLUTCH
NOTE:
ICompressor is a swash plate type. When trouble
occurs, replace compressor as a single unit.
ICompressor clutch trouble is often caused by
clutch slippage and noise. Check and take correc-
tive measures, as required.
1) Remove belt cover.
B4M0090
2) Compressor clutch trouble is often caused by
clutch slippage and noise. Check and take correc-
tive measures, as required.
Clearance:
0.3 Ð 0.6 mm (0.012 Ð 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.
B: REMOVAL
1) Disconnect ground cable from battery.2) Discharge refrigerant using refrigerant recovery
system. <Ref. to 4-7 [W6A0].>
(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,
compressor oil will be discharged along with
refrigerant.
B4M0760A
3) Remove low-pressure hose (a) and high-pres-
sure hose (b).
CAUTION:
IBe careful not to lose O-ring of low-pressure
hose.
IPlug the opening to prevent foreign matter
from entering.
B4M0761D
24
4-7[W11A1]SERVICE PROCEDURE
11. Compressor

4) Remove compressor belt cover and alternator
belt cover:
Remove bolts which secure belt covers.
G4M0624
5) Remove alternator V-belt:
(1) Loosen lock bolt on alternator bracket.
(2) Turn adjusting bolt and remove V-belt.
G4M0625
6) Remove compressor V-belt:
(1) Loosen lock nut on idler pulley.
(2) Turn adjusting bolt and remove V-belt.
G4M0626
7) Disconnect alternator harness.
G4M0627
8) Disconnect compressor harness:
Disconnect compressor harness from body har-
ness.
9) Lower bracket:
Remove bolts which secure lower compressor
bracket.
G4M0628
10) Remove compressor:
(1) Remove bolt which secure compressor.
(2) Remove compressor from bracket.
G4M0629
C: INSTALLATION
1) Install compressor:
Install compressor on bracket.
G4M0630
2) Connect compressor harness.
3) Connect alternator harness.
4) Install compressor V-belt (Rear):
After adjusting belt tension, tighten tension pulley
lock nut securely.
25
[W11C0]4-7SERVICE PROCEDURE
11. Compressor

5) Install alternator V-belt:
After adjusting V-belt tension, tighten alternator
bracket lock bolt securely.
G4M0632
6) Check drive belt tension and adjust it if neces-
sary by changing alternator position and/or idler
pulley position.
CAUTION:
IEnsure that the V-belt is aligned correctly. If
it is not, check for loose bolts.
IThe 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.
IAfter completing the compressor installation
and testing the system operation, check and
adjust the tension of both V-belts again.
G4M0634
B4M1098A
26
4-7[W11C0]SERVICE PROCEDURE
11. Compressor

7) Install high-pressure hose (b).
Connect high-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periph-
ery of O-ring.
B4M0761D
8) Install low-pressure hose (a).
Connect low-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periph-
ery of O-ring.
B4M0761D
9) Install belt cover.
10) Connect ground cable to negative terminal of
battery.
11) Charge refrigerant. <Ref. to 4-7 [W7H0].>
12. Condenser
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery
system. <Ref. to 4-7 [W6A0].>
3) Remove front grille.
B4M0095
4) Remove canister from bracket.
CAUTION:
IDo not disconnect hose from canister.
IInsert air vent hose of canister into the hole
on body.
G2M0375
5) Remove the radiator upper bracket of both side.
6) Disconnect high-pressure hose (a) and high-
pressure pipe (b) from condenser.
B4M0096C
27
[W12A0]4-7SERVICE PROCEDURE
12. Condenser

7) Install high-pressure hose (b).
Connect high-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periph-
ery of O-ring.
B4M0761D
8) Install low-pressure hose (a).
Connect low-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periph-
ery of O-ring.
B4M0761D
9) Install belt cover.
10) Connect ground cable to negative terminal of
battery.
11) Charge refrigerant. <Ref. to 4-7 [W7H0].>
12. Condenser
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery
system. <Ref. to 4-7 [W6A0].>
3) Remove front grille.
B4M0095
4) Remove canister from bracket.
CAUTION:
IDo not disconnect hose from canister.
IInsert air vent hose of canister into the hole
on body.
G2M0375
5) Remove the radiator upper bracket of both side.
6) Disconnect high-pressure hose (a) and high-
pressure pipe (b) from condenser.
B4M0096C
27
[W12A0]4-7SERVICE PROCEDURE
12. Condenser

7) Remove the two bolts which secure condenser.
While lifting condenser, remove it through space
between radiator and radiator panel.
B4M0097
8) The condenser should be installed in the
reverse order in which it was removed. When
installing the condenser, pay attention to the fol-
lowing:
CAUTION:
Before connecting the pipe, be sure to apply oil
to the periphery of O-ring.
NOTE:
After installing condenser, ensure that guide on
lower side of condenser is inserted into hole in
radiator panel. Tighten attaching bolts.
B4M0098A
9) Charge refrigerant. <Ref. to 4-7 [W7H0].>
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 con-
denser is installed in an actual vehicle.
2) Check the condenser to see if it shows any sign
of oil. If oil ooze or gas leak occur from the
condenser, replace it with a new one.
13. Receiver Drier
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery
system. <Ref. to 4-7 [W6A0].>
3) Disconnect pressure switch harness (a).
4) Disconnect pipes (b).
5) Remove mounting bolt (c) and 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.
B4M1083B
6) Install the receiver drier in the reverse order of
removal.
7) Charge refrigerant. <Ref. to 4-7 [W7H0].>
28
4-7[W12B0]SERVICE PROCEDURE
13. Receiver Drier

7) Remove the two bolts which secure condenser.
While lifting condenser, remove it through space
between radiator and radiator panel.
B4M0097
8) The condenser should be installed in the
reverse order in which it was removed. When
installing the condenser, pay attention to the fol-
lowing:
CAUTION:
Before connecting the pipe, be sure to apply oil
to the periphery of O-ring.
NOTE:
After installing condenser, ensure that guide on
lower side of condenser is inserted into hole in
radiator panel. Tighten attaching bolts.
B4M0098A
9) Charge refrigerant. <Ref. to 4-7 [W7H0].>
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 con-
denser is installed in an actual vehicle.
2) Check the condenser to see if it shows any sign
of oil. If oil ooze or gas leak occur from the
condenser, replace it with a new one.
13. Receiver Drier
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery
system. <Ref. to 4-7 [W6A0].>
3) Disconnect pressure switch harness (a).
4) Disconnect pipes (b).
5) Remove mounting bolt (c) and 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.
B4M1083B
6) Install the receiver drier in the reverse order of
removal.
7) Charge refrigerant. <Ref. to 4-7 [W7H0].>
28
4-7[W12B0]SERVICE PROCEDURE
13. Receiver Drier

14. Evaporator Unit
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery
system. <Ref. to 4-7 [W6A0].>
3) Disconnect discharge pipe, suction pipe and
grommets
G4M0641
4) Remove glove box and pocket back panel.
<Ref. to 5-4 [W1A0].>
B5M0025
5) Disconnect the harness connector from evapo-
rator.
6) Disconnect drain hose.
7) Remove evaporator mounting bolt and nut.
G4M0642
8) Install the evaporator in the reverse order of
removal.
9) Charge refrigerant. <Ref. to 4-7 [W7H0].>
B: DISASSEMBLY AND ASSEMBLY
1) Remove resistor assembly and remove six
screws from evaporator case.
B4M0099B
(1) Resistor ASSY
2) Remove thermostat (a) from upper case. (Ther-
mistor (b) is inserted into specified evaporator fin
position.) When installing thermostat, be sure to
insert thermistor into specified fin position.
B4M0100C
3) Disconnect the connection between the expan-
sion valve and pipe from receiver drier.
4) Remove the expansion valve from pipes.
B4M0101A
5) To install expansion valve, reverse removal pro-
cedures. 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 evapo-
rator.
29
[W14B0]4-7SERVICE PROCEDURE
14. Evaporator Unit

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 disassembly.
NOTE:
Confirm that the O-ring is inserted in the specified
position.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)
B4M0102A
30
4-7[W15A0]SERVICE PROCEDURE
15. Condenser Fan Assembly

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 disassembly.
NOTE:
Confirm that the O-ring is inserted in the specified
position.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)
B4M0102A
30
4-7[W15A0]SERVICE PROCEDURE
15. Condenser Fan Assembly