key SUBARU LEGACY 1995 Service Owner's Manual

G4M0615
5. LEAK TEST—LOW-PRESSURE SIDE
1) Begin at the connection of the low-pressure tube to the
evaporator, and work your way along the low-pressure of
the system to the compressor. There are three places to
check on each tube connection.
2) Check the area.
(1) Check the area where the fitting joins the tube.
(2) Check the area where the two parts of the fitting
join each other.
G4M0616
(3) Check the area where the nut joins the tube.
G4M0617
6. CHECK THE FLEXIBLE HOSES
Visually inspect the rubber portions of the flexible hoses for
cracking. Probe the rubber section, including the ends of
any insulators or protectors which may cover sections of
the rubber hose, and near the ends where the rubber
meets the metal collar.
NOTE:
Be certain to move the probe slowly [approximately 25 mm
(1 in) per second] when probing along any length of hose
or tube.
G4M0618
7. CHECK THE EVAPORATOR ASSEMBLY
1) Use one or both of the following methods to check the
evaporator assembly.
2) Remove the drain hose from the case drain nipple. Hold
the probe at the end of the case drain nipple for at least 10
seconds. Be certain to reconnect the drain hose when fin-
ished.
3) With the ignition key in the“ACC”position, run the
blower on high speed for 1 minute, then turn the blower off.
Place the probe in the center instrument panel vent, an turn
the blower on low speed for 1 to 2 seconds, then turn the
blower off. Leave the probe in the vent for at least 10 sec-
onds.
25
4-7SERVICE PROCEDURE
8. Leak Testing

A
Position fan switch between 1 and 4; Does con-
tinuity exist between fan switch vehicle side
connector (G/B) and ground?
Ye s
No
Faulty fan switch
Turn key switch ON.
Position fan switch between 1 and 4.
Turn A/C switch ON; Does 0 volt exist between
A/C vehicle side connector (G/W) and ground?
Ye s
No
Faulty A/C switch or harness
Turn A/C switch OFF; Does 12 volts exist
between A/C switch vehicle side connector
(G/W) and ground?
Ye s
No
Faulty harness
Start engine.
Turn A/C switch ON; Does 0 volt exist between
evaporator thermostat vehicle side connector
(BR/Y) and ground?
Ye s
No
Faulty evaporator thermostat
Turn A/C switch OFF; Does 12 volts exist
between evaporator thermostat vehicle side
connector (BR/Y) and ground?
Ye s
No
Faulty evaporator thermostat
ECM is faulty.






50
4-7DIAGNOSTICS
5. Compressor Clutch Diagnosis

G5M0144
2. Trunk Lid
A: REMOVAL
1. TRUNK LID
1) Open trunk lid.
2) Remove trunk lid mounting bolts and detach trunk lid
from hinges.
G5M0145
2. TORSION BAR
1) Open trunk lid. Remove torsion bars from hinge links
using ST.
ST 927780000 REMOVER
CAUTION:
Be careful because torsion bar quickly swings back
when released.
2) Remove the left and right torsion bars.
WARNING:
Be careful because trunk lid drops under its own
weight when torsion bars are removed.
G5M0146
3. TRUNK LID LOCK ASSEMBLY AND KEY
CYLINDER
1) Remove rod of lock assembly from rod holder of key
lock assembly.
2) Remove nuts which hold lock assembly and remove
lock assembly.
NOTE:

Always remove rear skirt trim panel beforehand, if so
equipped.

Be careful not to bend opener cable.
B5M0269A
3) Remove rod holder and detach key cylinder from trunk
lid.
33
5-1SERVICE PROCEDURE
2. Trunk Lid

5. Rear Gate and Glass
B5M0056A

1Rear gate


2Key cylinder


3Outer handle


4Door lock actuator


5Striker


6Latch


7Glass pin

8Glass


9Buffer


10Stopper


11Gas stay


12Hinge


13Rear gate handle
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 4.4±1.5 (0.45±0.15, 3.3±1.1)
T2: 7.4±2.0 (0.75±0.2, 5.4±1.4)
T3: 13±3 (1.3±0.3, 9.4±2.2)
T4: 14±4 (1.4±0.4, 10.1±2.9)
T5: 25±5 (2.5±0.5, 18.1±3.6)
7
5-2COMPONENT PARTS
5. Rear Gate and Glass

1. Procedure Chart for Removing and
Installing Door and Related Parts
NOTE:
This flow chart shows the main procedures for removing
and installing the door and its related parts. For details,
refer to the text.
DoorDoor lock systemDoor regulator

Door glass

Remove door trim parts, etc.

REMOVALRemove front and rear upper stoppers
and stabilizer (inner).

Remove door.Disconnect joints
between latch, outer
handle, key lock and
remote assembly.Separate door glass from regulator.
Remove guide
channel B.Remove door
glass.
Remove door
lock system.Remove
regulator.
Install door.Install door
lock system.Install regulator.
Install guide
channel.Insert door glass.

Adjust door alignment.Adjust door
lock system.Mount door glass on regulator.

INSTALLATION
AND
ADJUSTMENTAdjust striker.Link latch, outer handle,
key lock and remote
assembly together.Install front and rear upper stoppers
and stabilizer (inner).

Adjust glass position.

Install door trim parts, etc.

Confirm.












12
5-2SERVICE PROCEDURE
1. Procedure Chart for Removing and Installing Door and Related Parts

7. DOOR LATCH
1) Remove trim panel.
2) Remove inner remote assembly.
3) Remove sealing cover around latch service hole. to 5-2 [W2A3].>
4) Completely close door glass.
B5M0067
5) Remove latch and actuator assembly.
(1) Turn rod holder to disconnect joint between key
lock and rod.
(2) Turn rod holder to disconnect joint between outer
handle and rod.
(3) Turn rod holder to disconnect joint between crank
and rod.
G5M0396
6) Loosen screws securing both latch and actuator, then
remove latch and actuator assembly through service hole
in bottom.
Tightening torque (screw):
6.4±2.0 N⋅m (0.65±0.2 kg-m, 4.7±1.4 ft-lb)
7) Installation is in the reverse order of removal.
Some special items will be described below.
8) Check operation of each part.
9) Check each sliding part for proper lubrication.
CAUTION:
After installation, be sure lock mechanism operates
normally.
17
5-2SERVICE PROCEDURE
2. Door

B5M0068
8. OUTER HANDLE
1) Remove trim panel.
2) Remove sealing cover.
3) Detach door latch rod from outer handle and key lock.
4) Loosen nut securing outer handle and then remove
outer handle from outside.
CAUTION:
Be careful not to damage door.
Installation is in the reverse order of removal.
Tightening torque:
7.4±2.0 N⋅m (0.75±0.2 kg-m, 5.4±1.4 ft-lb)
B5M0069A
9. KEY LOCK
1) Remove trim panel.
2) Remove sealing cover.
3) Completely close door glass.
4) Remove outer handle.
5) Loosen spring

1securing key lock.
6) Remove key lock from outer handle.
Installation is in the reverse order of removal.
NOTE:
Install so that key slot in key lock comes to center of hole
in outer handle.
B5M0070A
10. GUSSET
NOTE:
Be sure window is all the way down.
1) Remove trim panel.
2) Remove door rearview mirror.
3) Remove sealing cover.
4) Remove bolts and nuts which secure gusset.
5) Lift out gusset

1.
To install, reverse the above removal procedures.
18
5-2SERVICE PROCEDURE
2. Door

4. REAR DOOR GLASS
Alignment of rear door glass is basically the same as for
the front door glass. Due to slight difference in adjustment
dimensions for fore-aft, up-down, and in-out alignments,
key points for rear door adjustment are described below.
B5M0078A
B5M0074A
Fore-aft adjustment
1) Door glass alignment must be adjusted so that glass-
to-center pillar fit is equal at all points. Always use dimen-
sions (indicated in figure) as a guide during adjustment.
NOTE:
If dimensions are smaller than those indicated, glass will be
caught in weatherstrip and may not raise to the fully closed
position.
2) After making fore-aft adjustment, raise and lower glass
to ensure it is free from any binding.
25
5-2SERVICE PROCEDURE
2. Door

G5M0551
9) General precautions in handling rear gate gas stay.
CAUTION:
Do not attempt to disassemble gas stay because its
cylinder is filled with gas.
Before discarding gas stay, place it at a slight angle
with the cylinder body side facing up and drilla2to3
mm (0.08 to 0.12 in) dia. hole to completely discharge
the content. (Gas is odorless, colorless and harmless;
however, metal powder may come out of the hole.)
G5M0491
It is good practice to place a vinyl sack over it before
drilling the hole because oil may spurt out. Be careful
to prevent vinyl cover from becoming entangled on the
drill.
Be careful not to scratch the exposed section of
piston rod or allow oil or paint to come in contact with
it.
Do not attempt to rotate the extended piston rod.
10) Installation is in the reverse order of removal.
CAUTION:
Be sure to add sealer to hinge.
When installing rear gate, be careful not to damage
coating on body and rear gate.
G5M0404
2. LATCH
1) Remove trim panel.
2) Disengage rod from holder (= key cylinder).
3) Remove bolts from auto-door lock actuator.
4) Remove bolts from latch, and detach latch.
5) Disconnect rear gate switch connector.
6) Disconnect auto-door lock actuator connector.
7) Detach latch.
8) Installation is in the reverse order of removal.
B5M0083
3. OUTER HANDLE
1) Remove trim panel.
2) Disconnect rod from outer handle.
3) Remove two nuts used to hold outer handle to the
inside of rear gate, and detach outer handle.
CAUTION:
Be careful not to damage packing when removing
outer handle.
4) Installation is in the reverse order of removal.
28
5-2SERVICE PROCEDURE
3. Rear Gate

B5M0084A
4. KEY CYLINDER
1) Remove trim panel.
2) Disengage rod from holder

1.
3) Remove nut from key cylinder, and detach key cylinder.
4) Installation is in the reverse order of removal.
B5M0085
5. STRIKER
Remove two bolts from striker and detach striker.
G5M0492
6. WEATHERSTRIP
1) Place weatherstrip so that its joints meet at lower cen-
ter of vehicle body, and install by inserting flanged portion
from below, as shown in section A—A in figure.
2) Tap along entire length with a rubber hammer to firmly
insert body flange into weatherstrip.
CAUTION:
Be careful not to install in wrong direction.
Install weatherstrip carefully and firmly.
G5M0552
B5M0086
B: ADJUSTMENT
1) Loosen striker screw.
2) For lateral adjustment, align striker and latch at their
centers.
29
5-2SERVICE PROCEDURE
3. Rear Gate