SUBARU LEGACY 1995 Service Repair Manual

1. Supplemental Restraint System
“Airbag”
Airbag system wiring harness is routed near the instrument
panel, heater unit, blower motor and control unit.
CAUTION:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuit.

Be careful not to damage Airbag system wiring har-
ness when servicing the instrument panel, heater unit,
blower motor and control unit.
2. Heater Unit
A: REMOVAL AND INSTALLATION
1) Disconnect GND cable from battery.
2) Remove heater hoses (inlet, outlet) in engine compart-
ment.
NOTE:
Drain as much coolant from heater unit as possible, and
plug disconnected hose with cloth.

3) Remove instrument panel.

4) Remove steering support beam.

5) Remove evaporator. (With A/C model)

G4M0554
6) Remove heater unit.
11
4-6SERVICE PROCEDURE
1. Supplemental Restraint System“Airbag”- 2. Heater Unit

1. Supplemental Restraint System
“Airbag”
Airbag system wiring harness is routed near the instrument
panel, heater unit, blower motor and control unit.
CAUTION:

All Airbag system wiring harness and connectors
are colored yellow. Do not use electrical test equip-
ment on these circuit.

Be careful not to damage Airbag system wiring har-
ness when servicing the instrument panel, heater unit,
blower motor and control unit.
2. Heater Unit
A: REMOVAL AND INSTALLATION
1) Disconnect GND cable from battery.
2) Remove heater hoses (inlet, outlet) in engine compart-
ment.
NOTE:
Drain as much coolant from heater unit as possible, and
plug disconnected hose with cloth.

3) Remove instrument panel.

4) Remove steering support beam.

5) Remove evaporator. (With A/C model)

G4M0554
6) Remove heater unit.
11
4-6SERVICE PROCEDURE
1. Supplemental Restraint System“Airbag”- 2. Heater Unit

7) Installation is in the reverse order of removal.
Fitted length of heater hose over pipe:
25 — 30 mm (0.98 — 1.18 in)
8) Pour coolant.
B5M0025
3. Blower Motor Assembly
A: REMOVAL AND INSTALLATION
1) Disconnect GND cable from battery.
2) Remove glove box and pocket back panel. [W1A0].>
3) Disconnect blower motor harness connector.
G4M0555
4) Disconnect aspirator pipe1.
5) Remove blower motor mounting screw.
6) Remove blower motor assembly.
7) Installation is in the reverse order of removal.
12
4-6SERVICE PROCEDURE
2. Heater Unit - 3. Blower Motor Assembly

7) Installation is in the reverse order of removal.
Fitted length of heater hose over pipe:
25 — 30 mm (0.98 — 1.18 in)
8) Pour coolant.
B5M0025
3. Blower Motor Assembly
A: REMOVAL AND INSTALLATION
1) Disconnect GND cable from battery.
2) Remove glove box and pocket back panel. [W1A0].>
3) Disconnect blower motor harness connector.
G4M0555
4) Disconnect aspirator pipe1.
5) Remove blower motor mounting screw.
6) Remove blower motor assembly.
7) Installation is in the reverse order of removal.
12
4-6SERVICE PROCEDURE
2. Heater Unit - 3. Blower Motor Assembly

B5M0027
4. Control Unit
A: REMOVAL
1) Disconnect GND cable from battery.
2) Set temperature control lever to“FULL COLD”position.
3) Remove temperature control cable from heater unit.
NOTE:
Do not attempt to move link of heater unit during installa-
tion.
B4M0370
4) Remove cup holder.
5) Remove center panel and then disconnect connector.
B4M0059
6) Remove control unit assembly and disconnect connec-
tor.
B4M0060A
B: INSPECTION
1. FAN SWITCH
Check continuity between terminals at each switch posi-
tion.
LHD model
Switch
positionTerminals
123456
1

2
3
4
GND IGN
13
4-6SERVICE PROCEDURE
4. Control Unit

RHD model
Switch
positionTerminals
123456
1

2

3

4

GND IGN
B4M0061A
2. CONTROL UNIT
Check circuit continuity between each terminal, when push
control switch is turned ON.
LHD model
Terminal
No.Mode selector switch RECIRC switch
A/C
switchIllumi.
VENT BI-LEV HEATDEF/
HEATDEF RECIRC FRESH
1
2
3
4
5
6
7
8
9
10
11
12

13
14
15
16
17
18
19
14
4-6SERVICE PROCEDURE
4. Control Unit

RHD model
Terminal
No.Mode selector switch RECIRC switch
A/C
switchIllumi.
VENT BI-LEV HEATDEF/
HEATDEF RECIRC FRESH
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
B4M0062A
C: ADJUSTMENT
1) Operate temperature control lever to“FULL COLD”
position.
2) Install control cable to lever
1. While pushing outer
cable, secure control cable with clip
2.
D: INSTALLATION
Installation is in the reverse order of removal.
NOTE:
Before control unit installation, set temperature control
lever to“FULL COLD”position.
15
4-6SERVICE PROCEDURE
4. Control Unit

B5M0025
5. Intake Door Motor
A: REMOVAL
1) Disconnect GND cable from battery.
2) Remove glove box and pocket back panel. [W1A0].>
3) Remove heater duct or evaporator. (With A/C model).

G4M0561
4) Remove intake unit from the vehicle.
G4M0562
5) Remove screws which secure intake door motor to
intake unit.
NOTE:
Ensure that RECIRC switch is set to“ON”.
B4M0294A
B: INSPECTION
1) When approx. 12 V is applied to the intake door motor
terminals, intake door motor operates as follows:
LHD model
Intake
door motor
positionTerminal
Intake door motor operation


FRESH
32 Door motor moved to FRESH position.
RECIRC 1 Door motor moved to RECIRC position.
RHD model
Intake
door motor
positionTerminal
Intake door motor operation


FRESH
21 Door motor moved to FRESH position.
RECIRC 3 Door motor moved to RECIRC position.
16
4-6SERVICE PROCEDURE
5. Intake Door Motor

G4M0564
2) Connect harness to intake door motor.
3) Turn ignition switch to“ACC”and RECIRC switch to
“ON”then, set to“RECIRC”.
NOTE:
Ensure that intake door motor is set in the“RECIRC”mode.
4) Install intake door motor on intake unit.
5) Secure rod holder to link, and install link to intake unit.
6) Manually set rod in the“RECIRC”mode, and secure to
rod holder.
7) Operate mode selector switch to ensure that system
changes from intake air to“RECIRC”and from“RECIRC”
to intake air in full-stroke range.
C: INSTALLATION
Installation is in the reverse order of removal.
17
4-6SERVICE PROCEDURE
5. Intake Door Motor

B4M0063
6. Mode Door Motor
A: REMOVAL
1) Remove instrument panel.
2) Remove mode door motor.
B4M0064A
B: INSPECTION
1) When approx. 12 V is applied to the mode door motor
terminals, mode door motor operates as follows:
LHD model
Terminal No.
Mode door motor
21
Polarity of power supply
terminalsMode door motor
operationDirection of linkage
rotation
+ VENT,DEF Clockwise
+ DEF,VENT Counterclockwise
RHD model
Terminal No.
Mode door motor
76
Polarity of power supply
terminalsMode door motor
operationDirection of linkage
rotation
+ VENT,DEF Clockwise
+ DEF,VENT Counterclockwise
2) Check mode door motor position switch.
When the mode door motor is moved to each mode posi-
tion by using the mode selector switch, check if continuity
exists between each terminal as follows:
LHD model
Mode selector switch
positionsTerminal No.
VENT 8 or 7
9 (GND) BI-LEV 6 or 7
HEAT 5or6
DEF/HEAT 4 or 5
DEF 3or4
18
4-6SERVICE PROCEDURE
6. Mode Door Motor