light SUBARU LEGACY 1995 Service Manual Online

1. Pedal System and Control Cables
Trouble Corrective action
Excessively worn brake pedal pad Replace.
Failure of clutch and/or accelerator pedals to operate Connect cables correctly.
Stop light switch does not light up. Adjust position of stop light switch.
Stop light switch is not smooth and/or stroke is not correct. Replace.
Insufficient pedal play Adjust pedal play.
Clutch and/or brake pedal free play insufficient Adjust pedal free play.
Maladjustment of brake pedal or booster push rod Inspect and adjust.
Excessively worn and damaged pedal shaft and/or bushing Replace bushing and/or shaft with new one.
19
4-5DIAGNOSTICS
1. Pedal System and Control Cables

3. REFRIGERANT
Do not put CFC-12 refrigerant into a HFC-134a air condi-
tioning system. Also, do not put HFC-134a refrigerant into
a CFC-12 air conditioning system. If the wrong refrigerant
is used, poor lubrication will result and the compressor
itself may be destroyed.
G4M0979
4. HANDLING OF REFRIGERANT
Because refrigerant boils at approx. 30°C (22°F) at sea
level, it is cold enough to give you severe frostbite. Always
wear goggles to protect your eyes and gloves to protect
your hands. Also, even under the pressures normally found
in CFC-12 containers, refrigerant will boil with the addition
of heat. This could raise the pressure inside the container
to a dangerous level.
Never expose a can of HFC-134a to direct sunlight, or to
temperatures over 40°C (104°F). One more thing to
remember about HFC-134a is that when it is exposed to an
open flame or to hot metal, it forms phosgene, a deadly
gas. Do not discharge HFC-134a into the atmosphere on
purpose. Always read and follow the precautions on the
HFC-134a bottle.
10
4-7SERVICE PROCEDURE
1. Safety Precautions

3. Tools and Equipment
The following section provides information about the tools
and equipment that will be necessary to properly service
the A/C system.
Since equipment may vary slightly depending on the
manufacturer, it is important to always read and follow the
manufacturer’s instructions.
CAUTION:
When working on vehicles with the HFC-134a system,
only use HFC-134a specified tools and parts. Do not
mix with CFC-12 tools and parts. If HFC-134a and
CFC-12 refrigerant or compressor oil is mixed, poor
lubrication will result and the compressor itself may be
destroyed.
In order to help prevent mixing HFC-134a and CFC-12
parts and liquid, the tool and screw type and the type
of service valves used are different. The gas leak
detectors for the HFC-134a and CFC-12 systems must
also not be interchanged.
HFC-134a CFC-12
Tool & screw type Millimeter size Inch size
Valve type Quick joint type Screw-in type
Tools and Equipment Description
WRENCH
VariousWRENCHESwill be required to service any A/C
system. A 7 to 40 N⋅m (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque
wrench with various crowfoot wrenches will be needed. Open
end or flare nut wrenches will be needed for back-up on the
tube and hose fittings.
G4M0571
APPLICATOR BOTTLE
A smallAPPLICATOR BOTTLEis recommended to apply
refrigerant oil to the various parts. They can be obtained at a
hardware or drug store.
G4M0572
12
4-7SERVICE PROCEDURE
3. Tools and Equipment

G4M0612
4. LEAK TEST — HIGH-PRESSURE SIDE
Operate the A/C system for approx. 10 minutes, then turn
the engine off and begin the leak test.
1) Begin at the connection of the high-pressure tube to the
evaporator, and work your way along the high- pressure
side 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.
G4M0613
(2) Check the area where the two parts of the fitting
join each other.
G4M0614
(3) Check the area where the nut joins the tube.
3) Check the area of the sight glass and pressure switch
(dual switch), and also check the seams of the receiver
drier.
4) Check the connections of the tubes to the condenser,
and also check any welded joints on the condenser.
CAUTION:
An oily area on the fins of the condenser may indicate
a leak.
5) Check the area where the hoses attach to the compres-
sor.
6) Check around the machined portions of the compressor
(where the compressor sections join each other).
7) If equipped, check the thermal limiter on the compres-
sor housing.
8) Check the compressor shaft seal by probing near the
center of the compressor clutch pulley.
NOTE:
Some shaft seals have a very slight amount of normal
leakage [approximately 28 g (1.0 oz) per year].
24
4-7SERVICE PROCEDURE
8. Leak Testing

B4M0092A
B: REMOVAL
1) Disconnect ground cable from battery.
2) Discharge refrigerant using refrigerant recovery system.

(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

2. Performance Test Diagnosis
If various conditions caused to other air conditioning
system, the characteristics revealed on manifold gauge
reading are shown in the following:
As to the method of a performance test, refer to the item
of“Performance Test”.
Each shaded area on the following tables indicates a read-
ing of the normal system when the temperature of outside
air is 32.5°C (91°F).
Condition Probable cause Corrective action
INSUFFICIENT REFRIGERANT CHARGE
G4M0673
Insufficient cooling Refrigerant is small, or
leaking a little.1. Perform leak test.
2. Repair leak.
3. Charge system.
Evacuate, as
necessary, and
recharge system.
ALMOST NO REFRIGERANT
G4M0674
No cooling action Serious refrigerant leak.Stop compressor
immediately.
1. Perform leak test.
2. Discharge system.
3. Repair leak(s).
4. Replace receiver
drier if necessary.
5. Check oil level.
6. Evacuate and
recharge system.
FAULTY EXPANSION VALVE
G4M0675
Slight cooling;
Sweating or frosted
expansion valve inlet.Expansion valve
restricts refrigerant flow.
Expansion valve is
clogged.
Expansion valve is
inoperative.
Valve stuck closed.
Thermal bulb has lost
charge.If valve inlet reveals
sweat or frost:
1. Discharge system.
2. Remove valve and
clean it. Replace it if
necessary.
3. Evacuate system.
4. Charge system.
If valve does not oper-
ate:
1. Discharge system.
2. Replace valve.
3. Evacuate and charge
system.
44
4-7DIAGNOSTICS
2. Performance Test Diagnosis

9. Sight Glass Inspection
1. INSPECTION CONDITION
1) Operate the engine at approximately 1,500 rpm.
2) Open the door windows.
3) Set the fan switch to the 4th (High) position.
4) Set the mode selector switch to“A/C”position.
5) Set the temperature control switch to Full cold position.
6) Ensure that compressor discharge pressure is at least
588 kPa (6 kg/cm
2, 85 psi).
NOTE:
When discharge pressure does not reach 588 kPa (6
kg/cm
2, 85 psi) in areas where outside air temperature is
low, proceed as follows:
a. Set the TEMP. SWITCH to the Full hot position.
b. Set the temperature control switch to“MAX. A/C”posi-
tion.
c. Close the door windows completely.
d. Increase the compartment temperature so that dis-
charge pressure reaches at least 588 kPa (6 kg/cm
2,85
psi).
2. REFRIGERANT CHARGE AMOUNT CHECKING
Check the refrigerant charge amount using the following
table as a guide.
Item to check Adequate Insufficient Almost in refrigerant Too much refrigerant
State in sight glassCLEAR
Air bubbles sometimes
appear when engine
speed is increased or
decreased.
G4M0669
FOAMY or BUBBLY
Air bubbles always
appear.
G4M0670
FROSTY
Frost-like appears.
G4M0671
NO FOAM
No air bubbles appear.
G4M0672
Temperature of high
and low pressure linesHigh-pressure side is
hot while low-pressure
side is cold. (A big
temperature difference
between high and low
pressure side)High-pressure side is
warm and low-pressure
side is slightly cold.
(Not so big temperature
difference between high
and low pressure side)There is almost no
temperature difference
between high and low
pressure side.High-pressure side is
hot and low-pressure
side is slightly warm.
(Slight temperature
difference between high
and low pressure side)
Pressure of systemBoth pressures on high
and low pressure sides
are normal.Both pressures on high
and low pressure sides
are slightly low.High-pressure side is
abnormally low.Both pressures on high
and low pressure sides
are abnormally high.
54
4-7DIAGNOSTICS
9. Sight Glass Inspection

1. ENGINE COMPARTMENT AND ROOM
B5M0187A
0Cowl panel weather attaching hole 6 mm (0.24 in) dia.

1Hood hinge front attaching hole M8

2Strut mount attaching hole (Front center) 9.5 mm (0.374 in)
dia.

3Front fender attaching hole (Tip) M6

4Rear upper surface of front side frame 12 mm (0.47 in) dia.

5Middle upper surface of front side frame 20 mm (0.79 in) dia.

6Front side frame front upper surface 14 x 16 mm (0.55 x 0.63
in) dia. oblong hole

7Side frame of front side frame 12 mm (0.47 in) dia.

8Headlight attaching hole at radiator side panel 6.2x9mm
(0.244 x 0.35 in) dia.

9Radiator panel side (LWR) gauge hole 23 mm (0.91 in) dia.

23Rear strut mount attaching hole (Side) 10 mm (0.39 in) dia.

24Rear strut mount attaching hole (Center) 12 mm (0.47 in) dia.

25Radiator panel (UPR) middle hole 6 mm (0.24 in) dia.

26Front fender attaching hole at radiator panel side M6

27Front fender attaching hole at front pillar lower portion M6

28Hinge middle hole at front pillar center 10 mm (0.39 in) dia.

29Front fender attaching hole at front pillar center portion M6

30Retainer attaching square hole at front pillar7x7mm(0.28
x 0.28 in)
31Retainer attaching hole at center pillar (Front) 3.5 mm (0.138
in) dia.

32Retainer attaching hole at center pillar (Rear) 3.5 mm (0.138
in) dia.

33Lower side of rear door hinge M8

34Center pillar (LWR) gauge hole 27 mm (1.06 in) dia.

35Rear quarter outer corner patch attaching hole 5.2 mm (0.205
in) dia.

39Front rail center notch

40Front glass upper locating notch RH: 6.5 mm (0.256 in) dia.,
LH: 6.5 x 10 mm (0.256 x 0.39 in) dia. oblong hole

41Stud bolt lower locating notch

48Front center of rear floor pan 8 mm (0.31 in) dia.

51Front upper pillar (Inner) 7 mm (0.28 in) dia.

52Front seat belt adjust plate attaching hole 12 mm (0.47 in)
dia.

53Rear door hinge middle hole 10 mm (0.39 in) dia.

54Rear floor, near door 8 mm (0.31 in) dia.

55Trim upper attaching hole at 6 light 8 mm (0.31 in) dia.

56Trim lower attaching hole at 6 light 8 mm (0.31 in) dia.

58Rear floor, near floor strut 15 x 20 mm (0.59 x 0.79 in) dia.
oblong hole
3
5-1SERVICE DATA
2. Body Datum Points

2. LUGGAGE COMPARTMENT AND ROOM (SEDAN)
B5M0188A
366 light upper retainer attaching square hole7x7mm(0.28 x 0.28 in)

42Rear rail center notch

43Rear glass upper locating hole RH: 6.5 mm (0.256 in) dia., LH: 6.5 x 10 mm (0.256 x 0.39 in) dia. oblong hole

44Rear glass molding attaching square hole8x8mm(0.31 x 0.31 in)

45Rear panel drain locater concave part

46Front panel gauge hole 10 mm (0.39 in) dia.

47Tunnel center M8

59Rear bumper attaching hole 45 mm (1.77 in) dia.

65Rear wiper attaching hole M6

66Trim attaching hole at rear skirt (UPR) 7 mm (0.28 in) dia.

67Rear bumper side attaching hole 6 mm (0.24 in) dia.

68Rear combination light mounting hole 8 mm (0.31 in) dia.

69Rear bumper beam attaching hole RH: 8 mm (0.31 in) dia., LH:8x12mm(0.31 x 0.47 in) dia. oblong hole
4
5-1SERVICE DATA
2. Body Datum Points

3. LUGGAGE COMPARTMENT AND ROOM (WAGON)
B5M0189A
37D pillar cover attaching hole 12x8mm(0.47 x 0.31 in) dia.

38Shoulder mole attaching hole 8 mm (0.31 in) dia.

49Front pillar (LWR) gauge hole 10 mm (0.39 in) dia. (On both Sedan and Wagon)

50Front pillar (UPR) gauge hole 16 mm (0.63 in) dia. (On both Sedan and Wagon)

57Retainer attaching square hole at C pillar (UPR)7x7mm(0.28 x 0.28 in)

60Trim attaching hole at rear skirt (UPR) 15 mm (0.59 in) dia.

61Rear bumper side attaching hole 6 mm (0.24 in) dia.

62Rear seat belt bolt hole 13 mm (0.51 in) dia.

63Rear rail locator concave part

64Buffer attaching hole (UPR) M6

70Rear quarter end (LWR) gauge hole 20 mm (0.79 in) dia.

71Rear combination light mounting hole 7 mm (0.28 in) dia.
5
5-1SERVICE DATA
2. Body Datum Points