radiator SUBARU LEGACY 1997 Service Service Manual
[x] Cancel search | Manufacturer: SUBARU, Model Year: 1997, Model line: LEGACY, Model: SUBARU LEGACY 1997Pages: 3342, PDF Size: 62.95 MB
Page 1489 of 3342
9) Install belt cover.
10) Connect ground cable to negative terminal of battery.
11) Charge refrigerant.
B4M0095
12. Condenser
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery system.
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.
34
4-7SERVICE PROCEDURE
11. Compressor - 12. Condenser
Page 1490 of 3342
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.
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.
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.
35
4-7SERVICE PROCEDURE
12. Condenser
Page 1494 of 3342
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)
B4M0103
B4M0764
16. Flexible Hose
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery system.
3) Remove low-pressure hose.
(1) Remove hose attaching bolts.
CAUTION:
Plug the opening to prevent foreign matter from get-
ting in.
(2) Disconnect the connector at evaporator module.
4) Remove high-pressure hose.
(1) Disconnect hose attaching bolt (compressor side).
(2) Disconnect hose attaching bolt (condenser side).
CAUTION:
Plug the opening to prevent foreign matter from get-
ting in.
5) Installation is in the reverse order of removal.
6) Charge refrigerant.
38
4-7SERVICE PROCEDURE
15. Condenser Fan Assembly - 16. Flexible Hose
Page 1495 of 3342
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)
B4M0103
B4M0764
16. Flexible Hose
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery system.
3) Remove low-pressure hose.
(1) Remove hose attaching bolts.
CAUTION:
Plug the opening to prevent foreign matter from get-
ting in.
(2) Disconnect the connector at evaporator module.
4) Remove high-pressure hose.
(1) Disconnect hose attaching bolt (compressor side).
(2) Disconnect hose attaching bolt (condenser side).
CAUTION:
Plug the opening to prevent foreign matter from get-
ting in.
5) Installation is in the reverse order of removal.
6) Charge refrigerant.
38
4-7SERVICE PROCEDURE
15. Condenser Fan Assembly - 16. Flexible Hose
Page 1496 of 3342
G4M0649
17. Relay and Fuse
A: LOCATION
Relays used with A/C system are located as shown in fig-
ure.
1) A/C relay
2) Main fan (radiator fan) relay
3) Sub fan (condenser fan) relay
4) Sub fan (condenser fan) water temperature relay
5) Fuses (10 A and 20 A)
G4M0651
B: INSPECTION
1) Check conduction with a circuit tester (ohm range)
according to the following table in figure.
B4M0105A
2) Replace relays which do not meet specifications.
39
4-7SERVICE PROCEDURE
17. Relay and Fuse
Page 1506 of 3342
6. Radiator Fan (Main Fan) Diagnosis
EPA0048
49
4-7DIAGNOSTICS
6. Radiator Fan (Main Fan) Diagnosis
Page 1511 of 3342
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
Page 1514 of 3342
4. UNDERBODY
B5M0190A
10Radiator panel (LWR) frame gauge hole 10 mm (0.39 in) dia.
11Front side frame front lower surface 20 mm (0.79 in) dia.
12Front side frame center lower surface 20 mm (0.79 in) dia.
13Front suspension attaching hole M14
14Suspension attaching bracket M14
15Front side frame rear lower center surface 20 mm (0.79 in) dia.
16Transmission mount attaching hole M10
17Front side frame rear lower surface 15 mm (0.59 in) dia.
18Rear frame front M12
19Rear frame front hole 25 mm (0.98 in) dia.
20Rear crossmember attaching hole M12
21Rear frame center hole 7 mm (0.28 in) dia.
22Rear frame rear concave part 15 mm (0.59 in) dia.
6
5-1SERVICE DATA
2. Body Datum Points
Page 1542 of 3342
1. Hood
The hood lock has a dual locking design which consists of
a main lock and a safety lock mechanism. When the
release knob located at the front pillar on the driver’s side
is pulled back, the main lock is released through the cable
attached to the knob.
The safety lock can be released by pushing the lever pro-
truding above the front grill while opening the hood.
G5M0137
A: REMOVAL
1. HOOD
1) Open front hood, and remove washer hose.
2) Remove attaching bolts.
3) Detach front hood from hinges.
B5M0267
2. HOOD LOCK
1) Open front hood and remove front grille.
2) Remove bolts which secure lock assembly to radiator
panel, and remove lock assembly.
3) Disconnect release cable from lock assembly.
B5M0319
3. RELEASE CABLE
1) Remove front grille.
2) Remove release cable from opener lever in passenger
compartment.
3) Remove release cable from lock assembly.
4) Remove cable clip from engine compartment.
B5M0465A
4. HOOD DUCT
1) Open front hood.
2) Remove attaching tapping screws and screw rivet, then
remove hood inner.
3) Remove attaching nuts, then remove hood duct.
33
5-1SERVICE PROCEDURE
1. Hood
Page 1543 of 3342
G5M0140
B: POINTS TO CHECK
1) Check striker for bending or abnormal wear.
2) Check safety lever for improper movement.
3) Check other levers and spring for rust formation and
unsmooth movement.
G5M0141
C: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
With buffer protruding about 18 mm (0.71 in) beyond
radiator panel, make sure that:
No clearance exists between buffer and inner hood.
Hood main lock is applied when hood is released at
a height of approximately 10 cm (3.94 in) above the
closed position.
G5M0142
NOTE:
Align the center of striker with lock during installation.
Make sure safety lever is properly caught by striker under
the hood’s own weight.
Route hood lock release cable and hold with clips.
After installing release cable, ensure it operates
smoothly.
Apply grease to sliding surfaces of parts.
B5M0268A
D: ADJUSTMENT
1) Fore-aft and left-right adjustments
Loosen striker mounting bolts and adjust fore-and-aft posi-
tion of striker.
CAUTION:
Do not adjust striker position using the lock. Doing so
may result in a misaligned front grille.
2) Up-down adjustment
Make up-and-down adjustment of striker only when hood
does not properly contact buffer or hood is not flush with
fender, or when release cable does not properly operate.
Adjustment can be made by adjusting the stroke length of
striker after lock assembly mounting screws are removed.
34
5-1SERVICE PROCEDURE
1. Hood