compressor SUBARU LEGACY 1999 Service User Guide

Available retaining plates
Part No. Thickness mm (in)
31667AA320
31667AA330
31667AA340
31667AA350
31667AA360
31667AA370
31667AA3804.2 (0.165)
4.5 (0.177)
4.8 (0.189)
5.1 (0.201)
5.4 (0.213)
5.7 (0.224)
6.0 (0.236)
13) Install leaf spring of low and reverse brake.
CAUTION:
Pay attention to the direction and position of
leaf spring during installation.
B3M0956A
14) Install O-ring to 2-4 brake piston.
CAUTION:
IIf O-ring breaks or damage is noted, replace
with new O-ring.
IApply a coat of vaseline to inner side of
O-ring before installation.
15) Install 2-4 brake piston to 2-4 brake piston
retainer.
B3M1080A
16) Install 2-4 brake piston and retainer to trans-
mission case.
CAUTION:
Align the hole in the 2-4 brake seal of transmis-
sion case with the hole in 2-4 brake piston
retainer during installation.
B3M1079A
17) Install 2-4 brake piston return spring to trans-
mission case.
B3M1078A
18) Position snap ring in transmission. Using ST,
press the snap ring into place.
ST 498677100 COMPRESSOR
B3M1101A
63
[W11C2]3-2SERVICE PROCEDURE
11. Overall Transmission

B: DISASSEMBLY
1) Remove oil strainer from lower control valve
body.
B3M1038A
2) Remove the duty solenoid S, solenoids and
sensor from the lower valve body.
B3M1039A
(A) Lock-up duty solenoid (Blue)
(B) Low clutch timing solenoid (Gray)
(C) Line pressure duty solenoid (Red)
(D) Shift solenoid 1 (Yellow)
(E) Shift solenoid 2 (Green)
(F) 2-4 brake timing solenoid (Black)
(G) 2-4 brake duty solenoid D (Red)
(H) ATF temperature sensor
3) Remove the upper-lower valve body tightening
bolts.
B3M1130
4) Separate the control valve body.CAUTION:
IDo not lose the ten (10) steel balls contained
in the upper valve body and middle valve body.
IDo not lose strainers contained in the lower
valve body.
NOTE:
During ordinary servicing, clean the control valve
bodies in this condition, without further disassem-
bly. In the event of a seized clutch or other
problem, disassemble the control valve bodies
further, and clean the component parts.
5) Remove upper separator plate from middle
valve body.
B3M1132A
6) Remove valve springs from upper valve body.
7) Using air compressor, remove accumulator pis-
ton from upper valve body.
B3M1133
C: INSPECTION
Make sure that each component is free of harmful
gouges, cuts, or dust.
78
3-2[W14B0]SERVICE PROCEDURE
14. Control Valve Body

1) Remove the snap ring, and take out the retain-
ing plate, drive plates, driven plates.
B3M1142A
2) Remove snap ring, and take out the retaining
plate, drive plates and driven plates.
B3M1143A
3) Using ST1 and ST2, remove snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
B3M1144A
4) Take out clutch cover, spring retainer, high
clutch piston and reverse clutch piston.
B3M1145A
5) Remove seal rings and lip seal from high clutch
piston and reverse clutch piston.
B3M1146A
B: INSPECTION
1) Drive plate facing for wear and damage
2) Snap ring for wear, return spring for breakage
or setting, and spring retainer for deformation
3) Lip seal and lathe cut seal ring for damage
4) Piston check ball for operation
86
3-2[W17B0]SERVICE PROCEDURE
17. High Clutch and Reverse Clutch

1) Install seal rings and lip seal to high clutch pis-
ton and reverse clutch piston.
2) Install high clutch piston to reverse clutch pis-
ton.
B3M1146A
3) Install reverse clutch to high clutch drum.
NOTE:
Align the groove on the reverse clutch piston with
the groove on the high clutch drum during installa-
tion.
B3M1148A
4) Install spring retainer to high clutch piston.
B3M1149A
5) Install ST to high clutch piston.
ST 498437000 HIGH CLUTCH PISTON
GAUGE
B3M1150A
6) Install cover to high clutch piston.
CAUTION:
Be careful not to fold over the high clutch pis-
ton seal during installation.
7) Using ST1 and ST2, install snap ring.
NOTE:
After installing snap ring, remove STs.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 498437000 HIGH CLUTCH PISTON
GAUGE
B3M0973A
8) Install driven plate, drive plate and retaining
plate to high clutch drum.
NOTE:
Install thicker driven plate on the piston side.
B3M1151
9) Install snap ring to high clutch drum.
88
3-2[W17C0]SERVICE PROCEDURE
17. High Clutch and Reverse Clutch

1) Remove snap ring from the low clutch drum.
B3M1156A
2) Take out front planetary carrier and thrust
needle bearing from low clutch drum.
B3M1157A
3) Take out rear sun gear.
B3M1158A
4) Take out rear planetary carrier, washer and
thrust needle bearing.
B3M1159A
5) Take out rear internal gear.
B3M1160A
6) Remove the snap ring from the low clutch drum.
B3M1161A
7) Remove the retaining plate, drive plates, driven
plates and dish plate.
8) Compress the spring retainer, and remove the
snap ring from the low clutch drum, by using ST1
and ST2.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
B3M1162A
92
3-2[W18A0]SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear

4) Install ST to low clutch drum.
ST 498437100 LOW CLUTCH PISTON
GUIDE
B3M1167A
5) Set the cover on the piston with a press using
ST1 and ST2, and attach the snap ring.
CAUTION:
Be careful not to fold cover seal during instal-
lation.
NOTE:
After installing snap ring, remove ST1, ST2 and
ST3.
ST1 498627100 SEAT
ST2 398673600 COMPRESSOR
ST3 498437100 LOW CLUTCH PISTON
GUIDE
B3M1168A
6) Install the dish plate, driven plates, drive plates,
and retaining plate, and secure with the snap ring.
NOTE:
Pay attention to the orientation of the dish plate.
B3M1169A
7) Check the low clutch for operation.
Set the one-way clutch inner race, and apply com-
pressed air for checking.
B3M0960A
8) Checking low clutch clearance
Measure the gap between the retaining plate and
the operation of the low clutch.
NOTE:
Before measuring clearance, place the same thick-
ness of shim on both sides to prevent retaining
plate from tilting.
If the clearance is out of the specified range, select
a proper retaining plate so that the standard clear-
ance can be obtained.
Standard value:
0.7 Ð 1.1 mm (0.028 Ð 0.043 in)
Allowable limit:
1.6 mm (0.063 in)
B3M0975A
Available retaining plates
Part No. Thickness mm (in)
31567AA830
31567AA840
31567AA850
31567AA860
31567AA8703.8 (0.150)
4.0 (0.157)
4.2 (0.165)
4.4 (0.173)
4.6 (0.181)
95
[W18C0]3-2SERVICE PROCEDURE
18. Low Clutch Drum and Planetary Gear

4) Remove the snap ring with ST1, ST2 and ST3,
and take out the return spring and transfer clutch
piston seal.
ST1 399893600 PLIERS
ST2 398673600 COMPRESSOR
ST3 398623600 SEAT
B3M1415A
5) Apply compressed air to the rear drive shaft to
remove the piston.
G3M0497
B: INSPECTION
1) Check the drive plate facing for wear and dam-
age.
2) Check the snap ring for wear, return spring for
permanent set and breakage, and return spring for
deformation.
3) Check the lathe cut ring for damage.
C: ASSEMBLY
1) Install the transfer clutch piston.
B3M1400A
2) Install return spring to transfer piston.
B3M1177A
3) Install transfer clutch piston seal.
B3M1401A
4) Install ST to rear drive shaft.
ST 499257300 SNAP RING OUTER GUIDE
B3M1402A
5) Install snap ring to ST.
ST 499257300 SNAP RING OUTER GUIDE
B3M1180A
100
3-2[W20B0]SERVICE PROCEDURE
20. Transfer Clutch

7) Remove two bolts securing housing to strut.
CAUTION:
While holding head of adjusting bolt, loosen
self-locking nut.
8) Remove the three nuts securing strut mount to
body.
G4M0505
B: DISASSEMBLY
1) Using a coil spring compressor, compress coil
spring.
G4M0506
2) Using ST, remove self-locking nut.
ST 927760000 STRUT MOUNT SOCKET
G4M0507
3) Remove strut mount, upper spring seat and
rubber seat from strut.
4) Gradually decreasing compression force of
spring compressor, and remove coil spring.
5) Remove dust cover and helper.
C: INSPECTION
Check the disassembled parts for cracks, damage
and wear, and replace with new parts if defective.
1. DAMPER STRUT
1) Check for oil leakage.
2) Move the piston rod up and down to check its
operates smoothly without any binding.
3) Play of piston rod
IMeasure the play as follows:
Fix outer shell and fully extend the rod. Set a dial
gauge at the end of the rod: L [10 mm (0.39 in)],
then apply a force of W [20 N (2 kg, 4 lb)] to
threaded portion. With the force of 20 N (2 kg, 4 lb)
applied, read dial gauge indication: P
1. Apply a
force of 20 N (2 kg, 4 lb) in the opposite direction
of ªWº, then read dial gauge indication: P
2.
G4M0508
The free play is determined by the following equa-
tion:
Play = P1,P2
Limit of play:
Less than 0.8 mm (0.031 in)
If the play is greater, replace the strut with new
one.
19
[W4C1]4-1SERVICE PROCEDURE
4. Front Strut

2. STRUT MOUNT
Check rubber part for wear, cracks and
deterioration, and replace it with new one if defec-
tive.
3. DUST COVER
If any cracks or damage are found, replace it with
new one.
4. COIL SPRING
When vehicle posture is uneven, although there
are no considerable reasons like tire puncture,
uneven loading, etc., check coil spring and spring
seats for cracks, deformation, etc., and replace it
with a new one if defective.
5. HELPER
Replace it with new one if cracked or damaged.
D: ASSEMBLY
1) Before installing coil spring, strut mount, etc.,
on the strut, check for the presence of air in the
dampening force generating mechanism of the
strut since air prevents proper dampening force
from being produced.
2) Checking for the presence of air
(1) Place the strut vertically with the piston rod
facing upward.
(2) Move the piston rod to the center of its
entire stroke.
(3) While holding the piston rod end with finger-
tips, move the rod up and down.
(4) If the piston rod moves at least 10 mm (0.39
in) in former step, purge air from the strut.
3) Air purging procedure
(1) Place the strut vertically with the piston rod
facing upward.
(2) Fully extend the piston rod.
(3) With the piston rod fully extended, place the
piston rod side down. The strut must stand ver-
tically.
(4) Fully contract the piston rod.
(5) Repeat 3 or 4 times from first step.
NOTE:
After completely purging air from the strut, be sure
to place the strut with the piston rod facing upward.
If it is laid down, check for entry of air in the strut
as outlined under ªChecking for the presence of
airº.4) Using a coil spring compressor, compress the
coil spring.
NOTE:
Make sure that the vertical installing direction of
coil spring is as shown in figure.
B4M0568A
5) Set the coil spring correctly so that its end face
fits well into the spring seat as shown.
G4M0510
6) Install helper and dust cover to the piston rod.
7) Pull the piston rod fully upward, and install rub-
ber seat and spring seat.
NOTE:
Ensure that upper spring seat is positioned with
ªOUTº mark facing outward.
G4M0511
8) Install strut mount to the piston rod, and tighten
the self-locking nut temporarily.
CAUTION:
Be sure to use a new self-locking nut.
20
4-1[W4C2]SERVICE PROCEDURE
4. Front Strut

1. Air Conditioning System
A: SPECIFICATIONS
Item Specifications
Type of air conditioner Reheat air-mix type
Cooling capacity (IMACA)4.885 kW
(4,200 kcal/h, 16,666 BTU/h)
RefrigerantHFC-134a (CH
2FCF3)
[0.55 Ð 0.65 kg
(1.21 Ð 1.43 lb)]
CompressorType 5-vane rotary, fix volume (DKV-14G)
Discharge 140 cm
3(8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Magnet clutchType Dry, single-disc type
Power consumption 45 W
Type of belt V-Ribbed 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
CondenserType Corrugated fin (Multi-flow)
Core face area 0.215 m
2(2.31 sq ft)
Core thickness 19 mm (0.75 in)
Radiation area 4.7 m
2(51 sq ft)
Receiver drier Effective inner capacity 290 cm3(17.70 cu in)
Expansion valve Type Internal equalizing
EvaporatorType A-laminate
Dimensions (W´H´T)60´224´235 mm
(2.36´8.82´9.25 in)
Blower fanFan type Sirocco fan
Outer diameter´width 150´75 mm (5.91´2.95 in)
Power consumption 230 W at 12 V
Condenser fan
(Sub fan)Motor type Magnet
Power consumption 120 W at 12 V
Fan outer diameter 320 mm (12.60 in)
Radiator fan
(Main fan)Motor type Magnet
Power consumption 120 W at 12 V
Fan outer diameter 320 mm (12.60 in)
Idling speed with
F.I.C.D. in operationMPFI model850±100 rpm (700±100 rpm ªDº range in AT
model)
Dual switch
(Pressure switch)
High-pressure line
B4M0755A
Compressor relief valve
blow-out pressure
B4M0084A
2
4-7[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Air Conditioning System