compressor SUBARU LEGACY 1999 Service Owner's Guide

5) Install alternator V-belt:
After adjusting V-belt tension, tighten alternator
bracket lock bolt securely.
G4M0632
6) Check drive belt tension and adjust it if neces-
sary by changing alternator position and/or idler
pulley position.
CAUTION:
IEnsure that the V-belt is aligned correctly. If
it is not, check for loose bolts.
IThe V-belt should not be too tight or too
loose.
A belt which is too tight may break bearing or
cause gas to leak from the shaft seal. A belt
which is too loose slips, thereby causing the
belt cut.
IAfter completing the compressor installation
and testing the system operation, check and
adjust the tension of both V-belts again.
G4M0634
B4M1098A
26
4-7[W11C0]SERVICE PROCEDURE
11. Compressor

7) Install high-pressure hose (b).
Connect high-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periph-
ery of O-ring.
B4M0761D
8) Install low-pressure hose (a).
Connect low-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periph-
ery of O-ring.
B4M0761D
9) Install belt cover.
10) Connect ground cable to negative terminal of
battery.
11) Charge refrigerant.
12. Condenser
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery
system.
3) Remove front grille.
B4M0095
4) Remove canister from bracket.
CAUTION:
IDo not disconnect hose from canister.
IInsert air vent hose of canister into the hole
on body.
G2M0375
5) Remove the radiator upper bracket of both side.
6) Disconnect high-pressure hose (a) and high-
pressure pipe (b) from condenser.
B4M0096C
27
[W12A0]4-7SERVICE PROCEDURE
12. Condenser

7) Install high-pressure hose (b).
Connect high-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periph-
ery of O-ring.
B4M0761D
8) Install low-pressure hose (a).
Connect low-pressure hose with compressor.
CAUTION:
Be sure to apply compressor oil to the periph-
ery of O-ring.
B4M0761D
9) Install belt cover.
10) Connect ground cable to negative terminal of
battery.
11) Charge refrigerant.
12. Condenser
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery
system.
3) Remove front grille.
B4M0095
4) Remove canister from bracket.
CAUTION:
IDo not disconnect hose from canister.
IInsert air vent hose of canister into the hole
on body.
G2M0375
5) Remove the radiator upper bracket of both side.
6) Disconnect high-pressure hose (a) and high-
pressure pipe (b) from condenser.
B4M0096C
27
[W12A0]4-7SERVICE PROCEDURE
12. Condenser

16. Flexible Hose
A: REMOVAL AND INSTALLATION
1) Disconnect battery negative terminal.
2) Discharge refrigerant using refrigerant recovery
system.
3) Remove low-pressure hose:
CAUTION:
With the following cautions, replace flexible
hoses with new ones if they are damaged or
swollen.
IThe flexible hoses should be free from twists
and tension after they have been connected.
IThe flexible hoses must not be bent or
twisted forcibly.
(1) Remove hose attaching bolts.
CAUTION:
Plug the opening to prevent foreign matter
from getting in.
(2) Disconnect the connector at evaporator
unit.
B4M0103
4) Remove high-pressure hose:
CAUTION:
With the following cautions, replace flexible
hoses with new ones if they are damaged or
swollen.
IThe flexible hoses should be free from twists
and tension after they have been connected.
IThe flexible hoses must not be bent or
twisted forcibly.
(1) Disconnect hose attaching bolt (compressor
side).
(2) Disconnect hose attaching bolt (condenser
side).
CAUTION:
Plug the opening to prevent foreign matter
from getting in.
B4M0764
5) Installation is in the reverse order of removal.
6) Charge refrigerant.
31
[W16A0]4-7SERVICE PROCEDURE
16. Flexible Hose

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 ªPerformance Testº.
Each shaded area on the following tables indicates a reading of the normal system when the temperature
of outside air is 32.5ÉC (91ÉF).
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.
IExpansion valve is
clogged.
IExpansion valve is
inoperative.
IValve stuck closed.
IThermal 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.
35
[K200]4-7DIAGNOSTICS
2. Performance Test Diagnosis

Condition Probable cause Corrective action
FAULTY CONDENSER
G4M0680
No cooling action;
Engine may overheat.
Suction line is very hot.Condenser is often
found not functioning
well.ICheck condenser
cooling fan.
ICheck condenser for
dirt accumulation.
ICheck engine cooling
system for overheat.
ICheck for refrigerant
overcharge.
If pressure remains
high in spite of all
above actions taken,
remove and inspect
the condenser for
possible oil clogging.
HIGH-PRESSURE LINE BLOCKED
G4M0681
Insufficient cooling;
Frosted high-pressure
liquid line.Drier is clogged, or
restriction in high- pres-
sure line.(1) Discharge system.
(2) Remove receiver
drier or strainer and
replace it.
(3) Evacuate and
charge system.
FAULTY COMPRESSOR
G4M0682
Insufficient cooling Internal problem is in
compressor, or dam-
aged gasket and valve.(1) Discharge system.
(2) Remove and check
compressor.
(3) Repair or replace
compressor.
(4) Check oil level.
(5) Replace receiver
drier.
(6) Evacuate and
charge system.
37
[K200]4-7DIAGNOSTICS
2. Performance Test Diagnosis

4. Compressor Diagnosis
B4M1104A
39
[K400]4-7DIAGNOSTICS
4. Compressor Diagnosis

5. Compressor Clutch Diagnosis
B4M1105A
40
4-7[K500]DIAGNOSTICS
5. Compressor Clutch Diagnosis

B4M1106A
41
[K500]4-7DIAGNOSTICS
5. Compressor Clutch Diagnosis

7. Electrical Unit Location
A: LIST
Electrical unit Index No.
ABS control module
ABS G sensor (MT)
A/C compressor relay
A/C fuse
A/C main fan relay 1
A/C main fan relay 2
A/C pressure switch
A/C sub fan relay 2
ATF temperature sensor
Blower motor resistor
Blower relay
Camshaft position sensor
Check connector
Clutch switch (MT)
Crankshaft position sensor
Cruise control module
Cruise control pump
Data link connector (for
OBD-II G.S.T.)
Data link connector (for
S.S.M.)
Diagnosis connector
Diagnosis terminal (Ground)
Door lock timer
Engine control module
Engine coolant temperature
sensor
Engine hood switch (Secu-
rity)
Evaporator thermoswitch
F/B
FRESH/RECIRC actuator
Fuel pump relay
Fuel gauge module
Fuel gauge sub module
(AWD)
FWD switch (AT)
Headlight alarm relay
(Security)
Headlight relay LH
Electrical unit Index No.
Headlight relay RH
Horn relay
Hydraulic unit (ABS)
Ignition coil
Ignitor
Idle air control solenoid
valve
Illumination control module
Inhibitor switch
Knock sensor
Main fan relay
Main relay
Mass air flow sensor
Mode actuator
M/B
Oil pressure switch
Oxygen sensor
Pedal stroke sensor (TCS)
Power window and sunroof
relay
Power window circuit
breaker
Purge control solenoid valve
Rear defogger relay
Seat belt timer
Security control module
Shift lock control module
Starter interrupt relay (Secu-
rity)
Stop & brake switch (With
cruise control)
Sunroof control module
Tail and illumination relay
TCS control module
TCS motor relay
TCS valve relay
Throttle position sensor
Test mode connector
Transmission control mod-
ule
Turn & hazard module
Vehicle speed sensor 1
Vehicle speed sensor 2
133
[D7A0]6-3WIRING DIAGRAM
7. Electrical Unit Location