SUBARU LEGACY 1999 Service Repair Manual

MEMO:
16
4-5DIAGNOSTICS

1. Specifications
A: HEATER SYSTEM
Item Specifications Condition
Heating capacity 4.652 kW (4,000 kcal/h, 15,872 BTU/h) or more ...
When 300 m
3(10,593 cu ft)/hMode selector switch HEAT
Temp. control lever FULL HOT
Temperature difference
between hot water and
inlet air65ÉC (149ÉF)
Hot water flow rate 360(95.1 US
gal, 79.2 Imp
gal)/h
Air flow rate 300 m
3(10,593 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5
V
Max air flow rate 510 m
3(18,008 cu ft)/h Temperature control
leverFULL COLD
Blower fan speed 4th position
RECIRC switch position RECIRC
Heater core size (height´
length´width´thickness)193.5´152.0´25.0´0.9 mm
(7.62´5.98´0.984´0.035 in)Ð
Blower
motorType Magnet motor 230 W or less at 12 V
Fan type and
size
(diameter´
width)Sirocco fan type
150´75 mm (5.91´2.95 in)
Ð
2
4-6[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Specifications

1. Heater System
B4M0368B
(1) Intake unit
(2) Grommet
(3) Hose (Inlet)
(4) Hose (Outlet)
(5) Heater duct(6) Clamp
(7) Grommet
(8) Heater unit
(9) Rear heater duct
(10) ResistorTightening torque: N´m (kg-m, ft-lb)
T:
7.35±1.96 (0.750±0.200,
5.421
±1.446)
3
[C100]4-6COMPONENT PARTS
1. Heater System

2. Heater Unit
B4M1080A
(1) Vent lever
(2) Side link
(3) DEF. lever
(4) Heater case upper
(5) Heater grommet
(6) Heater core
(7) Mix door
(8) Heater case lower(9) Mix rod
(10) Mix link
(11) Mix lever
(12) Foot duct (RH)
(13) Foot duct (CTR)
(14) Foot duct (LH)
(15) Foot lever lower
(16) Foot door(17) Vent door
(18) DEF. door
(19) Foot lever upper
Tightening torque: N´m (kg-m, ft-lb)
T:
7.35±1.96 (0.750±0.200,
5.421
±1.446)
4
4-6[C200]COMPONENT PARTS
2. Heater Unit

3. Intake Unit
B4M1081A
(1) Intake unit case upper
(2) Lever (A)
(3) Link
(4) Door (A)
(5) Bell mouth-intake(6) Intake unit case lower
(7) Blower motor ASSY
(8) Hose
(9) Actuator rod
(10) Actuator motor(11) Actuator bracket
Tightening torque: N´m (kg-m, ft-lb)
T:
7.35±1.96 (0.750±0.200,
5.421
±1.446)
5
[C300]4-6COMPONENT PARTS
3. Intake Unit

4. Control Unit
B4M0369B
(1) Back plate
(2) Bulb
(3) Fan switch ASSY
(4) Illumi. plate
(5) Switch base(6) Control panel
(7) Fan switch knob
(8) RECIRC switch
(9) A/C switch
(10) Temp. switch knob(11) Mode switch
(12) Temp. lever ASSY
(13) Base plate
(14) Control amp.
(15) Temp. control cable
6
4-6[C400]COMPONENT PARTS
4. Control Unit

1. Precaution
A: SUPPLEMENTAL RESTRAINT
SYSTEM ªAIRBAGº
CAUTION:
IAll Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
IBe careful not to damage Airbag system wir-
ing harness when servicing the instrument
panel, heater unit, blower motor and control
unit.
Airbag system wiring harness is routed near 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
compartment.
NOTE:
Drain as much coolant from heater unit as
possible, and plug disconnected hose with cloth.

3) Remove instrument panel. [W1A0].>
4) Remove steering support beam. [C600].>
5) Remove evaporator. (With A/C model) 4-7 [W14A0].>
6) Remove heater unit.
G4M0554
7) Installation is in the reverse order of removal.
Fitted length of heater hose over pipe:
25 Ð 30 mm (0.98 Ð 1.18 in)
8) Pour coolant.
7
[W2A0]4-6SERVICE PROCEDURE
2. Heater Unit

1. Precaution
A: SUPPLEMENTAL RESTRAINT
SYSTEM ªAIRBAGº
CAUTION:
IAll Airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuit.
IBe careful not to damage Airbag system wir-
ing harness when servicing the instrument
panel, heater unit, blower motor and control
unit.
Airbag system wiring harness is routed near 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
compartment.
NOTE:
Drain as much coolant from heater unit as
possible, and plug disconnected hose with cloth.

3) Remove instrument panel. [W1A0].>
4) Remove steering support beam. [C600].>
5) Remove evaporator. (With A/C model) 4-7 [W14A0].>
6) Remove heater unit.
G4M0554
7) Installation is in the reverse order of removal.
Fitted length of heater hose over pipe:
25 Ð 30 mm (0.98 Ð 1.18 in)
8) Pour coolant.
7
[W2A0]4-6SERVICE PROCEDURE
2. Heater Unit

3. Blower Motor Assembly
A: REMOVAL AND INSTALLATION
1) Disconnect GND cable from battery.
2) Remove glove box and pocket back panel.

3) Disconnect blower motor harness connector.
B5M0025
4) Disconnect aspirator pipe (A).
5) Remove blower motor mounting screw.
B4M1082B
6) Remove blower motor assembly.
7) Installation is in the reverse order of removal.
4. Control Unit
A: REMOVAL AND INSTALLATION
1) Disconnect GND cable from battery.
2) Set temperature control lever to ªFULL COLDº
position.
3) Remove temperature control cable from heater
unit.
NOTE:
Do not attempt to move link of heater unit during
installation.
B5M0027
4) Remove cup holder.
5) Remove center panel and then disconnect con-
nector.
B4M0370
6) Remove control unit assembly and disconnect
connector.
B4M0059
7) Installation is in the reverse order of removal.
NOTE:
Before control unit installation, set temperature
control lever to ªFULL COLDº position.
8
4-6[W3A0]SERVICE PROCEDURE
3. Blower Motor Assembly

3. Blower Motor Assembly
A: REMOVAL AND INSTALLATION
1) Disconnect GND cable from battery.
2) Remove glove box and pocket back panel.

3) Disconnect blower motor harness connector.
B5M0025
4) Disconnect aspirator pipe (A).
5) Remove blower motor mounting screw.
B4M1082B
6) Remove blower motor assembly.
7) Installation is in the reverse order of removal.
4. Control Unit
A: REMOVAL AND INSTALLATION
1) Disconnect GND cable from battery.
2) Set temperature control lever to ªFULL COLDº
position.
3) Remove temperature control cable from heater
unit.
NOTE:
Do not attempt to move link of heater unit during
installation.
B5M0027
4) Remove cup holder.
5) Remove center panel and then disconnect con-
nector.
B4M0370
6) Remove control unit assembly and disconnect
connector.
B4M0059
7) Installation is in the reverse order of removal.
NOTE:
Before control unit installation, set temperature
control lever to ªFULL COLDº position.
8
4-6[W3A0]SERVICE PROCEDURE
3. Blower Motor Assembly