ac 25 procedure SUBARU TRIBECA 2009 1.G Service Owner's Guide

EI-26
Front Bumper
EXTERIOR/INTERIOR TRIM
9Welding
Using a heater gun and PP welding rod, weld the beveled spot while melting both the rod and
damaged area.
(1) Welding rod
(2) Melt hatched area
(3) Section
NOTE:•Melt the sections indicated by hatched area.
•Do not melt the welding rod until it flows out, in order to provide strength.
•Always keep the heater gun 1 to 2 cm (0.4 to 0.8 in) away from the welding spot.
•Leave the welded spot unattended until it cools completely.
10 Sanding (II)
Remove excess part of weld with a putty knife. If a drill or disc wheel is used instead of the knife,
operate it at a rate lower than 1,500 rpm and grind the excess part little by little. A higher rpm will
cause the PP substrate to melt from the heat.
Sand the welded spot smooth with #240 sand paper.
11 MaskingMask the black substrate section using masking tape.
Recommended masking tape: Nichiban No. 533 or equivalent
12Cleaning/degreas-
ingCompletely clean the entire coated area, using solvent similar to that used in Procedure 4.
13 Primer coating
Apply a coat of primer to the repaired surface and its surrounding areas. Mask these areas, if
necessary.
Recommended primer: Mp/ 364 PP Primer
NOTE:Be sure to apply a coat of primer using a spray gun at a pressure of 245 — 343 kPa (2.5 — 3.5
kg/cm2, 36 — 50 psi).
14 Leave unattended
Leave the repaired area unattended at 20°C (68°F) for 10 to 15 minutes until primer is half-dry.
NOTE:If dirt or dust comes in contact with the coated area, wipe it off with a cloth dampened with alcohol.
(Do not use thinner since the coated area tends to melt.)
15Primer surfacer
coating
Apply primer surfacer to the repaired area two or three times at an interval of 3 - 5 minutes.
Recommended surfacer:
•UPS 300 Flex Primer
•No. 303 UPS 300 Exclusive hardener
•NPS 725 Exclusive Reducer (thinner)
•Mixture ratio:
2 : 1 (UPS 300 : No. 303)
•Viscosity: 12 — 14 sec./20°C (68°F)
• Coating film thickness: 40 — 50 µ
16 Drying Allow the coated surface to dry for 60 minutes at 20°C (68°F) [or 30 minutes at 60°C (140°F)].
17 Sanding (III) Sand the coated surface and its surrounding areas using #400 sand paper and water.
Process
No.Process name Job contents
(1)
(2)
(2)
(3)
EI-00237
EI-00042

EI-41
Instrument Panel Assembly
EXTERIOR/INTERIOR TRIM
13) Make sure that the instrument panel upper is
removed from the steering support beam
14) Disconnect the connectors, and remove the in-
strument panel from vehicle body.
15) Remove the heater vent duct. REMOVAL, Heater Vent Duct.>
16) Remove the air vent grille. MOVAL, Air Vent Grille.>
17) Remove the passenger airbag module. to AB-16, REMOVAL, Passenger’s Airbag Mod-
ule.>
2. STEERING SUPPORT BEAM
1) Remove the instrument panel upper.
2) Remove the bolts, and then remove the knee
guard plate.
3) Remove the steering shaft from the steering
support beam. Steering Column.>
4) Remove the bolts and remove the steering sup-
port beam.
3. INSTRUMENT PANEL ASSEMBLY
1) Disconnect the ground cable from battery and
wait for at least 20 seconds before starting work.
2) Remove the console box. MOVAL, Console Box.>
3) Remove the instrument panel lower cover. to EI-36, REMOVAL, Instrument Panel Lower Cov-
er.>
4) Remove the glove box. AL, Glove Box.>
5) Remove the center console. MOVAL, Center Console.>
6) Remove the front pillar upper trim. 43, REMOVAL, Side Trim.>
7) Remove the steering shaft from the steering
support beam. Steering Column.>
8) Disconnect the connectors, and remove the in-
strument panel from vehicle body.
9) Remove the bolts and remove the steering sup-
port beam.
NOTE:
For positions of the mounting bolt of steering sup-
port beam, refer to the removal procedure of the
steering support beam.
10) Make sure that the each harness connector is
disconnected, and remove the instrument panel as-
sembly from the vehicle body.
NOTE:
Remove the passenger’s side door trim to facilitate
the work.
EI-01331
EI-01332

EI-52
Rear Gate Garnish
EXTERIOR/INTERIOR TRIM
25.Rear Gate Garnish
A: REMOVAL
1) Remove the hexagon cap nut (A).
2) Remove the rear gate garnish.
B: INSTALLATION
Use new double-sided tapes, and install in the re-
verse order of removal.
NOTE:
Refer to the installing procedure of side garnish.
Tightening torque:
4.5 N·m (0.46 kgf-m, 3.32ft-lb)
(A) Hexagon cap nut
(B) Double-sided tape
EI-01355
(A)
EI-01356
(B)
(A)

GW-21
Front Quarter Glass
GLASS/WINDOWS/MIRRORS
14.Front Quarter Glass
A: REMOVAL
Remove the front quarter glass in the same proce-
dure as for windshield glass. MOVAL, Windshield Glass.>
B: INSTALLATION
1) Cut out the nozzle head and apply adhesive to
the glass end surface as shown.
2) Install the glass in the same procedure as for
windshield glass. TION, Windshield Glass.>
3) After completion of all work, allow the vehicle to
stand for about 24 hours.
NOTE:
•When door is opened/closed after glass is bond-
ed, always lower the door glass first, and then
open/close it carefully.
•Move the vehicle slowly.
•For minimum drying time and vehicle standing
time before driving after bonding, follow instruc-
tions or instruction manual from the adhesive man-
ufacturer.
4) After curing of adhesive, pour the water on exter-
nal surface of vehicle to check that there are no wa-
ter leaks.
NOTE:
When a vehicle is returned to the user, tell him or
her that the vehicle should not be subjected to
heavy impact for at least three days.
(1) Locating pin
(2) Fastener
(3) Encap molding
(4) Adhesive
GW-00496(4)
(1)
(3)
(2)AB
C
C
B
A
(1) Encap molding
(2) Adhesive
(3) 8 mm (0.31 in)
(4) 9 mm (0.35 in)
(5) 2 mm (0.07 in)
(6) 10 mm (0.39 in)
(7) 4.5 mm (0.17 in)
(8) 11 mm (0.43 in)
GW-00497
(1)
(3)
(7)
(4)
(5)
(3)
(6)
(4)
(5)
(3)
(8)
(4)(5)
(2)

(1)(1)
(2)
(2)
A-A
C-CB-B
(6)(3)
(5)
(4)
60

GW-22
Rear Gate Glass
GLASS/WINDOWS/MIRRORS
15.Rear Gate Glass
A: REMOVAL
1) Remove the rear wiper motor. REMOVAL, Rear Wiper Motor.>
2) Disconnect the electrical connectors from rear
defogger terminal.
3) Remove the glass in the same procedure as for
windshield glass. Windshield Glass.>
B: INSTALLATION
1) Mount the fastener on the body.
2) Install the dam rubber.
3) Cut off the cartridge nozzle tip as shown and set
it in sealant gun.
4) Apply adhesive in the same procedure as for
windshield glass. TION, Windshield Glass.>
5) Insert the glass clip pin into rear gate hole, push
on the area around the clip pin to secure it, and
then push lightly all around the area to seal it.
(1) Glass
(2) Spacer
(3) Adhesive
(4) Fastener
(5) 4 mm (0.15 in)
(6) 8 mm (0.31 in)
(7) 10 mm (0.39 in)
(8) 5.5 mm (0.22 in)

GW-27
Rear Quarter Glass
GLASS/WINDOWS/MIRRORS
18.Rear Quarter Glass
A: REMOVAL
Remove the glass in the same procedure as for
windshield glass. Windshield Glass.>
B: INSTALLATION
1) Install the dam rubber.
2) Cut out the nozzle head and apply adhesive to
the glass end surface as shown.
3) Install the glass in the same procedure as for
windshield glass. TION, Windshield Glass.>
4) After completion of all work, allow the vehicle to
stand for about 24 hours.
NOTE:
•When door is opened/closed after glass is bond-
ed, always lower the door glass first, and then
open/close it carefully.
•Move the vehicle slowly.
•For minimum drying time and vehicle standing
time before driving after bonding, follow instruc-
tions or instruction manual from the adhesive man-
ufacturer.
5)After curing of adhesive, pour the water on external
surface of vehicle to check that there are no water leaks.
NOTE:
When a vehicle is returned to the user, tell him or
her that the vehicle should not be subjected to
heavy impact for at least three days.
(1) Locating pin
(2) Dam rubber
(3) Fastener
(4) Adhesive
(5) Encap molding
GW-00500
(4)
(2)
(5)
(2)
(1)(1)
(3)
C
B
BB
C
A
A
(1) Dam rubber
(2) Adhesive
(3) Encap molding
(4) 8 mm (0.31 in)
(5) 9 mm (0.35 in)
(6) 2 mm (0.07 in)
(7) 4 mm (0.15 in)
(8) 11 mm (0.43 in)
(9) 10 mm (0.39 in)
GW-00501
(3)
(4)(7)
(5)
(6)
(4)
(5)(6)
(7)
(2)
(1)
(3)
(2)
(8)
(4)
(6)
(5)
(3)
(2)
A-A
C-CB-B
(9)(4)
(6)
(5)
60

AC-14
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
C: CAUTION
1. HFC-134A A/C SYSTEM
•The cooling system components for the HFC-
134a system such as the refrigerant and compres-
sor oil are different from the conventional CFC-12
system components and they are incompatible with
each other.
•Vehicles with the HFC-134a system can be iden-
tified by the label (A) attached to the vehicle.
Before maintenance, check which A/C system is in-
stalled to the vehicle.
2. COMPRESSOR OIL
•HFC-134a compressor oil has no compatibility
with that of CFC-12 system.
•Use only Denso Oil 8, the manufacturer-autho-
rized compressor oil for the HFC-134a system.
•Do not mix multiple compressor oils.
If CFC-12 compressor oil is used in the HFC-134a
A/C system, the compressor may become stuck
due to poor lubrication, or the refrigerant may leak
due to swelling of rubber parts.
On the other hand, if HFC-134a compressor oil is
used in a CFC-12 A/C system, the durability of the
A/C system will be lowered.
•HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from atmosphere using a
plug or tape. In order to avoid moisture, store the oil
in a container with its cap tightly closed.
3. REFRIGERANT
•CFC-12 refrigerant cannot be used in a HFC-
134a A/C system. HFC-134a refrigerant, also can-
not be used in a CFC-12 A/C system.
•If an incorrect or no refrigerant is used, it will re-
sult in poor lubrication and the compressor itself
may be damaged.
4. HANDLING OF REFRIGERANT
•The refrigerant boils at approx. –30°C (22°F).
When handling it, be sure to wear protective gog-
gles and protective gloves. Direct contact of the re-
frigerant with skin may cause frostbite.
If the refrigerant gets into your eye, avoid rubbing
your eyes with your hands. Wash your eye with
plenty of water, and receive medical treatment from
an eye doctor.
•Do not heat a service can. If a service can is di-
rectly heated, or put into boiling water, the inside
pressure will become extremely high. This may
cause the can to explode. If a service can must be
warmed up, use warm water of 40°C (104°F) or less.
•Do not drop or subject a service can to impacts.
(Observe the precautions and operation procedure
described on the refrigerant can.)
•When the engine is running, do not open the
high-pressure valve of the manifold gauge. High-
pressure gas can back-flow resulting in an explo-
sion of the can.
•Provide good ventilation and do not work in a
closed area.
•In order to prevent global warming, avoid releas-
ing HFC-134a into the atmosphere. Using a refrig-
erant recovery system, discharge and recycle the
gas.
AC-01380
(A) Goggles
(B) Gloves
(C) Avoid open flame
(D) No direct heat on container
(E) Do not discharge
(F) Loosen
(A)(B)
(C) (D)
(E)
(F)
AC-00007

AC-19
Refrigerant Pressure with Manifold Gauge Set
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
2. Refrigerant Pressure with Manifold Gauge Set
A: PROCEDURE
1) Place the vehicle in the shade and windless condition.
2) Connect the manifold gauge set.
3) Open all windows and close all doors.
4) Increase the engine to 1,500 rpm.
5) Turn on the A/C switch.
6) Turn the temperature control switch to MAX COOL.
7) Put in RECIRC position.
8) Turn the blower control switch to HI.
9) Read the gauge.
Standard:
Low pressure: 127 — 196 kPa (1.3 — 2.0 kg/cm2, 18 — 28 psi)
High pressure: 1,471 — 1,667 kPa (15 — 17 kg/cm2, 213 — 242 psi)
Ambient temperature: 30 — 35°C (86—95°F)
B: INSPECTION
Symptom Probable cause Repair order
High-pressure side is unusually high.
•Defective condenser fan motor
•Clogged condenser fin
•Too much refrigerant
•Air inside the system
•Defective receiver dryer
•Replace the fan motor.
•Clean the condenser fin.
•Discharge refrigerant.
•Replace the receiver dryer.
•After evacuating again, charge an
appropriate amount of refrigerant.
High-pressure side is unusually low.
•Defective compressor
•Not enough refrigerant
•Clogged expansion valve
•Expansion valve frozen temporarily by
moisture.
•Replace the compressor.
•Check for leaks.
•Replace the expansion valve.
•Fully evacuate the expansion valve.
Low-pressure side is unusually high.
•Defective compressor
•Defective expansion valve
•Too much refrigerant
•Replace the compressor.
•Replace the expansion valve.
•Discharge refrigerant.
Low-pressure side is unusually low.
•Not enough refrigerant
•Clogged expansion valve
•Expansion valve frozen temporarily by
moisture.
•Saturated receiver dryer
•Check for leaks.
•Replace the expansion valve.
•Replace the receiver dryer.

AC-20
Refrigerant Recovery Procedure
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
3. Refrigerant Recovery Proce-
dure
A: PROCEDURE
CAUTION:
•During operation, be sure to wear protective
goggles and protective gloves.
•Connect the refrigerant recovery system with
the manifold gauge set to discharge the refrig-
erant from the A/C system and recycle the gas.
•When recycling the discharged refrigerant,
keep service cans on hand. Because the recov-
ery rate with the recovery system is approx.
90%, service cans are necessary to charge the
refrigerant.
•Follow the detailed operation procedure de-
scribed in the operation manual attached to the
refrigerant recovery system.
1) Perform the compressor oil return operation.

2) Stop the engine.
3) Make sure the valves on low-/high-pressure
sides of manifold gauge set are fully closed.
4) Install the low-/high-pressure hoses to the ser-
vice ports on the low-/high-pressure sides of the
vehicle respectively.
5) Connect the center hose to the refrigerant recov-
ery system.
6) Follow the operation manual to activate the re-
frigerant recovery system.
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
AC-00021
(A) (B)
(C)(C)
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
(D) Low-pressure side service port
(E) High-pressure side service port
AC-00022
(A) (B)
(C)(C)
(E)(D)

AC-21
Refrigerant Charging Procedure
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
4. Refrigerant Charging Proce-
dure
A: PROCEDURE
CAUTION:
•During operation, be sure to wear protective
goggles and protective gloves.
•Before charging the refrigerant, evacuate the
system to remove small amounts of moisture
remaining in the system.
The moisture in the system can be completely
evacuated only under the minimum vacuum
level. The minimum vacuum level affects the
temperature in the system.
•The list below shows the vacuum values nec-
essary to boil water at various temperatures. In
addition, the vacuum levels indicated on the
gauge are approx. 3.3 kPa (25 mmHg, 0.98 inHg)
lower than those measured at 304.8 m (1,000 ft)
above sea level.
1) Close the valves on low-/high-pressure sides of
the manifold gauge.
2) Install the low-/high-pressure hoses to the corre-
sponding service ports on the vehicle.
3) Connect the center hose of the manifold gauge
set with the vacuum pump.
4) Carefully open the valves on the low-/high-pres-
sure sides to activate the vacuum pump.
5) After the low-pressure gauge reaches 100.0 kPa
(750 mmHg, 29.5 inHg) or higher, evacuate the
system for approx. 15 minutes. (Continue evacua-
tion).
6) After 15 minutes of evacuation, if the reading
shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher,
close the valves on the both sides to stop the vac-
uum pump.
Va c u u m l eve l r e q u i r e d t o b o i l w a t e r ( a t s e a l eve l )
Te m p e r a t u r e Va c u u m
1.7°C (35°F) 100.9 kPa (757 mmHg, 29.8 inHg)
7.2°C (45°F) 100.5 kPa (754 mmHg, 29.7 inHg)
12.8°C (55°F) 99.8 kPa (749 mmHg, 29.5 inHg)
18.3°C (65°F) 99.2 kPa (744 mmHg, 29.3 inHg)
23.9°C (75°F) 98.5 kPa (739 mmHg, 29.1 inHg)
29.4°C (85°F) 97.2 kPa (729 mmHg, 28.7 inHg)
35°C (95°F) 95.8 kPa (719 mmHg, 28.3 inHg)
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
AC-00023
(A) (B)
(C)(C)
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Slowly open
(D) Vacuum pump turn on
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
(D) Vacuum pump turn off
AC-00024
(A) (B)
(D)
(C)(C)
AC-00025
AC-00026
(A) (B)
(D)
(C)(C)