2004 IMPREZA SERVICE MANUAL QUICK
Contents
1. AC 00031 A Low pressure gauge Compound pressure gauge High pressure gauge Close Ignition switch OFF Slowly open CAUTION Never run the engine during charging from the high pressure side 16 Close the high pressure valve when the low pressure gauge reaches 98 kPa 1 kg cm 14 psi Using a leak tester check the system for leaks If any leakage is found after the refrigerant recov ery is completed repair the applicable area AC 23 Refrigerant Charging Procedure HVAC SYSTEM HEATER VENTILATOR AND 17 After confirming that there are no leaks with the leak test charge the required amount of refrigerant CAUTION Never run the engine during charging from the high pressure side 18 Close the high pressure valve when the readings of low high pressure gauges be come almost equal after the charging speed is re duced the HFC 134a source becomes empty or the system is filled with the gas V b o 5 SS KS 19 If the HFC 134a source is empty close the high pressure valve close the valve on the can tap and replace the HFC 134a source with new one to restart the operation AC 00032 C C ey amem Co AC 00033 A Low pressure gauge Compound pressure gauge B High pressure gauge C Close 20 Confirm that both the low high pressur2. CAUTION Becareful not to damage the condenser fins If a damaged fin is found repair it using a thin screwdriver If the condenser is replaced add appropriate amount of compressor oil to the compressor Ref to AC 26 REPLACEMENT Compressor Cil HVAC SYSTEM HEATER VENTILATOR AND A C B INSTALLATION 1 Install in the reverse order of removal CAUTION Replace the O rings on hoses or pipes with new ones and then apply compressor oil Confirm that lower guide of condenser A has been fit ted into holes on radiator panel Ny A AC 00631 2 Charge refrigerant lt Ref to AC 22 OPERA TION Refrigerant Charging Procedure gt Tightening torque Refer to COMPONENT in General Descrip tion lt Ref to AC 11 AIR CONDITIONING UNIT COMPONENT General Description gt and lt Ref to CO H4SO 4 RADIATOR AND RADIATOR FAN COMPONENT General De scription gt C INSPECTION 1 Confirm that no dust or insects are found on the condenser fins Air blow or flush fins with water as needed 2 Confirm that no oil leaks from condenser If a failure is found replace the condenser with a new one AC 33 Heater and Cooling Unit HVAC SYSTEM HEATER VENTILATOR AND 14 Heater and Cooling Unit A REMOVAL 1 Disconnect the ground cable from battery 2 Using the refrigerant recovery system dis charge refrigerant lt Ref to AC 21 OPER
3. 7 Remove the low pressure hose and high pres sure hose 8 Disconnect the compressor harness from body harness 9 Loosen the bolts to remove the compressor bracket LH OF C UN TRR JD AU Et AC 00627 10 Remove the bolts and then separate the com pressor and bracket AC 00628 C INSTALLATION 1 Install in the reverse order of removal 2 Replace the O rings on low high pressure hos es with new ones then apply compressor oil 3 When replacing compressor adjust amount of compressor oil lt Ref to AC 26 OPERATION Compressor Oil gt 4 Charge refrigerant lt Ref to AC 22 OPERA TION Refrigerant Charging Procedure gt Tightening torque Refer to COMPONENT in General Descrip tion lt Ref to AC 11 AIR CONDITIONING UNIT COMPONENT General Description gt and lt Ref to AC 13 COMPRESSOR COMPONENT General Description gt AC 32 Condenser 13 Condenser A REMOVAL 1 Using the refrigerant recovery system dis charge refrigerant lt Ref to AC 21 OPERATION Refrigerant Recovery Procedure gt 2 Disconnect the ground cable from battery 3 Disconnect the pressure hose and pipe from condenser 5 Remove the two bolts While lifting the condens er pull it out through the space between radiator and radiator panel Bs a l 0210
4. 125 mm 4 92 in Pulley ratio 1 064 Condenser Type Corrugated fin Sub cool type Core face area 0 21 m 2 26 sq ft Core thickness 16 mm 0 63 in Radiation area 5 34 m 57 48 sq ft Receiver drier Effective inner capacity 250 cm 15 26 cu in Expansion valve Type Internal equalizing Evaporator Type Single tank Dimensions W x H x T 255 x 200 x 48 mm 10 x 7 87 x 1 89 in Blower fan Fan type Sirocco fan Outer diameter x width 150 x 75 mm 5 91 x 2 95 in Power consumption AC 2 200W Condenser fan Sub fan General Description HVAC SYSTEM HEATER VENTILATOR AND A C Motor type Magnet Power consumption 120 W Turbo model 70 W Non turbo model Fan outer diameter 320 mm 12 6 in Radiator fan Main fan Motor type Magnet Power consumption 120 W Turbo model 70 W Non turbo model Fan outer diameter 320 mm 12 6 in Idling speed A C ON MPFI model 850 100 rpm Low pressure switch operating pressure Dual switch ON gt OFF 278 29 kPa 2 83 0 3 kg cm 40 3 4 2 psi OFF 3 ON 287199 xr kPa 2 9 9 5 kg cm 42 57 3 g psi Pressure switch High pressure switch operating pressure ON 5 OFF 2 800100 kPa 2931 kg cm 406 15 psi DIFF 6004200 kPa 6 1242 kg cm 87429 psi Thermo control amplifier workin
5. 5 4 10 Unit duct cover 20 Packing AC 5 General Description HVAC SYSTEM HEATER VENTILATOR AND A C MANUAL A C MODEL Sd 10 8 AC 00733 1 Unit cover 10 Heater core 18 O ring 2 Side link 11 Drain hose 19 Expansion valve 3 Mode lever 12 Mix lever 20 Evaporator 4 Foot lever 13 Unit assembly 21 Evaporator cover 5 Spring 14 Foot duct 22 Thermistor 6 Mode link 15 Clip 7 Defroster lever 16 Packing Tightening torque N m kgf m ft lb 8 Foot nozzle 17 Cooling unit block 7 4 0 75 5 4 9 Unit duct cover AC 6 General Description HVAC SYSTEM HEATER VENTILATOR AND A C 2 BLOWER MOTOR UNIT AUTO A C MODEL AC 00605 1 Upper case 6 Blower link lever C 11 Power transistor 2 Servo motor 7 Filter cover 12 Power transistor cover 3 Blower link 8 Filter 4 Blower link lever A 9 Blower motor assembly Tightening torque N m kgf m ft Ib 5 Blower link lever B 10 Hose T 7 4 0 75 5 4 AC 7 General Description HVAC SYSTEM HEATER VENTILATOR AND A C WITHOUT A C MODEL AND MANUAL A C MODEL 2 4 dd PS PDS ME SS 1 7 00734 1 Upper case 6 Filter cover Tightening torque N m kgf m ft lb 2 Blower link 7 Filter T 7 4 0 75 5 4 3 Blower link lever A 8 Blower motor assembly 4 Bl
6. AC 11 General Description HVAC SYSTEM HEATER VENTILATOR AND A C RHD MODEL AC 00979 1 Condenser 4 Tube Tightening torque N m kgf m ft Ib 2 Hose High pressure 5 Compressor Ti 7 4 0 75 5 4 3 Hose Low pressure 6 O ring T2 15 1 5 10 8 AC 12 General Description HVAC SYSTEM HEATER VENTILATOR AND A C 5 COMPRESSOR T5 l T2 AC 00611 1 Idler pulley bracket 7 V belt Tightening torque N m kgf m ft Ib 2 Idler pulley adjuster 8 Compressor belt cover 1 7 4 0 75 5 4 3 Idler pulley 9 Compressor belt cover bracket T2 22 6 2 3 16 6 4 Compressor upper bracket 23 0 2 35 17 0 5 Compressor T4 28 9 2 95 21 3 6 Compressor lower bracket T5 35 3 6 26 AC 13 General Description HVAC SYSTEM HEATER VENTILATOR AND 6 HEATER DUCT AC 00612 Front defroster nozzle Side defroster duct LH Side defroster duct RH Side ventilation duct LH Side ventilation duct RH Rear heater duct LH AC 14 7 Rear heater duct RH General Description HVAC SYSTEM HEATER VENTILATOR AND A C C CAUTION 1 HFC 134A A C SYSTEM Unlike the old conventional CFC 12 system com ponents the cooling system components for the HFC 134a system suc
7. AND A C 7 Note the low pressure gauge reading AC 00027 8 Leave it at least 5 minutes and then check the low pressure gauge reading for any changes When a gauge indicator shows near to zero point this is a sign of leakage Check pipe connector points repair them make sure there is no leakage by air bleeding 9 Following the can tap operation manual instruc tions install it to the refrigerant can AC 00028 A Tap valve B Center manifold hose 10 Disconnect the center manifold hose from the vacuum pump and connect the hose to the tap valve 11 When a 13 6 kg 30 Ib refrigerant container is used measure the refrigerant amount in use using a weighting scale AC 00029 A Refrigerant container HFC 134a B Weight scale 12 Confirm that all the 3 hoses are tightly connect ed to the manifold gauge set AC 00030 A Low pressure gauge Compound pressure gauge B High pressure gauge C Close 13 Open the valve on the HFC 134a source 14 Loosen the center hose connection on the manifold gauge set if applicable press a purge valve on the manifold gauge set only for a couple of seconds to allow the air in the center hose to es cape by the refrigerant 15 Carefully open the high pressure valve with the engine stopping CAUTION Do not open the low pressure valve
8. to damage the sensors and inte rior trims when removing them B INSTALLATION Install in the reverse order of removal C INSPECTION Ref to AC diag 33 SUNLOAD SENSOR Diag nostic Procedure for Sensors AC 40 Air Vent Grille HVAC SYSTEM HEATER VENTILATOR AND A C 21 Air Vent Grille A REMOVAL 1 CENTER GRILLE 1 Disconnect the ground cable from battery 2 Remove the center console panel A 3 Loosen the two screws to remove the center air vent grille B AC 00644 2 SIDE GRILLE 1 Disconnect the ground cable from battery 2 Remove the heater vent duct lt Ref to AC 43 REMOVAL Heater Vent Duct gt 3 Loosen the screws to remove the side air vent grille UO TF T AC 00645 B INSTALLATION Install in the reverse order of removal C INSPECTION The direction and amount of air should be adjusted smoothly The adjustment should be kept in each position AC 41 Heater Duct HVAC SYSTEM HEATER VENTILATOR AND A C 22 Heater Duct A REMOVAL 1 Remove the front seat lt Ref to SE 6 REMOV AL Front Seat gt 2 Remove the front side sill cover 3 Pull off the floor mat to remove the heater duct AC 00646 B INSTALLATION Install in the reverse order of removal AC 42 Heater Vent Duct HVAC SYSTEM HEATER VENTILATOR AND A C 23 Heater Vent Duct A REMOVAL 1 Remove the instrument panel
9. 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION HVAC SYSTEM HEATER VENTILATOR AND A C HVAC SYSTEM AUTO A C DIAGNOSTICS AIRBAG SYSTEM AB AIRBAG SYSTEM DIAGNOSTICS This service manual has been prepared to provide SUBARU service personnel with the necessary information and data for the correct maintenance and repair of SUB ARE HII LIGHTING SYSTEM LI This manual includes the procedures for maintenance disassembling reas sembling inspection and adjustment of WIPER AND WASHER SYSTEMS components and diagnostics for guid ance of experienced mechanics Please peruse and utilize this manual ENTERTAINMENT fully to ensure complete repair work for satisfying our customers by keeping their vehicle in optimum condition COMMUNICATION SYSTEM When replacement of parts during repair work is needed be sure to use SUBARU genuine parts GLASS WINDOWS MIRRORS GW SEAT BELT SYSTEM SB BODY STRUCTURE BS INSTRUMENTATION DRIVER INFO IDI SEATS SE SECURITY AND LOCKS SL SUNROOF T TOP CONVERTIBLE gp SUNROOF EXTERIOR INTERIOR TRIM EI All information illustration and specifi cations contained in this manual are based on the latest product information available at the time of publication approval EXTERIOR BODY PANELS FUJI HEAVY INDUSTRIES LTD G1870GE6 2004 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX BODY SECTION CRUISE CONTROL SYSTEM CC
10. ATION Refrigerant Recovery Procedure gt 3 Drain LLC from the radiator 4 Remove the bolt securing expansion valve and pipe in engine compartment Release the heater hose clamps in engine compartment to remove the hoses e LHD MODEL 5 Remove the instrument panel lt Ref to El 43 REMOVAL Instrument Panel Assembly gt 6 Remove the support beam 7 Remove the blower motor unit assembly lt Ref to AC 27 REMOVAL Blower Motor Unit Assem bly gt 8 Disconnect the servo motor connectors 9 Loosen the bolt and nuts to remove the heater and cooling unit B INSTALLATION 1 Install in the reverse order of removal 2 Charge refrigerant lt Ref to AC 22 OPERA TION Refrigerant Charging Procedure gt Tightening torque Refer to COMPONENT in General Descrip tion lt Ref to AC 5 HEATER COOLING UNIT COMPONENT General Description gt AC 34 Evaporator HVAC SYSTEM HEATER VENTILATOR AND A C 15 Evaporator A REMOVAL 1 Remove the heater and cooling unit Ref to AC 34 REMOVAL Heater and Cooling Unit 2 Loosen the screws and clip to remove the evap orator cover AC 00633 AC 00634 4 Loosen the two bolts to remove the expansion valve DW 2 ge U 00635 CAUTION If the evaporator is replaced add appropriate amount of compressor oil
11. ATOR AND A C 2 Refrigerant Pressure with Manifold Gauge Set A OPERATION 1 Place the vehicle in the shade and windless condition Connect the manifold gauge set Open the front windows and close all doors Open the front hood Turn ON the A C switch Turn the temperature control switch to MAX COOL 2 3 4 5 Increase the engine to 1 500 rpm 6 7 8 Put in RECIRC position 9 Turn the blower control switch to HI 10 Read the gauge Standard Low pressure 127 196 kPa 1 3 2 0 kg cm 18 28 psi High pressure 1 471 1 667 kPa 15 17 kg cm 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 revacuating the receiver dryer charge appropriate amount of refriger ant 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 Defecti
12. C Model HVAC SYSTEM HEATER VENTILATOR AND A C 8 Power Transistor Auto A C Model A REMOVAL 1 Remove the glove box lt Ref to El 39 REMOV AL Glove Box gt 2 Disconnect the power transistor connector 3 Loosen the two screws to remove the power transistor AC 00615 B INSTALLATION Install in the reverse order of removal AC 28 Blower Resistor Without Model and Manual Model 9 Blower Resistor Without A C Model and Manual A C Model A REMOVAL 1 Remove the glove box lt Ref to El 39 REMOV AL Glove Box gt 2 Disconnect the blower resistor connector 3 Loosen the two screws to remove the blower re sistor AC 00615 B INSTALLATION Install in the reverse order of removal C INSPECTION AC 00621 Measure the blower resistor resistance Terminal No Standard 3 and 1 Approx 0 51 2 2 Approx 2 70 Q 3 and 4 Approx 1 43 If NG replace the blower resistor AC 29 HVAC SYSTEM HEATER VENTILATOR AND A C Heater Core HVAC SYSTEM HEATER VENTILATOR AND A C 10 Heater Core A REMOVAL 1 Remove the heater and cooling unit Ref to AC 34 REMOVAL Heater and Cooling Unit 2 Loosen the screws to remove the heater core cover AC 00622 AC 00623 B INSTALLATION Install in th
13. CRUISE CONTROL SYSTEM CC diag DIAGNOSTICS IMMOBILIZER DIAGNOSTICS IM diag G1870GE6 HVAC SYSTEM HEATER VENTILATOR AND A C SO Bo ROC qe ea Tore PO PO NMP AH AH AH AH AH AH AB AB Aa at SINNI m 0 ND Page General Description ss 2 Refrigerant Pressure with Manifold Gauge 20 Refrigerant Recovery Procedure 21 Refrigerant Charging Procedure 22 Refrigerant Leak 25 C mpressor Qil ass alva ft S ETE 26 Blower Motor Unit Assembly 27 Power Transistor Auto A C Model sse 28 Blower Resistor Without A C Model and Manual A C 29 Heater Core oe contio ena da tin naines 30 Control UNU soo e dnd dti v Get 31 COMDASSO 32 GONGENS SM es sn danoise b duda vl tipa 33 Heater and Cooling Unit sandrine 34 E A der 35 Hose and 22 10 saa see 36 Relay andi FUSE RER EE 37 Pressure Switch Dual Switch 38 Ambient Sensor Auto A C Model 39 Sunload Sensor Auto A C Model 40 guider 41 Heater ves ac ennemies sant 42 Heater Vent DUCH ie aetema ee VR TEE CER ERR 43 General Diagnostic Table 44 General Descri
14. Disconnect the drain hose from the heater case and check the hose end for at least 10 sec onds After the test is finished reconnect the drain hose 11 Turn the ignition key to ON position and run the blower at high speed for 1 minute Stop the blower to check the ventilation grille on the instru ment panel While moving the tester closer to the grille run the blower for 1 or 2 seconds then stop it Check the grille at that point for at least 10 seconds AC 00037 12 Check the valve in the service port 13 Visually check the rubber seal in service port cap AC 00038 AC 25 Compressor Oil HVAC SYSTEM HEATER VENTILATOR AND A C 6 Compressor Oil A OPERATION NOTE Before making repairs conduct the oil return oper ation to return the compressor oil in circulation with the refrigerant to compressor 1 Increase the engine speed to 1 500 rpm 2 Turn ON the A C switch 3 Turn the temperature control switch to MAX COOL 4 Put in RECIRC position 5 Turn the blower control switch to HI 6 Leave in this condition for 10 minutes B REPLACEMENT NOTE f a component is replaced add an appropriate amount of compressor oil When replacing the compressor the new com pressor will already have the specified amount of oil in it Install the new compressor after removing the same amount of oil that is remaining in the com pressor removed R
15. Fan outer diameter 320 mm 12 6 in Radiator fan Main fan Motor type Magnet Power consumption 120 W Turbo model 70 W Non turbo model Fan outer diameter 320 mm 12 6 in Idling speed A C ON MPFI model 850 100 rpm Low pressure switch operating pressure Dual switch ON gt OFF 278 29 kPa 2 83 0 3 kg cm 40 3 4 2 psi OFF 3 ON 287 39 r kPa 2 9 0 4 0 25 kg cm dorus psi Pressure switch High pressure switch operating pressure ON gt OFF 2 800 100 kPa 291 kg cm 406 15 psi DIFF 6004200 kPa 6 1242 kg cm 87429 psi Thermo control amplifier working temperature Evaporator outlet air 1 ON 2 OFF 3 1 5 0 5 C 35 0 9 F 4 3 0 0 5 C 37 0 99F AC 4 AC 00601 General Description HVAC SYSTEM HEATER VENTILATOR AND A C B COMPONENT 1 HEATER COOLING UNIT AUTO A C MODEL AC 00603 1 Unit cover 11 Heater core clamp 21 Cooling unit block 2 Mode actuator 12 Heater core 22 O ring 3 Side link 13 Drain hose 23 Expansion valve 4 Mode actuator lever 14 Mix actuator 24 Evaporator 5 Foot lever 15 Mix actuator lever 25 Evaporator cover 6 Spring 16 Unit assembly 26 Thermistor 7 Mode actuator link 17 Aspirator hose 8 Defroster lever 18 Aspirator Tightening torque N m kgf m ft lb 9 Foot nozzle 19 Foot duct T 7 4 0 75
16. Hg 29 1 inHg 97 2 kPa 729 mmHg 28 7 inHg 95 8 kPa 719 mmHg 28 3 inHg 18 3 C 65 23 9 C 75 29 4 C 85 35 C 95 F F F F F 1 Close the valves on low high pressure sides of the manifold gauge C AC 00023 DU ET A Low pressure gauge Compound pressure gauge B High pressure gauge C Close 2 Install the low high pressure hoses to the corre sponding service ports on the vehicle respectively 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 AC 00024 A Low pressure gauge Compound pressure gauge B High pressure gauge C Slowly open D Vacuum pump turn on 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 OHO ej eae 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 A Low pressure gauge Compound pressure gauge High pressure gauge Close Vacuum pump turn off 9939 AC 22 Refrigerant Charging Procedure HVAC SYSTEM HEATER VENTILATOR
17. aminants and moisture have been removed from the refrigerant AC 17 General Description HVAC SYSTEM HEATER VENTILATOR AND A C Description Tools and Equipment Syringe graduated plastic SYRINGE will be needed to add oil back into the system The syringe can be found at pharmacy or drug store Jo AC 00015 Vacuum pump VACUUM PUMP in good working condition is necessary and may be obtained from either commercial refrigeration supply house or an automotive equipment supplier AC 00016 Can tap CAN TAP for the 397 g 14 02 can is available from an auto supply store AC 00017 Thermometer Pocket THERMOMETERS are available from either industrial hard ware store or commercial refrigeration supply houses AC 00018 AC 18 Description General Description HVAC SYSTEM HEATER VENTILATOR AND A C Tools and Equipment AC 00019 Electronic leak detector An ELECTRONIC LEAK DETECTOR can be obtained from either specialty tool supply or an A C equipment supplier AC 00020 Weight scale WEIGHT SCALE such as an electronic charging scale or bath room scale with digital display will be needed if a 13 6 kg 30 Ib refrig erant container is used AC 19 Refrigerant Pressure with Manifold Gauge Set HVAC SYSTEM HEATER VENTIL
18. and excessive tension exists af ter installing Seal the disconnected hose with a plug or vi nyl tape to prevent contamination from enter ing 1 Install in the reverse order of removal 2 Charge refrigerant Ref to AC 22 OPERA TION Refrigerant Charging Procedure Tightening torque Refer to COMPONENT in General Descrip tion Ref to AC 11 AIR CONDITIONING UNIT COMPONENT General Description C INSPECTION NOTE If cracking damage or swelling is found on a hose replace it with a new one AC 36 17 Relay and Fuse A LOCATION Relay and Fuse AC 00640 1 Joint box 2 Main fuse box Main Fan Relay 1 HVAC SYSTEM HEATER VENTILATOR AND A C B INSPECTION BU EE AC 00093 1 2 Continuity exists 3 4 Continuity exists 3 5 No continuity While applying battery voltage to the terminal be tween 1 and 2 check continuity between 3 and Main Fan Relay 2 5 Sub Fan Relay 1 If no continuity exists replace the relay with a new Sub Fan Relay 2 one A C Relay Main Fan Fuse Sub Fan Fuse A C Fuse gt AC 37 Pressure Switch Dual Switch HVAC SYSTEM HEATER VENTILATOR AND A C 18 Pressure Switch Dual Switch A INSPECTION 1 Connect the manifold gauge to the service valve
19. e valves can be closed Start the engine with the A C switch OFF 21 Quickly repeat ON OFF cycles a few times to prevent initial compressor damage 22 Set up the vehicle to the following status A C switch ON Engine running at 1 500 rpm Blower speed setting to HI Temperature setting to MAX COOL e Air inlet setting to RECIRC Windows open 23 While reading the low pressure gauge careful ly open the low pressure valve with the refrigerant source connected and the service hose purged CAUTION Never open the high pressure valve with the en gine running Doing so may result in a reflow of high pressure gas and refrigerant can s explo sion k DAL Ci 24 Adjust the refrigerant flow to maintain the pres sure on the low pressure side at 276 kPa 2 81 kg cm 40 psi max 25 After the system is fully charged close the low pressure valve 26 Close the valve on the refrigerant source AC 00034 Refrigerant amount Minimum 450 g 0 99 Ib Maximum 550 g 1 21 Ib Refrigerant HFC 134a 27 Disconnect the hose from the service port and install the service port cap AC 24 Refrigerant Leak Check HVAC SYSTEM HEATER VENTILATOR AND A C 5 Refrigerant Leak Check A INSPECTION 1 Operate the A C system for approx 10 minutes and confirm that the high pressure side shows at least 690 kPa 7 03 kg cm 100 psi Then stop the engine to sta
20. e reverse order of removal AC 30 Control Unit HVAC SYSTEM HEATER VENTILATOR AND A C 11 Control Unit A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the center console panel 3 Disconnect the connector and aspirator hose AC 00624 B INSTALLATION Install in the reverse order of removal AC 31 Compressor HVAC SYSTEM HEATER VENTILATOR AND 12 Compressor A INSPECTION 1 MAGNETIC CLUTCH CLEARANCE Check the clearance of the entire circumference around the drive plate and pulley Standard 0 45 0 15 mm 0 0177 0 0059 in 2 MAGNETIC CLUTCH OPERATION 1 Disconnect the compressor connector 2 Connect the battery positive terminal to the terminal of compressor connector OHR Q O V o gt E Ba AC 00625 3 Make sure the magnet clutch engages If NG replace the compressor B REMOVAL 1 Perform the compressor oil return operation lt Ref to AC 26 OPERATION Compressor Oil gt 2 Turn the A C switch OFF and stop the engine 3 Using the refrigerant recovery system dis charge refrigerant lt Ref to AC 21 OPERATION Refrigerant Recovery Procedure gt 4 Disconnect the ground cable from battery 5 Remove the V belt Ref to ME H4SO 43 RE MOVAL V belt gt or Ref to ME H4DOTC 54 REMOVAL V belt gt 6 Remove the generator Ref to SC H4SO 13 REMOVAL Generator
21. e ser vice ports on the low high pressure sides of the vehicle respectively AC 00022 A Low pressure gauge Compound pressure gauge High pressure gauge Close Low pressure side service port High pressure side service port B C D E 5 Connect the center hose to the refrigerant recov ery system 6 Follow the operation manual to activate the re frigerant recovery system AC 21 Refrigerant Charging Procedure HVAC SYSTEM HEATER VENTILATOR AND 4 Refrigerant Charging Proce dure A OPERATION CAUTION During operation be sure to wear safety gog gles 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 in various temperature 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 Vacuum level required to boil water at sea level Temperature 1 7 C 35 F 7 2 C 45 F 12 8 C 55 Vacuum 100 9 kPa 757 mmHg 29 8 inHg 100 5 kPa 754 mmHg 29 7 inHg 99 8 kPa 749 mmHg 29 5 inHg 99 2 kPa 744 mmHg 29 3 inHg 98 5 kPa 739 mm
22. eplacement parts Amount of oil replenishment Evaporator 114m2 3 9 US fl oz 4 0 Imp fl oz Condenser 7 m Q 0 24 US fl oz 0 25 Imp fl oz Hose 1m2 0 03 US fl oz 0 04 Imp fl oz AC 26 Blower Motor Unit Assembly HVAC SYSTEM HEATER VENTILATOR AND A C 7 Blower Motor Unit Assembly 6 Loosen the bolt and nut to remove the blower motor unit assembly A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the glove box lt Ref to El 39 REMOV AL Glove Box gt 3 Loosen the nut to remove the support beam stay B INSTALLATION Install in the reverse order of removal Tightening torque Refer to COMPONENT in General Descrip tion lt Ref to AC 5 HEATER COOLING UNIT 4 Disconnect the blower motor connector COMPONENT General Description gt and lt Ref to AC 7 BLOWER MOTOR UNIT COMPONENT General Description gt C INSPECTION Connect the motor connector terminal 1 from the battery to the positive lead and terminal 2 to the negative lead Make sure the motor runs smoothly A AC 00614 5 Disconnect the power transistor or blower resis tor connector AC 00617 AC 00615 AC 27 Power Transistor Auto A
23. g temperature Evaporator outlet air MANUAL A C MODEL 1 ON 2 OFF 3 2 5 0 5 36 5 0 9 4 1 5 0 5 35 0 9 00601 Specifications Type of air conditioner Reheat air mix type Cooling capacity 5 1 kW 4 385 kcal h 17 402 BTU h Refrigerant HFC 134a CHoFCF3 0 5 0 05 kg 1 10 0 11 Ib Compressor Type Vane rotary fix volume CR 14 Discharge 144 cm 8 79 cu in rev Max permissible speed 7 000 rpm Magnet clutch Type Dry single disc type Power consumption 47 W Type of belt V Ribbed 4 PK Pulley dia effective dia 125 mm 4 92 in Pulley ratio 1 064 Condenser Type Corrugated fin Sub cool type Core face area 0 21 m 2 26 sq ft Core thickness 16 mm 0 63 in Radiation area 5 34 m 57 48 sq ft Receiver drier Effective inner capacity 250 cm 15 26 cu in Expansion valve Type AC 3 Externally equalizing Evaporator General Description HVAC SYSTEM HEATER VENTILATOR AND A C Type Single tank Dimensions W x H x 255 x 200 x 48 mm 10 x 7 87 x 1 89 in Blower fan Fan type Sirocco fan Outer diameter x width 150 x 75 mm 5 91 x 2 95 in Power consumption 200 W Condenser fan Sub fan Motor type Magnet Power consumption 120 W Turbo model 70 W Non turbo model
24. h as the refrigerant and com pressor oil are incompatible 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 in the vehicle AC 00006 2 COMPRESSOR OIL HFC 134a compressor oil has no compatibility with that for R12 system Use only the manufacturer authorized compres sor oil for the HFC 134a system only use DH PR Do not mix multiple compressor oils If CFC 12 compressor oil is used in a 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 the atmosphere us ing a plug or tape In order to avoid moisture store the oil in a container with its cap tightly closed 3 REFRIGERANT The CFC 12 refrigerant cannot be used in the HFC 134a A C system The HFC 134a refrigerant also cannot be used in the CFC 12 A C system f an incorrect or no refrigerant is used poor lu brication will result and the compressor itself may be damaged 4 HANDLING OF REFRIGERANT The refrigerant boils at approx 30 C 22 F When handling it be s
25. lt Ref to El 43 REMOVAL Instrument Panel Assembly gt 2 Remove the screws 3 Remove the heater vent duct AC 00647 B INSTALLATION Install in the reverse order of removal AC 43 General Diagnostic Table HVAC SYSTEM HEATER VENTILATOR AND 24 General Diagnostic Table A INSPECTION Symptom Repair order Doesn t move Blower motor Fuse Blower motor relay Blower motor Blower motor resistor Blower switch Wire harness Strange noise Blower motor Doesn t move Compressor Refrigerant Fuse Air conditioning relay Magnet clutch Compressor Pressure switch A C switch Blower switch Wire harness Strange noise V Belt Magnet clutch Compressor Cold air not emitted Refrigerant V Belt Magnet clutch Compressor Pressure switch A C switch Blower switch Wire harness Heater duct Heater vent duct Warm air not emitted Engine coolant Blower switch Heater core Temperature of air from vents does not change Engine coolant Mode actuator Wire harness Unable to switch blow vents Mode actuator Air flow switch Wire harness Unable to switch suction vents Air inlet select switch FRESH RECIRC actuator Wire harness AC 44
26. nd parts Do not mix with CFC 12 tools and parts If HFC 134a and CFC 12 refrigerant or compres sor oil is mixed poor lubrication will result and the compressor itself may be destroyed In order to help prevent mixing HFC 134a and CFC 12 parts and liquid the tool and screw type and the type of service valves used are dif ferent The gas leak detectors for the HFC 134a and CFC 12 systems must also not be inter changed HFC 134a Millimeter size Quick joint type CFC 12 Inch size Screw in type Tool amp screw type Valve type AC 16 General Description Description HVAC SYSTEM HEATER VENTILATOR AND A C Tools and Equipment AC 00213 Wrench Various WRENCHES will be required to service any A C system A 7 to 40 N m 0 7 to 4 1 kgf m 5 to 30 ft Ib torque wrench with various crow foot wrenches will be needed Open end or flare nut wrenches will be needed for back up on the tube and hose fittings AC 00012 Applicator bottle A small APPLICATOR BOTTLE is recommended to apply refrigerant oil to the various parts They can be obtained at a hardware or drug store AC 00013 Manifold gauge set A MANIFOLD GAUGE SET with hoses can be obtained from either a commercial refrigeration supply house or from an auto shop equipment supplier AC 00014 Refrigerant recovery system A REFRIGERANT RECOVERY SYSTEM is used for the recovery and reuse of A C system refrigerant after cont
27. on high pressure side 2 Remove the pressure switch harness connector Using a circuit tester inspect the ON OFF operation of pressure switch ap AC 00981 Terminal Standard No p kPa kg cm psi Increasing to 2 800 100 2941 40615 Decreasing to 278 29 2 83 0 3 40 3 4 2 Increasing to 287 99 or 2 9 04 005 42 97 3 6 Decreasing to 2 200 200 22 4 2 319 29 Turns OFF High and low pressure switch Turns ON AC 38 Ambient Sensor Auto Model 19 Ambient Sensor Auto A C Model A REMOVAL 1 Open the front hood 2 Disconnect the ground cable from battery 3 Disconnect the ambient sensor connector 4 Remove the ambient sensor from radiator lower panel SE AC 00125 B INSTALLATION Install in the reverse order of removal C INSPECTION Ref to AC diag 29 AMBIENT SENSOR Diag nostic Procedure for Sensors AC 39 HVAC SYSTEM HEATER VENTILATOR AND A C Sunload Sensor Auto A C Model HVAC SYSTEM HEATER VENTILATOR AND A C 20 Sunload Sensor Auto A C Model A REMOVAL 1 Disconnect the ground cable from battery 2 Remove the front defroster grille 3 Disconnect the sunload sensor connector A f AC 00643 CAUTION Be careful not
28. ower link lever B 9 Hose 5 Clip 10 Blower resistor AC 8 3 CONTROL UNIT AUTO A C MODEL General Description HVAC SYSTEM HEATER VENTILATOR AND A C AC 00607 wo anana AR N TE Switch Control lever Control panel In vehicle sensor I EGG in Lx Aspirator hose 9 Bulb Switch assembly 10 Control case Control base Electronic control unit AC 9 General Description HVAC SYSTEM HEATER VENTILATOR AND A C WITHOUT A C MODEL AND MANUAL A C MODEL 1 AC 00608 1 Dial 6 Heater control panel 11 Mode cable 2 Fan control plate 7 switch with A C model 12 Temperature cable 3 Temperature control plate 8 Rear window defogger switch 13 Bulb 4 Mode control plate 9 Heater control base 14 Fan switch ASSY 5 FRESH RECIRC switching knob 10 Intake cable 15 Harness AC 10 General Description HVAC SYSTEM HEATER VENTILATOR AND A C 4 AIR CONDITIONING UNIT LHD MODEL T di s R T1 AC 00609 1 Condenser 6 O ring Tightening torque N m kgf m ft Ib 2 Hose High pressure 7 Tl 7 4 0 75 5 4 3 Low pressure 8 T2 15 1 5 10 8 4 Bracket 9 To condenser 5 Compressor 10 Tube To evaporator
29. ption HVAC SYSTEM HEATER VENTILATOR AND A C 1 General Description A SPECIFICATIONS 1 HEATER SYSTEM Item Specifications Condition Heating capacity 5 0 KW 4 300 kcal h 17 062 BTU h or more Mode selector switch HEAT Temperature control switch FULL HOT Temperature difference between hot water and inlet air 65 149 F Hot water flow rate 360 2 95 1 US gal 79 2 Imp gal h Air flow rate 280 m 9 888 cu ft h Heat mode FRESH FULL HOT at 12 5 V Max air flow rate 450 m 15 892 cu ft h Temperature control switch FULL COLD Blower fan speed 4th position Mode selector lever RECIRC Heater core size height x length x width 163 9 x 200 x 25 0 mm 6 45 x 7 87 x 0 984 in Type Magnet motor 200 W or less at 12V Blower motor Fan type and size diameter x width 2 A C SYSTEM AUTO A C MODEL Sirocco fan type 150 x 75 mm 5 91 x 2 95 in Specifications Type of air conditioner Reheat air mix type Cooling capacity 5 1 kW 4 385 kcal h 17 402 BTU h Refrigerant HFC 134a CH FCF 0 5 0 05 kg 0 99 0 11 Ib Compressor Type Vane rotary fix volume CR 14 Discharge 144 cm 8 79 cu in rev Max permissible speed 7 000 rpm Magnet clutch Type Dry single disc type Power consumption 47 W Type of belt V Ribbed 4 PK Pulley dia effective dia
30. rt the leak test 2 Starting from the connection between the high pressure pipe and evaporator check the system for leaks along the high pressure side through the compressor The following items must be checked thoroughly 3 Check the joint and seam between the pressure switch dual pressure switch and high pressure pipe 4 Check the connections between the condenser and pipes and welded joints on the condenser The leak tester may detect the oil on the condenser fins as a leak 5 Check the joint between the compressor and hoses 6 Check the machined area of compressor and other joints on the compressor 7 Check the compressor shaft seal at the area near the center of compressor clutch pulley Some shaft seals show a slight amount of leakage about 3 g 0 1 0z per year This is not a problem 8 Starting from the connection between the low pressure pipe and evaporator check the system for leakage along the low pressure side through the compressor The following items must be checked thoroughly e Connection between two parts Connection between the pipe and plate 9 Visually check the rubber area of the flexible hose for cracks Check the entire length of the flexible hose espe cially the connection with the metal hose end CAUTION Carefully check the external surface of hoses and tubes at approx 25 mm 0 98 in per sec ond 7 00036 Flexible hose 10
31. shop cloths Apply the compressor oil to the O rings to avoid sticking then install them e Use a torque wrench to tighten the O ring fittings Over tightening will damage the O ring and tube end distortion Ifthe operation is interrupted before completing a pipe connection recap the tubes components and fittings with a plug or tape to prevent contamination from entering AC 00008 Visually check the surfaces and mating surfaces of O rings threads and connecting points If a fail ure is found replace the applicable parts e Install the O rings at right angle to the tube beards A B 1 D C 1 0 00009 A O ring Bead Use the oil specified in the service manual to lu bricate the O rings Apply the oil to the top and sides of the O rings be fore installation Apply the oil to the area including the O rings and tube beads AC 00010 After tightening use clean shop cloth to re move excess oil from the connections and any oil which may have run on the vehicle body or other parts f any leakage is suspected after tightening do not retighten the connections Disconnect the con nections remove the O rings and check the O rings threads and connections D PREPARATION TOOL CAUTION When working on vehicles with the HFC 134a system only use HFC 134a specified tools a
32. to evaporator lt Ref to AC 26 REPLACEMENT Compressor Oil gt B INSTALLATION Install in the reverse order of removal AC 35 Hose and Tube HVAC SYSTEM HEATER VENTILATOR AND 16 Hose and Tube A REMOVAL CAUTION When disconnecting connecting hoses do not apply excessive force to them Confirm that no torsion and excessive tension exists after installing Seal the disconnected hose with a plug or vi nyl tape to prevent contamination from enter ing 1 Disconnect the ground cable from battery 2 Using the refrigerant recovery system dis charge refrigerant Ref to AC 21 OPERATION Refrigerant Recovery Procedure 3 Remove the evaporator unit mounting bolt A 4 Remove the low pressure hose attaching bolts B 5 Disconnect the low pressure hose from evapo rator unit 6 Disconnect the low pressure hose from com pressor 7 Remove the low pressure hose from vehicle 8 Remove the high pressure hose attaching bolts C 9 Disconnect the high pressure hose from com pressor 10 Disconnect the high pressure hose from con denser 11 Remove the high pressure hose from vehicle 12 Remove the high pressure tube attaching bolt D 13 Remove the high pressure tube from vehicle AC 00639 B INSTALLATION CAUTION When disconnecting connecting hoses do not apply an excessive force to them Confirm that no torsion
33. ure to wear safety goggles and protective gloves Direct contact of the refriger ant 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 hot water in 40 104 F max Do not drop or impact a service can 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 The high pressure gas will back flow resulting in an ex plosion of the can Provide good ventilation and do not work in a closed area n order to prevent global warning avoid releas ing HFC 134a into the atmosphere Using a refrig erant recovery system discharge and reuse it GS A Goggles Gloves Avoid open flame D No direct heat on container N F E AC 00007 Do not discharge Loosen AC 15 General Description HVAC SYSTEM HEATER VENTILATOR AND 5 O RING CONNECTIONS Use new O rings In order to keep the O rings free of lint which will cause a refrigerant gas leak perform operations without gloves and
34. ve 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 AC 20 Check for leaks Replace the expansion valve Replace the receiver dryer Refrigerant Recovery Procedure HVAC SYSTEM HEATER VENTILATOR AND A C 3 Refrigerant Recovery Proce dure A OPERATION CAUTION During operation be sure to wear safety gog gles and protective gloves Connectthe refrigerant recovery system with the manifold gauge set to discharge the refrig erant from the A C system and reuse it When reusing the discharged refrigerant keep service cans on hand Because the dis charge 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 Ref to AC 26 OPERATION Compressor Oil 2 Stop the engine 3 Make sure the valves on low high pressure sides of manifold gauge set are fully closed AC 00021 A Low pressure gauge Compound pressure gauge B High pressure gauge C Close 4 Install the low high pressure hoses to th
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