Subaru 2004 LEGACY User manual

FUJI HEAVY INDUSTRIES LTD. G2320GE7
2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifi-
cations contained in this manual are
based on the latest product information
available at the time of publication
approval.
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C) AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTICS) AC(diag)
AIRBAG SYSTEM AB
AIRBAG SYSTEM (DIAGNOSTICS) AB(diag)
SEAT BELT SYSTEM SB
LIGHTING SYSTEM LI
WIPER AND WASHER SYSTEMS WW
ENTERTAINMENT ET
COMMUNICATION SYSTEM COM
GLASS/WINDOWS/MIRRORS GW
BODY STRUCTURE BS
INSTRUMENTATION/DRIVER INFO IDI
SEATS SE
SECURITY AND LOCKS SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF) SR
EXTERIOR/INTERIOR TRIM EI
EXTERIOR BODY PANELS EB

2003 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX
BODY SECTION
G2320GE7
CRUISE CONTROL SYSTEM CC
CRUISE CONTROL SYSTEM
(DIAGNOSTICS) CC(diag)
IMMOBILIZER (DIAGNOSTICS) IM(diag)
LAN SYSTEM (DIAGNOSTICS) LAN(diag)

HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
AC
Page
1. General Description ....................................................................................2
2. Refrigerant Pressure with Manifold Gauge Set.........................................19
3. Refrigerant Recovery Procedure...............................................................20
4. Refrigerant Charging Procedure ...............................................................21
5. Refrigerant Leak Check ............................................................................24
6. Compressor Oil .........................................................................................25
7. Blower Motor Unit Assembly .....................................................................26
8. Blower Motor .............................................................................................27
9. Power Transistor (Auto A/C Model) ..........................................................28
10. Blower Resistor (Manual A/C Model) ........................................................29
11. Heater Core...............................................................................................30
12. Control Unit (Manual A/C Model) ..............................................................31
13. Control Unit (Auto A/C Model)...................................................................32
14. Compressor...............................................................................................33
15. Condenser.................................................................................................35
16. Heater and Cooling Unit............................................................................36
17. Evaporator.................................................................................................37
18. Hose and Tube..........................................................................................38
19. Relay and Fuse .........................................................................................39
20. Pressure Switch (Triple Pressure Switch).................................................40
21. Ambient Sensor (Auto A/C Model) ............................................................41
22. Sunload Sensor (Auto A/C Model) ............................................................42
23. In-Vehicle Sensor (Auto A/C Model) .........................................................43
24. Air Vent Grille ............................................................................................44
25. Heater Duct ...............................................................................................45
26. Heater Vent Duct.......................................................................................46
27. Heater Cock Solenoid Valve .....................................................................47
28. General Diagnostic Table..........................................................................48

AC-2
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
1. General Description
A: SPECIFICATION
1. HEATER SYSTEM
2. A/C SYSTEM
• Auto A/C model
Item Specification On condition
Heating capacity 5.2 kW (4,471 kcal/h,
17,743 BTU/h) or more
• Mode selector switch: HEAT
• Temperature control switch: FULL HOT
• Temperature difference between hot water
and inlet air: 65!C (149!F)
• Hot water flow rate: 360 2(95.1 US gal,
79.2 Imp gal)/h
Air flow rate 370 m3(13,066 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V
Max air flow rate 460 m3(16,245 cu ft)/h
• Temperature control switch: FULL COLD
• Blower fan speed:
Auto A/C: 6th position
Manual A/C: 4th position
• Mode selector lever: RECIRC
Heater core size
(height "length "width)
264 "110 "27 mm
(10.4 "4.33 "1.06 in) —
Blower motor
Type Magnet motor 220 W or less 12 V
Fan type and size
(diameter "width)
Sirocco fan type
150 "75 mm (5.91 "2.95 in) —
Item Specification
Type of air conditioner Reheat air-mix type
Cooling capacity 5.3 kW
(4,557 kcal/h, 18,084 BTU/h)
Refrigerant HFC-134a (CH2FCF3)
[0.4#0.03 kg (0.88#0.07 lb)]
Compressor
Type Scroll, constant volume (SCSA 08C)
Discharge 74.5 cc (4.55 cu in)/rev
Max. permissible speed 9,000 rpm
Magnet clutch
Type Dry, single-disc type
Power consumption 35 W
Type of belt H4 model: V-belt 4 PK
H6 model: V-belt 6 PK
Pulley dia. (effective dia.) 93 mm (3.7 in)
Pulley ratio 1.43
Condenser
Type Corrugated fin (Sub cool type)
Core face area 0.186 m2(2.002 sq ft)
Core thickness 16 mm (0.63 in)
Radiation area 5.49 m2(59.09 sq ft)
Receiver drier Effective inner capacity 190 cm3(11.6 cu in)
Expansion valve Type Internal equalizing
Evaporator
Type Single tank
Dimensions (W "H "T) 298.6 "151 "38 mm
(11.76 "5.94 "1.50 in)
Blower fan
Fan type Sirocco fan
Outer diameter "width 150 "75 mm (5.91 "2.95 in)
Power consumption 220 W

AC-3
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• Manual A/C model
Condenser fan (Sub fan)
Motor type Magnet
Power consumption H4 model: 90 W
H6 model: 160 W
Fan outer diameter H4 model: 300 mm (11.8 in)
H6 model: 320 mm (12.6 in)
Radiator fan (Main fan)
Motor type Magnet
Power consumption H4 model: 90 W
H6 model: 160 W
Fan outer diameter H4 model: 300 mm (11.8 in)
H6 model: 320 mm (12.6 in)
Idling speed (A/C ON) MPFI model 800#100 rpm
Triple switch
(Pressure switch)
Low-pressure switch
operating pressure
ON $OFF 196#20 kPa
(2.00#0.20 kg/cm2, 28.4#2.9 psi)
OFF $ON 225+25%29 kPa
(2.29+0.25%0.30 kg/cm2, 32.6+3.6%4.2 psi)
High-pressure switch
operating pressure
ON $OFF 3,140+50%200 kPa
(32.02+0.51%2.04 kg/cm2, 455.4+7.25%29.0 psi)
OFF $ON 2,550#200 kPa
(26.00#2.04 kg/cm2, 369.8#29.0 psi)
Middle-pressure switch
operating pressure
ON $OFF 1,370#120 kPa
(13.97#1.22 kg/cm2, 198.65#17.35 psi)
OFF $ON 1,770#100 kPa
(18.05#1.02 kg/cm2, 256.81#14.50 psi)
Thermo-control amplifier working temperature
(Evaporator outlet air)
(1) ON
(2) OFF
(3) 1#0.5!C (33.8#0.9!F)
(4) 4+1.50!C (39.2+2.70!F)
Item Specification
Type of air conditioner Reheat air-mix type
Cooling capacity 5.3 kW (4,557 kcal/h, 18,084 BTU/h)
Refrigerant HFC-134a (CH2FCF3)
[0.4#0.03 kg (0.88#0.07 lb)]
Compressor
Type Scroll, constant volume (SCSA 08C)
Discharge 74.5 cc (4.55 cu in)/rev
Max. permissible speed 9,000 rpm
Magnet clutch
Type Dry, single-disc type
Power consumption 35 W
Type of belt V-belt 4 PK
Pulley dia. (effective dia.) 93 mm (3.7 in)
Pulley ratio 1.43
AC-0060
1
(1)
(2)
(3)
(4)

AC-4
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
Condenser
Type Corrugated fin (Sub cool type)
Core face area 0.186 m2(2.002 sq ft)
Core thickness 16 mm (0.63 in)
Radiation area 5.49 m2(59.09 sq ft)
Receiver drier Effective inner capacity 250 cm3(15.26 cu in)
Expansion valve Type Externally equalizing
Evaporator
Type Single tank
Dimensions (W "H "T) 298.6 "151 "38 mm
(11.7 "5.94 "1.50 in)
Blower fan
Fan type Sirocco fan
Outer diameter "width 150 "75 mm (5.91 "2.95 in)
Power consumption 220 W
Condenser fan (Sub fan)
Motor type Magnet
Power consumption 90 W
Fan outer diameter 300 mm (11.8 in)
Radiator fan (Main fan)
Motor type Magnet
Power consumption 90 W
Fan outer diameter 300 mm (11.8 in)
Idling speed (A/C ON) MPFI model 800#100 rpm
Triple switch
(Pressure switch)
Low-pressure switch
operating pressure
ON $OFF 196#20 kPa
(2.00#0.20 kg/cm2, 28.4#2.9 psi)
OFF $ON 225+25%29 kPa
(2.29+0.25%0.30 kg/cm2, 32.6+3.6%4.2 psi)
High-pressure switch
operating pressure
ON $OFF 3,140+50%200 kPa
(32.02+0.51%2.04 kg/cm2, 455.4+7.25%29.0 psi)
OFF $ON 2,550#200 kPa
(26.00#2.04 kg/cm2, 369.8#29.0 psi)
Middle-pressure switch
operating pressure
ON $OFF 1,370#120 kPa
(13.97#1.22 kg/cm2, 198.65#17.35 psi)
OFF $ON 1,770#100 kPa
(18.05#1.02 kg/cm2, 256.81#14.50 psi)
Thermo control amplifier working temperature
(Evaporator outlet air)
(1) ON
(2) OFF
(3) 1#0.5!C (33.8#0.9!F)
(4) 4+1.50!C (39.2+2.70!F)
AC-0060
1
(1)
(2)
(3)
(4)

AC-5
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
B: COMPONENT
1. HEATER COOLING UNIT
• Auto A/C model
(1) Foot duct (RH) (8) Mix actuator (15) Foot duct (LH)
(2) Evaporator center (9) Mode actuator (16) Unit ASSY
(3) Pipe cover (10) Heater pipe clamp (17) Drain hose
(4) Evaporator cover (11) Heater core
(5) Expansion valve (12) Heater core cover Tightening torque: N
& m (kgf-m, ft-lb)
(6) Packing (13) Aspirator T: 7.5 (0.76, 5.5)
(7) Evaporator (14) Aspirator hose
AC-00906
T
(16)
(13)
T
(17)
(15)
(10)
(9)
(11)
(12)
(14)
(8)
(7)
(4)
(5)
(3)
(2)
(1)
(6)

AC-6
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
• Manual A/C model
(1) Foot duct (RH) (8) Clip (15) Unit ASSY
(2) Thermo amplifier (9) Air mix door linkage (16) Drain hose
(3) Pipe cover (10) Mode actuator
(4) Evaporator cover (11) Heater pipe clamp Tightening torque: N
& m (kgf-m, ft-lb)
(5) Expansion valve (12) Heater core T: 7.5 (0.76, 5.5)
(6) Packing (13) Heater core cover
(7) Evaporator (14) Foot duct (LH)
AC-00907
(4)
(5)
(6)
(11)
(12)
(13)
T
(16)
T
(15)
(10)
(9)
(14)
(8)
(7)
(3)
(2)
(1)

AC-7
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
2. BLOWER MOTOR UNIT
(1) Upper case (6) Control unit (Auto A/C model) Tightening torque: N & m (kgf-m, ft-lb)
(2) Intake door actuator (7) Power transistor (Auto A/C model) T: 7.5 (0.76, 5.5)
(3) Filter (Auto A/C model) Blower resistor (Manual A/C
model)
(4) Filter cover
(5) Blower motor ASSY
T
T
(1)
(2)
(7)
(5)
(3)
(4)
(6)
AC-00908

AC-8
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
General Description
3. CONTROL PANEL
• Auto A/C model
(A) For integrated audio (B) For Mclntosh audio
(1) Temperature control dial (3) Board (4) Heater control base
(2) Control panel assembly
AC-00909
(1)
(2)
(1)
(2)
(3)
(4)
(A) (B)