AIR CONDITIONER
AC
  1. General Description
  2. Air Conditioning System
  3. Refrigerant Pressure with Manifold Gauge Set
  4. Refrigerant Recovery Procedure
  5. Refrigerant Charging Procedure
  6. Refrigerant Leak Check
  7. Relay and Fuse
  8. Compressor Oil
  9. Blower Motor
  10. Power Transistor
  11. Heater Core
  12. Control Panel
  13. Compressor
  14. Condenser
  15. Heater and Cooling Unit
  16. Evaporator
  17. Expansion Valve
  18. Hose and Pipe
  19. Pressure Sensor
  20. Ambient Sensor
  21. Sunload Sensor (Auto A/C Model)
  22. Temperature and Humidity Sensor
  23. Evaporator Sensor
  24. Heater Core Sensor
  25. FRESH/RECIRC Door Actuator
  26. Mode Door Actuator
  27. Air Mix Door Actuator
  28. Air Vent Grille
  29. Air Vent Duct
  30. A/C Filter
  31. Diagnostics with Phenomenon
AIR CONDITIONER > General Description　
SPECIFICATION
1. HEATER SYSTEM

Item

Specifications

Condition

Heating capacity

5.5 kW (4,729 kcal/h, 18,765 BTU/h) or more

  • Air flow control switch: FOOT

  • Temperature control dial: HI (MAX HOT)

  • Temperature difference between hot water and inlet air: 65°C (149°F)

  • Hot water flow rate: 360 L (95.1 US gal, 79.2 Imp gal)/h

Air flow rate

370 m3 (13,068cu ft)/h or more

  • Temperature setting: HI (MAX HOT)

  • Fan speed: HI (MAX)

  • FRESH/RECIRC position: FRESH

  • Air flow control position: FOOT

Heater core

Size

(Width × Height × Thickness)

257.5 × 118.5 × 27 mm

(10.14 × 4.67 × 1.06in)

—

Blower motor

Motor type

Magnet

—

Power consumption

300 W or less

12 V

Fan type

Sirocco fan

—

Size

(Diameter × Height)

160 × 75 mm

(6.3 × 2.95in)

—

2. A/C SYSTEM

Item

Specifications

Condition

Type of air conditioner

Reheat air-mix

—

Cooling capacity

5.4 kW (4,643 kcal/h, 18,424 BTU/h) or more

  • Engine: Warmed up

  • Air vent grille: Full open

  • A/C switch: ON

  • Temperature setting: LO (MAX COOL)

  • Fan speed: HI (MAX)

  • FRESH/RECIRC position: RECIRC

  • Air flow control position: VENT

Air flow rate

530 m3 (18,720cu ft)/h or more

  • Temperature setting: LO (MAX COOL)

  • Fan speed: HI (MAX)

  • FRESH/RECIRC position: RECIRC

  • Air flow control position: VENT

Refrigerant

HFO-1234yf (CH2 = CFCF3)

[0.41±0.025 kg (0.91±0.06 lb)]

—

Compressor

Type

Variable capacity (VCS-14E)

—

Discharge

140 cc (8.54cu in)/rev

—

Max. permissible speed

9,000 r/min

—

Pulley

Type of belt

V-belt 6 PK

—

Pulley diameter

(Effective diameter)

110 mm (4.33in)

—

Pulley ratio

1.3

—

Condenser

Type

Corrugated fin (sub cool)

—

Core face area

0.226 m2 (2.433sq ft)

—

Core thickness

12 mm (0.47in)

—

Radiation area

5.54 m2 (59.634sq ft)

—

Receiver drier

Effective inner capacity

148 cm3 (9.03cu in)

—

Expansion

Valve

Type

Block

—

Evaporator

Type

Double tank

—

Size

(Width × Height × Thickness)

290.1 × 225 × 39 mm

(11.42 × 8.86 × 1.54in)

—

Blower motor

Motor type

Magnet

—

Power consumption

300 W or less

12 V

Fan type

Sirocco fan

—

Size

(Diameter × Height)

160 × 75 mm

(6.3 × 2.95in)

—

Radiator main fan

Motor type

Magnet

—

Power consumption

120 W

12 V

Fan outer diameter

320 mm (12.6in)

—

Radiator sub fan

Motor type

Magnet

—

Power consumption

120 W

12 V

Fan outer diameter

320 mm (12.6in)

—

Idle speed

675±100 r/min

No load

800 — 900±50 r/min

A/C ON
3. BASIC OPERATION

The cooling system cools down the compartment by using the pipes connecting parts and cycling the evaporative liquid (refrigerant) within the sealed system in a repeated process of “vaporization — liquefaction — re-vaporization”.

AC-02414 : LIQUID : MIST : GAS Heat is removed Heat is absorbed COMPRESSOR CONDENSER EVAPORATOR EXPANSION VALVE LOW PRESSURE HIGH PRESSURE

Item

Operation

Compressor

Sucks and pressurizes the low temperature, low pressure refrigerant gas that was vaporized at the evaporator by absorbing heat from the compartment, and sends the high temperature, high pressure refrigerant gas to the condenser.

Condenser

Cools the high temperature, high pressure refrigerant gas sent from the compressor for condense and liquefaction.

Expansion valve

  • Sprays the high temperature, high pressure liquid refrigerant from the small hole in order to let the refrigerant expand rapidly to turn it into low temperature, low pressure mist.

  • The refrigerant amount is adjusted according to the refrigerant vaporization condition in the evaporator.

Evaporator

The evaporator turns into a low temperature condition when the mist refrigerant that was turned into a low temperature, low pressure condition at the expansion valve is vaporized in large quantity in the evaporator. Passing air flow through the low temperature evaporator emits cold air.
AIR CONDITIONER > General Description　
LOCATION

For location, refer to “Electrical Component Location” for “AIR CONDITIONER (DIAGNOSTICS)” section. AIR CONDITIONER(DIAGNOSTICS)>Electrical Component Location

AIR CONDITIONER > General Description　
COMPONENT
1. HEATER AND COOLING UNIT ASSEMBLY

(1)

Shaft mix LH

(9)

Guide baffle plate

(17)

Clamp pipe

(2)

Shutter mix LH

(10)

Shutter defroster

(18)

Rear vent cover

(3)

Plate

(11)

Shutter vent

(19)

Pipe heater core

(4)

Shutter mix RH

(12)

Shutter foot

(20)

Cover heater core pipe

(5)

Shaft mix RH

(13)

Plate center vent

(21)

Clamp heater core pipe

(6)

Duct adapter

(14)

Heater core

(22)

Gasket heater core pipe

(7)

Gasket adapter

(15)

O-ring

(23)

Case heater unit LH

(8)

Case heater unit RH

(16)

Plate heater core

(1)

Motor actuator mode

(9)

Lever defroster door

(17)

Aspirator

(2)

Bracket actuator mode

(10)

Rod vent

(18)

Aspirator hose

(3)

Lever foot sub

(11)

Lever vent door

(19)

Joint aspirator hose

(4)

Washer heater

(12)

Lever vent sub

(5)

Lever mode

(13)

Heater unit ASSY

Tightening torque: N·m (kgf-m, ft-lb)

(6)

Lever foot door

(14)

Heater core sensor

T:

7.5 (0.8, 5.5)

(7)

Motor actuator air mix LH

(15)

Lever mix RH

(8)

Lever defroster sub

(16)

Motor actuator air mix RH

(1)

Gasket expansion valve

(9)

Gasket intake

(17)

Power transistor

(2)

Expansion valve

(10)

Case blower intake RH

(18)

Blower motor ASSY

(3)

Grommet

(11)

Shutter blower

(19)

Hose drain

(4)

Plate

(12)

Filter

(5)

O-ring

(13)

Case blower intake LH

Tightening torque: N·m (kgf-m, ft-lb)

(6)

Evaporator ASSY

(14)

Motor actuator intake

T1:

7.5 (0.8, 5.5)

(7)

Case heater UPR

(15)

Evaporator sensor

T2:

7.7 (0.8, 5.7)

(8)

Cover evaporator

(16)

Case heater LWR
2. CONTROL PANEL

(1)

Center panel ASSY

(2)

Heater control ASSY
3. AIR CONDITIONING UNIT

(1)

Condenser ASSY

(6)

Pressure sensor

Tightening torque: N·m (kgf-m, ft-lb)

(2)

Compressor ASSY

(7)

Pipe evaporator cooling

T1:

7.5 (0.8, 5.5)

(3)

Hose pressure suction

(8)

Clip pipe

T2:

9.8±1.5 (1.0±0.2, 7.2±1.1)

(4)

O-ring

T3:

10 (1.0, 7.4)

(5)

Hose pressure discharge
4. HEATER HOSE

(1)

Hose heater outlet

(3)

Clip

(4)

Clamp

(2)

Hose heater inlet

∗1: Engine side

∗2: Heater core side
5. COMPRESSOR

(1)

Grommet collector cover

(2)

Compressor ASSY

Tightening torque: N·m (kgf-m, ft-lb)

T:

36 (3.7, 26.6)

∗: Tighten the compressor assembly in the numerical order as shown in the figure.
6. HEATER DUCT

(1)

Duct foot driver

(5)

Duct rear heater front RH

(9)

Duct rear heater rear LH

(2)

Spacer foot

(6)

Duct joint RH

(10)

Duct joint LH

(3)

Heater unit ASSY

(7)

Duct rear heater rear RH

(11)

Duct rear heater front LH

(4)

Duct foot passenger

(8)

Duct extension∗1

∗1: Model with power amplifier
 

For exploded view of the heater duct (console), refer to “Console Box” of “EXTERIOR/INTERIOR TRIM” section. EXTERIOR/INTERIOR TRIM>General Description>COMPONENT > CONSOLE BOX

7. HEATER VENT DUCT AND GRILLE
 

For exploded view of the air vent duct and air vent grille that are secured on the instrument panel, refer to “Instrument Panel” of “EXTERIOR/INTERIOR TRIM” section. EXTERIOR/INTERIOR TRIM>General Description>COMPONENT > INSTRUMENT PANEL

AIR CONDITIONER > General Description　
CAUTION
1. A/C SYSTEM

Before maintenance, check the refrigerant and compressor oil for the A/C system described on the label (a). Use the listed refrigerant, compressor oil and tools dedicated for the A/C system.

2. COMPRESSOR OIL

  • Use the compressor oil listed on the label. The compressor oil is not compatible with any other brands of compressor oil.

  • 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

  • Use the refrigerant listed on the label.

  • If an incorrect or no refrigerant is used, it will result 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 goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite.

    If the refrigerant gets into your eye, avoid rubbing your eyes with your hands. Wash your eyes with plenty of water, and receive medical treatment from an eye doctor.

  • Do not heat a service can. If a service can is directly 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 impact a service can. (Observe the precautions and operation procedure described on the refrigerant container.)

  • When the engine is running, do not open the high-pressure valve of manifold gauge. The high-pressure gas will back-flow resulting in an explosion of the can.

  • Provide good ventilation and do not work in a closed area.

  • In order to prevent global warming, avoid releasing refrigerant into the atmosphere. Using a refrigerant recovery system, discharge and recycle the gas.

(A)

Goggles

(C)

Do not apply impact.

(E)

Do not discharge

(B)

Gloves

(D)

No direct heat on container
5. O-RING CONNECTIONS

  • Always use a new O-ring.

  • In order to keep the O-rings free of lint which will cause a refrigerant gas leak, perform work without using gloves or waste cloths.

  • Apply compressor oil to O-rings to avoid sticking, before installation.

  • Use a torque wrench to tighten the O-ring fittings. Over-tightening will result in damage of the O-ring and deformation of the pipe end.

  • If the work is interrupted before completing pipe connections, recap the pipes, components and fittings with a plug or tape to prevent foreign matter from entering.

  • Visually check the surfaces and mating surfaces of O-rings, threads and connecting points. If a failure is found, replace the applicable parts.

  • Install the O-rings straight against the pipe groove.

    (A)

    O-ring

    (B)

    OK

    (C)

    NG

  • Use compressor oil specified in the service manual to lubricate the O-rings.

  • Apply oil to the top and sides of O-rings before installation.

  • Apply compressor oil to the pipe grooves.

  • After tightening, use a clean cloth to remove excess compressor oil from the connections and any oil which may have run on the vehicle body or other parts.

  • If any leakage is suspected after tightening, do not tighten the connections further, but disconnect the connections, remove the O-rings, and check the O-rings, threads, and connections.

AIR CONDITIONER > General Description　
PREPARATION TOOL
1. SPECIAL TOOL

ILLUSTRATION

TOOL NUMBER

DESCRIPTION

REMARKS

—

SUBARU SELECT MONITOR 4

Used for setting of each function and troubleshooting for electrical system.

 

For detailed operation procedures, refer to “Help” of application.

73499SJ000

DISCONNECT TOOL

Used for separating the A/C pipes of a spring lock coupling type.
2. GENERAL TOOL
 

  • Use only tools and parts dedicated to the HFO-1234yf system. If other types of refrigerant or compressor oil are mixed, it will result in poor lubrication and the compressor may be damaged.

  • In order to prevent the mixture of other parts, grease or oil, the types of tools and screws and the replacement valves used are different. Use tools and parts appropriate for the system.

HFO-1234yf

HFC-134a

CFC-12

Tool and screw type

Millimeter size

Millimeter size

Inch size

Valve type

Quick joint type

Quick joint type

Screw-in type

TOOL NAME/ILLUSTRATION

REMARKS

Circuit tester

Used for measuring resistance, voltage and current.

DST-i

Used together with Subaru Select Monitor 4.

Clip remover

Used for removing clips.

Hexagon wrench

Used for removing and installing the expansion valve, etc.

Wrench

Various WRENCHES will be required to service any A/C system. 7 — 40 N·m (0.7 — 4.1kgf-m, 5 — 30 ft-lb) torque wrench and various crowfoot wrenches will be needed. Open end or flare nut wrenches will be needed to affix the pipe and hose fittings.

Applicator bottle

A small APPLICATOR BOTTLE is recommended to apply compressor oil to the various parts. It can be available at a hardware store.

Manifold gauge set

A MANIFOLD GAUGE SET (with hoses) is available at either a refrigerant supplier or an automotive equipment supplier.

Refrigerant recovery system

A REFRIGERANT RECOVERY SYSTEM is used for the recovery and recycling of A/C system refrigerant after contaminants and moisture have been removed from the refrigerant.

Syringe

A graduated plastic SYRINGE will be needed to add oil into the system again. A syringe can be available at a pharmacy or drug store.

Vacuum pump

A VACUUM PUMP is necessary (for a good working condition), and may be available at either a refrigerant supplier or an automotive equipment supplier.

Can tap

A CAN TAP for refrigerant cans is available at an automotive equipment supplier.

Thermometer/hygrometer

A pocket THERMOMETER/HYGROMETER is available at either an industrial hardware store or a refrigerant supplier.

Electronic leak detector

An ELECTRONIC LEAK DETECTOR can be available at either a specialty tool supplier or an A/C equipment supplier.

Weight scale

A WEIGHT SCALE such as an electronic charging scale or a bathroom scale with digital display will be needed, if a 13.6 kg (30 lb) refrigerant container is used.
AIR CONDITIONER > Air Conditioning System　
WIRING DIAGRAM

Refer to “Air Conditioning System” in the wiring diagram. WIRING SYSTEM>Air Conditioning System>WIRING DIAGRAM

AIR CONDITIONER > Air Conditioning System　
INSPECTION
1. BASIC INSPECTION

For basic inspection, refer to “Basic Diagnostic Procedure” of “AIR CONDITIONER (DIAGNOSTICS)” section. AIR CONDITIONER(DIAGNOSTICS)>Basic Diagnostic Procedure

2. SYSTEM BLOCK DIAGRAM

For system block diagram, refer to “System Block Diagram” in “AIR CONDITIONER (DIAGNOSTICS)” section. AIR CONDITIONER(DIAGNOSTICS)>General Description>SYSTEM BLOCK DIAGRAM

3. MODULE I/O SIGNAL

For the specification (electrical component), refer to “Control Module I/O Signal” of “AIR CONDITIONER (DIAGNOSTICS)” section. AIR CONDITIONER(DIAGNOSTICS)>Control Module I/O Signal>ELECTRICAL SPECIFICATION

AIR CONDITIONER > Air Conditioning System　
NOTE

For procedure of each component in the air conditioning system, refer to the respective section.

AIR CONDITIONER > Refrigerant Pressure with Manifold Gauge Set　
PROCEDURE
1. CHECK REFRIGERANT GAS PRESSURE
1.

Prepare the vehicle.

 

Check that the ambient temperature is 25 — 40°C (77 — 104°F) and that the humidity is 30 — 80%.

  • Place the vehicle in the shade and windless condition, and open the front hood.

  • Open the front and rear windows and close all doors.

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Check the refrigerant pressure.

(1)

Attach the manifold gauge set.

 

  • During operation, be sure to wear protective goggles and protective gloves.

  • Follow the detailed operation procedure described in the attached operation manual.

(1)

Manifold gauge

(4)

High pressure valve

(7)

High-pressure hose

(2)

Low pressure valve

(5)

Low-pressure hose

(8)

Low-pressure side service port

(3)

Center valve

(6)

Center manifold hose (vacuum pump and charge)

(9)

High-pressure side service port

Preparation tool:

Manifold gauge set

  1. Check that all valves are fully closed.

  2. Install the low/high pressure hoses to the service ports on the low/high pressure sides of the vehicle respectively.

     

    Confirm that the connections are secure.

(2)

Start the engine.

(3)

Set the vehicle to the following conditions.

Item

Condition

Engine

Warming-up

Air vent grille

Full open

A/C switch

ON

Temperature setting

LO (MAX COOL)

FRESH/RECIRC position

RECIRC

Air flow control position

VENT

Fan speed

HI (MAX)
(4)

In the condition of step (3), idle the engine for 30 minutes.

(5)

Read the gauge values on both high pressure side and low pressure side of the manifold gauge.

4.

Measure the air vent grille outlet opening temperature, ambient temperature and humidity.

Preparation tool:

Thermometer and hygrometer

 

For outlet opening temperature, measure the average temperature of center grille assembly and side grille assembly.

5.

Check that the high and low pressures and outlet opening temperature for ambient temperature and humidity is within the standard value described in the chart below.

25(77) 30(86) 35(95) 40(104) 25(77) 30(86) 35(95) 40(104) 0(32) 5(41) 10(50) 15(59) 20(68) 25(77) 30(86) MPa MPa AC-10877 2.0 1.0 0.5 2.5 1.5 0.1 0.5 0.4 0.3 0.2 AMBIENT TEMPERATURE AMBIENT TEMPERATURE : HIGH GAUGE PRESSURE    LOWER LIMIT (HUMIDITY 30%) : HIGH GAUGE PRESSURE    UPPER LIMIT (HUMIDITY 80%) : LOW GAUGE PRESSURE    LOWER LIMIT (HUMIDITY 30%) : LOW GAUGE PRESSURE    UPPER LIMIT (HUMIDITY 80%) : AIR FLOW OUTLET TEMPERATURE LOWER LIMIT (HUMIDITY 30%) : AIR FLOW OUTLET TEMPERATURE UPPER LIMIT (HUMIDITY 80%) AIR FLOW OUTLET TEMPERATURE LOW GAUGE PRESSURE HIGH GAUGE PRESSURE
6.

Refer to “DIAGNOSIS WITH SYMPTOM” if the inspection result is not within the standard value. AIR CONDITIONER>Refrigerant Pressure with Manifold Gauge Set>INSPECTION > INSPECTION WITH PRESSURE SYMPTOM

AIR CONDITIONER > Refrigerant Pressure with Manifold Gauge Set　
INSPECTION
2. BOTH HIGH AND LOW PRESSURE SIDES ARE LOW
1. CHECK REFRIGERANT LEAKS.

Check the refrigerant for leaks. AIR CONDITIONER>Refrigerant Leak Check>INSPECTION

 

When high-pressure side is less than 0.69 MPa: Go to step 2.

Are there refrigerant leaks?

Repair the refrigerant leaking points.

2

2. FILL PROPER AMOUNT OF REFRIGERANT.

Drain all refrigerant, and refill proper amount of refrigerant.

Is refrigerant pressure within the standard value?

Refrigerant pressure is normal.

Perform corresponding “INSPECTION WITH PRESSURE SYMPTOM”.

3. BOTH HIGH AND LOW PRESSURE SIDES ARE HIGH
1. FILL PROPER AMOUNT OF REFRIGERANT.

Drain all refrigerant, and refill proper amount of refrigerant.

Is refrigerant pressure within the standard value?

Refrigerant pressure is normal.

Perform corresponding “INSPECTION WITH PRESSURE SYMPTOM”.

4. HIGH AND LOW PRESSURE SIDES ARE EQUAL, OR HIGH-PRESSURE SIDE IS LOW
1. CHECK REFRIGERANT LEAKS.

Check the refrigerant for leaks. AIR CONDITIONER>Refrigerant Leak Check>INSPECTION

 

When high-pressure side is less than 0.69 MPa: Go to step 2.

Are there refrigerant leaks?

Repair the refrigerant leaking points.

2

2. FILL PROPER AMOUNT OF REFRIGERANT.

Drain all refrigerant, and refill proper amount of refrigerant.

Is refrigerant pressure within the standard value?

Refrigerant pressure is normal.

Inspect the compressor. AIR CONDITIONER(DIAGNOSTICS)>Diagnostics with Phenomenon>INSPECTION > COLD AIR DOES NOT COME OUT EVEN WHEN THE A/C SWITCH IS PRESSED. THE GLASS CANNOT BE DEFOGGED. (COMPRESSOR DOES NOT OPERATE.)

5. HIGH-PRESSURE SIDE IS HIGH
1. CHECK CONDENSER.

Check the condenser. AIR CONDITIONER>Condenser>INSPECTION

Is condenser OK?

2

Clean or replace the condenser.

2. CHECK RADIATOR FAN.

Check the radiator fan system. COOLING(H4DO)>Radiator Fan System>INSPECTION

Is radiator fan system normal?

3

Repair the radiator fan system or replace the faulty parts.

3. FILL PROPER AMOUNT OF REFRIGERANT.

Drain all refrigerant, and refill proper amount of refrigerant.

Is refrigerant pressure within the standard value?

Refrigerant pressure is normal.

Check the high-pressure hose and condenser for kinks or clogging, and replace if defective.

6. LOW-PRESSURE SIDE IS LOW
1. CHECK REFRIGERANT LEAKS.

Check the refrigerant for leaks. AIR CONDITIONER>Refrigerant Leak Check>INSPECTION

 

When high-pressure side is less than 0.69 MPa: Go to step 2.

Are there refrigerant leaks?

Repair the refrigerant leaking points.

2

2. FILL PROPER AMOUNT OF REFRIGERANT.

Drain all refrigerant, and refill proper amount of refrigerant.

Is refrigerant pressure within the standard value?

Refrigerant pressure is normal.

3

3. REPLACE EXPANSION VALVE.

Replace the expansion valve. AIR CONDITIONER>Expansion Valve>REMOVAL

Is refrigerant pressure within the standard value?

Refrigerant pressure is normal.

Inspect the compressor. AIR CONDITIONER(DIAGNOSTICS)>Diagnostics with Phenomenon>INSPECTION > COLD AIR DOES NOT COME OUT EVEN WHEN THE A/C SWITCH IS PRESSED. THE GLASS CANNOT BE DEFOGGED. (COMPRESSOR DOES NOT OPERATE.)

7. LOW-PRESSURE SIDE IS HIGH
1. FILL PROPER AMOUNT OF REFRIGERANT.

Drain all refrigerant, and refill proper amount of refrigerant.

Is refrigerant pressure within the standard value?

Refrigerant pressure is normal.

2

2. REPLACE EXPANSION VALVE.

Replace the expansion valve. AIR CONDITIONER>Expansion Valve>REMOVAL

Is refrigerant pressure within the standard value?

Refrigerant pressure is normal.

Replace the evaporator. AIR CONDITIONER>Evaporator>REMOVAL

AIR CONDITIONER > Refrigerant Recovery Procedure　
PROCEDURE
1.

Perform compressor oil return operation. AIR CONDITIONER>Compressor Oil>PROCEDURE

2.

Turn the ignition switch to OFF.

3.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

4.

Attach the manifold gauge set.

 

  • During operation, be sure to wear protective goggles and protective gloves.

  • Connect the refrigerant recovery system with the manifold gauge set to discharge the refrigerant from the A/C system and recycle the gas.

  • When recycling the discharged refrigerant, keep service cans on hand. Because the recovery rate with the recovery system is approx. 90%, service cans are necessary to charge the refrigerant.

  • Follow the detailed operation procedure described in the attached operation manual.

(1)

Manifold gauge

(4)

High pressure valve

(7)

High-pressure hose

(2)

Low pressure valve

(5)

Low-pressure hose

(8)

Low-pressure side service port

(3)

Center valve

(6)

Center manifold hose (vacuum pump and charge)

(9)

High-pressure side service port

Preparation tool:

Manifold gauge set

(1)

Check that all valves are fully closed.

(2)

Install the low/high pressure hoses to the service ports on the low/high pressure sides of the vehicle respectively.

 

Confirm that the connections are secure.

(3)

Connect the center manifold hose to the refrigerant recovery system.

Preparation tool:

Refrigerant recovery system

5.

Follow the operation manual attached to the refrigerant recovery system to collect the refrigerant.

AIR CONDITIONER > Refrigerant Charging Procedure　
PROCEDURE
1.

Attach the manifold gauge set.

 

  • While working, be sure to wear protective goggles and protective gloves.

  • Air in the cycle can cause insufficient air conditioning, and water in the cycle can cause clogging in the cycle (icing) and rust. To remove this air and water content, use a vacuum pump to perform evacuation before filling with refrigerant. By making the inside of the cycle a vacuum, the water content will evaporate even at normal temperatures, and can be removed.

  • Follow the detailed operation procedure described in the attached operation manual.

(1)

Manifold gauge

(4)

High pressure valve

(7)

High-pressure hose

(2)

Low pressure valve

(5)

Low-pressure hose

(8)

Low-pressure side service port

(3)

Center valve

(6)

Center manifold hose (vacuum pump and charge)

(9)

High-pressure side service port

Preparation tool:

Manifold gauge set

(1)

Check that all valves are fully closed.

(2)

Install the low/high pressure hoses to the service ports on the low/high pressure sides of the vehicle respectively.

 

Confirm that the connections are secure.

(3)

Connect the center manifold hose of the manifold gauge to the vacuum pump.

Preparation tool:

Vacuum pump

2.

Perform evacuation.

 

Make sure to perform evacuation using a vacuum pump.

(1)

Open the low-pressure side valve, high-pressure side valve and center valve.

(2)

Operate the vacuum pump.

(3)

Perform evacuation for 5 minutes or more, and when the low pressure gauge needle reaches −0.1 MPa (−1 kgf/cm2, −14 psi), close the center manifold hose valve, and stop the vacuum pump.

(4)

Leave alone for 5 to 10 minutes after closing the low pressure valve and high pressure valve, and check whether there is any change in the low pressure gauge needle indication.

If the needle position changes, this indicates a leak. Check the pipe and hose connections, and repair the location with the problem.

After repair, retry charging the refrigerant from the step (1).

(5)

If there is no leakage, continue evacuation for additional 20 — 30 minutes, close all valves and then stop the vacuum pump.

3.

Charge refrigerant.

(1)

Follow the can tap operation manual to attach it to the refrigerant can.

Preparation tool:

Can tap

(2)

Disconnect the center manifold hose from the vacuum pump, and connect the hose to the tap valve.

Preparation tool:

Weight scale

 

When 13.6 kg (30 lb) refrigerant container (1) is used, measure the amount of refrigerant with a refrigerant charging scale (2), and connect with the center manifold hose.

(3)

Open the tap valve of the supply container (refrigerant can or refrigerant container).

(4)

Loosen the center manifold hose connection on the manifold gauge for a few seconds (if there is a purge valve on the manifold gauge, push this instead) to allow the air in the center manifold hose to be bled by the refrigerant pressure.

(5)

Open the low pressure valve and high pressure valve of the manifold gauge to fill with refrigerant.

 

If the supply container is empty, close all manifold gauge valves and the tap valve of the supply container, and replace the empty supply container with a new one. After replacing with a new supply container, perform air purge, and resume the filling operation.

(6)

If the low pressure gauge indicates approximately 0.2 MPa (2 kgf/cm2, 29 psi) or refrigerant filling efficiency drops, close the low pressure and high pressure valves.

(7)

Check that the low pressure valve and high pressure valve are closed, turn off the A/C switch and start the engine.

 

  • When filling operation is performed with the engine running, do not open the high pressure valve. Always fill from the low pressure valve.

  • Except for the magnet clutch type, do not start the engine before charging refrigerant.

(8)

To prevent damage to the compressor, push the A/C switch ON-OFF quickly a few times.

(9)

Set the vehicle to the following conditions.

Item

Condition

Engine speed

1,500 r/min

A/C switch

ON

Temperature setting

LO (MAX COOL)

Fan speed

HI (MAX)

FRESH/RECIRC position

RECIRC

Air flow control position

VENT

Window

OPEN
(10)

Open the low pressure valve, check the refrigerant pressure with a manifold gauge and fill with refrigerant up to the specified amount. AIR CONDITIONER>Refrigerant Pressure with Manifold Gauge Set>INSPECTION > INSPECTION WITH PRESSURE SYMPTOM

4.

Using an electronic leak detector (leak tester), check for refrigerant leaks in the system. AIR CONDITIONER>Refrigerant Leak Check>INSPECTION

5.

After filling with refrigerant, close all valves and remove the manifold gauge set.

6.

Attach cap to the service port of the low pressure side and high pressure side.

7.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

AIR CONDITIONER > Refrigerant Leak Check　
INSPECTION
1.

Check the refrigerant gas pressure. AIR CONDITIONER>Refrigerant Pressure with Manifold Gauge Set>PROCEDURE > CHECK REFRIGERANT GAS PRESSURE

2.

Stop the engine to start the leak test.

Preparation tool:

Electronic leak detector (leak tester)

Items

Condition

Corrective action

Pipe

Check the connections of pipe and expansion valve.

Check the O-ring at connection and tightening torque. If necessary, replace each part.

Check the connection between pressure sensor and pipe.

Replace the pressure sensor.

Check the connection between pipe and condenser.

Check the O-ring at connection and tightening torque. If necessary, replace each part.

Check the connection between pipe and hose (low pressure).

Check the O-ring and lock spring at the connection. If necessary, replace each part.

Condenser

Check the welded part of condenser and core.

Replace the condenser.

Hose (high-pressure)

Check the connection between hose (high-pressure) and compressor.

Check the O-ring at connection and tightening torque. If necessary, replace each part.

Check the connection between hose (high-pressure) and condenser.

Check the O-ring at connection and tightening torque. If necessary, replace each part.

Check the connection between pressure sensor and hose (high pressure).

Replace the pressure sensor.

Check the rubber part of the flexible hose and pipe seam.

 

Carefully check the external surface of flexible hoses and pipes at approx. 25 mm (0.98in) per second.

Replace the hose (high pressure).

Check the valve and cap in the service port.

Check the rubber seal of the valve and cap. If necessary, replace valve or cap.

Compressor

Check the compressor pulley and vicinity of shaft seal.

 

Some shaft seals will show a slight amount of leakage, about 3 g (0.1 oz) per year. This is not a problem.

Replace the compressor.

Hose (low-pressure)

Check the connection between hose (low pressure) and expansion valve.

Check the O-ring at connection and tightening torque. If necessary, replace each part.

Check the connection between hose (low pressure) and compressor.

Check the O-ring at connection and tightening torque. If necessary, replace each part.

Check the rubber part of the flexible hose and pipe seam.

 

Carefully check the external surface of flexible hoses and pipes at approx. 25 mm (0.98in) per second.

Replace the hose (low pressure).

Check the valve and cap in the service port.

Check the rubber seal of the valve and cap. If necessary, replace valve or cap.

Evaporator

Remove the drain hose from the heater case, and check the end part for 10 seconds or more.

Replace the evaporator.

Check the air vent grille.

 

Turn the ignition switch to ON, and run the blower at high speed for approx. 1 minute. Stop the blower to check the air vent grille on the instrument 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 position for at least 10 seconds.

Replace the evaporator.
AIR CONDITIONER > Relay and Fuse　
LOCATION

Main fuse box (M/B)

Fuse 15 A (blower motor relay)

(A)

Fuse 15 A (blower motor relay)

(B)

Fuse & relay box (F/B)

Fuse 7.5 A (A/C control panel)

(C)

Fuse 7.5 A (A/C control panel)

(D)

Fuse 15 A (A/C control panel, blower motor relay)

(E)

Fuse 10 A (A/C control panel, air mix actuator, mode actuator)

(F)

Fuse 7.5 A (A/C control panel)

(G)

Blower motor unit (B/U)

Blower motor relay

(H)
 

For other related fuses, refer to the wiring diagram. WIRING SYSTEM>Power Supply Circuit>WIRING DIAGRAM

AIR CONDITIONER > Relay and Fuse　
INSPECTION
1. CHECK FUSE
1.

Remove the fuse and inspect visually.

2.

If the fuse is blown out, replace the fuse.

 

If the fuse is blown again, check the system wiring harness.

2. CHECK RELAY.
1.

Measure the resistance between relay terminals.

  • Blower motor relay

    Terminal No.

    Inspection conditions

    Standard

    Circuit

    1 — 4

    Always

    1 MΩ or more

    Apply battery voltage between terminals 2 and 3.

    Less than 1 Ω
2.

Replace the relay if the inspection result is not within the standard value.

AIR CONDITIONER > Compressor Oil　
PROCEDURE
 

Before making repairs, perform the oil return operation to return the compressor oil in circulation with the refrigerant to the compressor.

1.

Start the engine.

2.

Set the vehicle to the following conditions.

Item

Condition

Engine speed

1,500 r/min

A/C switch

ON

Temperature setting

LO (MAX COOL)

FRESH/RECIRC position

RECIRC

Fan speed

HI (MAX)
3.

Leave in this condition for 10 minutes.

AIR CONDITIONER > Compressor Oil　
ADJUSTMENT
 

Since the hygroscopicity of compressor oil is high, perform this series of works quickly.

AIR CONDITIONER > Blower Motor　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>REMOVAL

3.

Remove the duct foot passenger. AIR CONDITIONER>Air Vent Duct>REMOVAL > FOOT DUCT

4.

Remove the blower motor assembly.

(1)

Disconnect the connector.

(2)

Remove the screws and detach the blower motor assembly.

AIR CONDITIONER > Blower Motor　
INSTALLATION
1.

Install the blower motor assembly.

2.

Install the duct foot passenger. AIR CONDITIONER>Air Vent Duct>INSTALLATION > FOOT DUCT

3.

Install the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > Blower Motor　
INSPECTION
1.

Check the motor operation when battery voltage is applied between the connector terminals.

Terminal No.

Inspection conditions

Specification

2 (+) — 1 (−)

Apply battery voltage.

Rotation
2.

If the blower motor does not operate normally, replace the blower motor assembly.

AIR CONDITIONER > Power Transistor　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>REMOVAL

3.

Remove the power transistor.

(1)

Disconnect the connector.

(2)

Remove the power transistor by pressing the claw part (a) and sliding it.

AIR CONDITIONER > Power Transistor　
INSTALLATION
1.

Install the power transistor.

2.

Install the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>INSTALLATION

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > Heater Core　
REMOVAL
 

  • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

  • Be careful not to damage the airbag system harness when servicing the instrument panel. Damage may cause the system to malfunction.

1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • For the power seat model, remove the console box before removing the ground terminal from the battery sensor.

3.

Drain the coolant from the radiator. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

4.

Remove the instrument panel assembly and the beam steering COMPL. EXTERIOR/INTERIOR TRIM>Instrument Panel Assembly>REMOVAL

5.

Remove the heater and cooling unit assembly. AIR CONDITIONER>Heater and Cooling Unit>REMOVAL

6.

Remove the motor actuator mode and the bracket actuator mode. AIR CONDITIONER>Mode Door Actuator>REMOVAL

7.

Remove the cover heater core pipe.

(1)

Remove the screws and detach the cover heater core pipe.

8.

Remove the gasket heater core pipe.

9.

Remove the clamp heater core pipe.

(1)

Remove the screw and detach the clamp heater core pipe.

10.

Remove the pipe heater core.

(1)

Remove the clamp pipe, and then remove the pipe heater core.

11.

Remove the plate heater core.

(1)

Remove the screws.

(2)

Release the claws and remove the plate heater core.

12.

Remove the heater core.

(1)

Pull out the heater core as shown in the figure.

AIR CONDITIONER > Heater Core　
INSTALLATION
 

  • Do not start the engine before charging refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • Replace O-rings with new parts and install securely.

  • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Attach the heater core.

2.

Attach the plate heater core.

3.

Attach the pipe heater core.

4.

Install the clamp heater core pipe.

5.

Install the gasket heater core pipe.

6.

Install the cover heater core pipe.

7.

Install the motor actuator mode and the bracket actuator mode. AIR CONDITIONER>Mode Door Actuator>INSTALLATION

8.

Install the heater and cooling unit assembly. AIR CONDITIONER>Heater and Cooling Unit>INSTALLATION

9.

Install the instrument panel assembly and the beam steering COMPL. EXTERIOR/INTERIOR TRIM>Instrument Panel Assembly>INSTALLATION

10.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

11.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

AIR CONDITIONER > Control Panel　
REMOVAL
1.

When the heater control assembly is replaced with a new part, read and store the ECM setting information. (Model with driver monitoring system): AIR CONDITIONER(DIAGNOSTICS)>Work Support

(1)

Connect the Subaru Select Monitor.

(2)

On [Start] screen, select [Diagnosis].

(3)

On [Select Vehicle] screen, enter vehicle information and select [OK].

(4)

On [Main Menu] screen, select [Each System].

(5)

On [Select System] screen, select [Air Conditioner], and then select [Next].

(6)

On [Select Function] screen, select [Work Support].

(7)

On the work support item list, select [Read Control module setting information].

(8)

According to the display screen, save and close the file.

2.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3.

Remove the heater control assembly.

(1)

Attach the protective tape (a).

(2)

Release the clips and claws, and then remove the heater control assembly.

 

Wrap a remover, etc. with protective tape or cloth. Use a remover, etc. by pressing it in the instrument panel side so that the heater control assembly should not be damaged.

(3)

Disconnect the connector, and remove the heater control assembly.

(4)

Remove the screws and remove the center panel assembly.

AIR CONDITIONER > Control Panel　
INSTALLATION
1.

Install the center panel assembly.

2.

Install the heater control assembly.

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

When the heater control assembly has been replaced with a new part, write the ECM setting information. (Model with driver monitoring system): AIR CONDITIONER(DIAGNOSTICS)>Work Support

(1)

Connect the Subaru Select Monitor.

(2)

On [Start] screen, select [Diagnosis].

(3)

On [Select Vehicle] screen, enter vehicle information and select [OK].

(4)

On [Main Menu] screen, select [Each System].

(5)

On [Select System] screen, select [Air Conditioner], and then select [Next].

(6)

On [Select Function] screen, select [Work Support].

(7)

On the work support item list, select [Write Control module setting information].

(8)

Perform file writing according to the display screen.

(9)

ECM setting information writing is completed.

AIR CONDITIONER > Control Panel　
INSPECTION
1.

Check the illumination operation when battery voltage is applied between the connector terminals.

 

When applying battery voltage, do not mix up the positive (+) side and the negative (−) side.

Incorrect polarity connection may cause LED damage inside the switch.

Terminal No.

Inspection conditions

Specification

37 (+) — 35 (−)

Apply battery voltage.

Light ON
2.

If it does not operate normally, replace the heater control assembly.

AIR CONDITIONER > Compressor　
REMOVAL
1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3.

Remove the V-belts. MECHANICAL(H4DO)>V-belt>REMOVAL

4.

Detach the hose pressure suction and the hose pressure discharge.

(1)

Remove the bolts and detach the hose pressure suction.

(2)

Remove the bolts and disconnect the hose pressure discharge.

 

Seal the disconnected hose and engaging part of compressor with a plug or vinyl tape to prevent foreign matter from entering.

5.

Remove the compressor assembly.

(1)

Remove the harness clip and connector.

(2)

Remove the bolts and remove the compressor assembly.

AIR CONDITIONER > Compressor　
INSTALLATION
 

  • After installing the compressor, do not start the engine until the A/C system is charged with refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • Replace the O-rings with new parts, and then apply compressor oil to install completely.

  • After replacing the compressor assembly, adjust the amount of the compressor oil. AIR CONDITIONER>Compressor Oil>ADJUSTMENT

1.

Install the compressor assembly.

Tightening torque:

36 N·m (3.7kgf-m, 26.6ft-lb)

 

Tighten the compressor assembly in the numerical order as shown in the figure. AIR CONDITIONER>General Description>COMPONENT > COMPRESSOR

2.

Install the hose pressure suction and the hose pressure discharge.

Tightening torque:

10 N·m (1 kgf-m, 7.4ft-lb)

3.

Install the V-belts. MECHANICAL(H4DO)>V-belt>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

5.

Charge refrigerant. AIR CONDITIONER>Refrigerant Charging Procedure>PROCEDURE

6.

If replacing the compressor assembly with a new part, perform a break-in operation according to the following steps.

 

Do not increase the engine speed to and above 4,000 r/min unless the break-in operation finishes.

(1)

Check that all connectors are locked securely.

(2)

Reset the heater control assembly. (Disconnect and then connect the connector)

(3)

Install the delivery mode fuse. PRE-DELIVERY INSPECTION>PRE-DELIVERY INSPECTION (PDI) PROCEDURE > DELIVERY MODE

(4)

Using the Subaru Select Monitor, perform the break-in operation. AIR CONDITIONER(DIAGNOSTICS)>Work Support

  1. Connect the Subaru Select Monitor.

  2. On [Start] screen, select [Diagnosis].

  3. On [Select Vehicle] screen, enter vehicle information and select [OK].

  4. On [Main Menu] screen, select [Each System].

  5. On [Select System] screen, select [Air Conditioner], and then select [Next].

  6. On [Select Function] screen, select [Work Support].

  7. Select [Variable compressor break-in drive] mode from the work support list, and display [Break-in variable compressor drive, finish status] by following the procedure.

  8. Start and idle the engine at or below 1,800 r/min. (The compressor operation is automatically changed to the break-in drive mode.)

  9. When [Break-in variable compressor drive, finish status] changes from [incomplete] to [ON], stop the engine.

 

If the engine may have been started with no refrigerant charge, check for any diagnosis code (DTC) using Subaru Select Monitor. If the code B14A8 (REFRIGERANT NOT SEALED DRIVE ERROR) is output, replace the compressor assembly.

(5)

Remove the delivery mode fuse.

(6)

The break-in operation finishes.

AIR CONDITIONER > Condenser　
REMOVAL
1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3.

Remove the air intake duct. INTAKE (INDUCTION)(H4DO)>Air Intake Duct>REMOVAL

4.

Remove the bracket grille front.

(1)

Apply the protective tapes on the bracket grille front and the grille assembly front UPR.

(2)

Remove the clips, and remove the bracket grille front.

5.

Remove the reservoir tank. COOLING(H4DO)>Reservoir Tank>REMOVAL

6.

Remove the bracket hood stay.

(1)

Remove the bolt and remove the bracket hood stay.

7.

Remove the radiator upper bracket.

(1)

Remove the bolts and remove the radiator upper bracket.

8.

Detach the hose pressure discharge and the pipe evaporator cooling.

(1)

Remove the bolts and disconnect the hose pressure discharge.

(2)

Remove the bolt, and detach the pipe evaporator cooling.

 

Seal the disconnected hose, pipe and engaging part of condenser assembly with a plug or vinyl tape to prevent foreign matter from entering.

9.

Remove the condenser assembly.

(1)

Remove the bolts and remove the condenser assembly as shown in the figure.

 

  • Push the radiator to the engine side, and pull it out through the space between the radiator and the radiator panel.

  • Be careful not to damage the condenser and radiator fin.

  • If a damaged fin is found, repair it using a thin screwdriver.

AIR CONDITIONER > Condenser　
INSTALLATION
 

  • Do not start the engine before charging refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • Replace the O-rings with new parts, and then apply compressor oil to install completely.

  • If the condenser assembly has been replaced, add an appropriate amount of compressor oil to the compressor. AIR CONDITIONER>Compressor Oil>ADJUSTMENT

1.

Install the condenser assembly.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

2.

Install the hose pressure discharge and the pipe evaporator cooling.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

3.

Install the radiator upper bracket.

Tightening torque:

12 N·m (1.2kgf-m, 8.9ft-lb)

4.

Install the bracket hood stay.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

5.

Install the reservoir tank. COOLING(H4DO)>Reservoir Tank>INSTALLATION

6.

Install the bracket grille front.

7.

Install the air intake duct. INTAKE (INDUCTION)(H4DO)>Air Intake Duct>INSTALLATION

8.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

9.

Charge refrigerant. AIR CONDITIONER>Refrigerant Charging Procedure>PROCEDURE

AIR CONDITIONER > Condenser　
INSPECTION
1.

Check to see that the condenser fins are not clogged with debris or insects. Blow with compressed air or flush fins with water as needed.

2.

If any oil leak is found, replace the condenser assembly.

AIR CONDITIONER > Heater and Cooling Unit　
REMOVAL
 

  • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

  • Be careful not to damage the airbag system harness when servicing the instrument panel. Damage may cause the system to malfunction.

  • Seal the disconnected hose, pipe and engaging part of expansion valve with a plug or vinyl tape to prevent foreign matter from entering.

1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • For the power seat model, remove the console box before removing the ground terminal from the battery sensor.

3.

Drain the coolant from the radiator. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

4.

Disconnect the hose pressure suction and the pipe evaporator cooling on the expansion valve side. AIR CONDITIONER>Hose and Pipe>REMOVAL > LOW-PRESSURE HOSE

5.

Disconnect the hose heater outlet and the hose heater inlet.

(1)

Loosen the clamp, and detach the hose heater outlet.

(2)

Loosen the clamp, and detach the hose heater inlet.

 

Put alignment marks to hoses, clamps, etc.

6.

Remove the instrument panel assembly and the beam steering COMPL. EXTERIOR/INTERIOR TRIM>Instrument Panel Assembly>REMOVAL

7.

Remove the duct foot. AIR CONDITIONER>Air Vent Duct>REMOVAL > FOOT DUCT

8.

Remove the heater and cooling unit assembly.

(1)

Remove the hose drain.

(2)

Remove the bolt and remove the heater and cooling unit assembly.

AIR CONDITIONER > Heater and Cooling Unit　
INSTALLATION
 

  • Do not start the engine before charging refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • Replace the O-rings with new parts, and then apply compressor oil to install completely.

  • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Install the heater and cooling unit assembly.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

2.

Install the hose drain.

3.

Install the duct foot. AIR CONDITIONER>Air Vent Duct>INSTALLATION > FOOT DUCT

4.

Install the instrument panel assembly and the beam steering COMPL. EXTERIOR/INTERIOR TRIM>Instrument Panel Assembly>INSTALLATION

5.

Install the hose heater outlet and the hose heater inlet.

6.

Install the hose pressure suction and the pipe evaporator cooling on the expansion valve side. AIR CONDITIONER>Hose and Pipe>INSTALLATION > LOW-PRESSURE HOSE

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

8.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

AIR CONDITIONER > Evaporator　
REMOVAL
 

  • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

  • Be careful not to damage the airbag system harness when servicing the instrument panel. Damage may cause the system to malfunction.

1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • For the power seat model, remove the console box before removing the ground terminal from the battery sensor.

3.

Drain the coolant from the radiator. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

4.

Remove the instrument panel assembly and the beam steering COMPL. EXTERIOR/INTERIOR TRIM>Instrument Panel Assembly>REMOVAL

5.

Remove the expansion valve. AIR CONDITIONER>Expansion Valve>REMOVAL

6.

Remove the heater and cooling unit assembly. AIR CONDITIONER>Heater and Cooling Unit>REMOVAL

7.

Remove the heater unit assembly. AIR CONDITIONER>Heater Core>REMOVAL

8.

Remove the gasket expansion valve.

9.

Remove the grommet.

10.

Remove the evaporator assembly.

(1)

Remove the evaporator assembly as shown in the figure.

11.

Remove the evaporator sensor. AIR CONDITIONER>Evaporator Sensor>REMOVAL

AIR CONDITIONER > Evaporator　
INSTALLATION
 

  • Do not start the engine before charging refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • If the evaporator has been replaced, add an appropriate amount of compressor oil to the compressor. AIR CONDITIONER>Compressor Oil>ADJUSTMENT

  • Replace the O-rings with new parts, and then apply compressor oil to install completely.

  • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Install the evaporator sensor to the specified location. AIR CONDITIONER>Evaporator Sensor>INSTALLATION

2.

Install the evaporator assembly.

3.

Install the grommet.

4.

Install the gasket expansion valve.

5.

Install the heater unit assembly. AIR CONDITIONER>Heater Core>INSTALLATION

6.

Install the heater and cooling unit assembly. AIR CONDITIONER>Heater and Cooling Unit>INSTALLATION

7.

Install the expansion valve. AIR CONDITIONER>Expansion Valve>INSTALLATION

8.

Install the instrument panel assembly and the beam steering COMPL. EXTERIOR/INTERIOR TRIM>Instrument Panel Assembly>INSTALLATION

9.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

10.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

AIR CONDITIONER > Evaporator　
INSPECTION
1.

Check the evaporator fin for dust. Blow with compressed air or flush fins with water as needed.

2.

If any oil leak is found from the evaporator, replace the evaporator assembly.

AIR CONDITIONER > Expansion Valve　
REMOVAL
1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Disconnect the hose pressure suction and the pipe evaporator cooling on the expansion valve side.

(1)

Disconnect the pipe evaporator cooling from the hose pressure suction using the ST.

Preparation tool: 73499SJ000

ST: DISCONNECT TOOL

  1. Open the disconnect tool, and set it to the pipe evaporator cooling while aligning the shape.

     

    Spring force closes the cover automatically.

  2. While checking through the inspection hole (a) of the disconnect tool, press in the protrusion (b) into the engaging portion of the pipe evaporator cooling.

  3. While holding the condition in step 2, pull out the pipe evaporator cooling from the hose pressure suction in the direction of the arrow.

  4. Detach the disconnect tool, and remove the indicator ring (a).

     

    • Do not damage the indicator ring remaining on the vehicle, because it will be necessary if the pipe evaporator cooling is reused.

    • If the indicator ring has been lost or damaged, there is no way to confirm the secure engagement of parts. So replace the pipe evaporator cooling with a new part.

(2)

Remove the bolt and nut, and detach the hose pressure suction.

3.

Remove the expansion valve.

 

Seal the engaging part of pipe and expansion valve with a plug or vinyl tape to prevent foreign matter from entering.

(1)

Remove the bolts, then remove the expansion valve.

Preparation tool:

Hexagon wrench: 4 mm (0.16in)

AIR CONDITIONER > Expansion Valve　
INSTALLATION
 

  • Do not start the engine before charging refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • Replace the O-rings with new parts, and then apply compressor oil to install completely.

  • If the lock spring of the pipe evaporator cooling is damaged, replace it with a new part.

1.

Install the expansion valve.

Preparation tool:

Hexagon wrench: 4 mm (0.16in)

Tightening torque:

7.7N·m (0.8kgf-m, 5.7ft-lb)

2.

Install the hose pressure suction.

(1)

If the pipe evaporator cooling is reused, install the indicator ring (a) as shown in the figure.

(2)

Engage the hose pressure suction and the pipe evaporator cooling, and press them in until a click sound is heard and the indicator ring jumps out.

 

If the aforementioned phenomenon cannot be confirmed, it is considered that the fastening of the pipe evaporator cooling was not successful. In this case, perform the installation work again by following the procedure.

(3)

Install the hose pressure suction.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

3.

Charge refrigerant. AIR CONDITIONER>Refrigerant Charging Procedure>PROCEDURE

AIR CONDITIONER > Hose and Pipe　
REMOVAL
1. LOW-PRESSURE HOSE
1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Remove the vacuum hose COMPL and vacuum pipe assembly. BRAKE>Brake Booster>REMOVAL > BRAKE VACUUM HOSE

3.

Remove the hose pressure suction.

(1)

Disconnect the pipe evaporator cooling from the hose pressure suction using the ST.

Preparation tool: 73499SJ000

ST: DISCONNECT TOOL

  1. Open the disconnect tool, and set it to the pipe evaporator cooling while aligning the shape.

     

    Spring force closes the cover automatically.

  2. While checking through the inspection hole (a) of the disconnect tool, press in the protrusion (b) into the engaging portion of the pipe evaporator cooling.

  3. While holding the condition in step 2, pull out the pipe evaporator cooling from the hose pressure suction in the direction of the arrow.

  4. Detach the disconnect tool, and remove the indicator ring (a).

     

    • Do not damage the indicator ring remaining on the vehicle, because it will be necessary if the pipe evaporator cooling is reused.

    • If the indicator ring has been lost or damaged, there is no way to confirm the secure engagement of parts. So replace the pipe evaporator cooling with a new part.

(2)

Remove the bolt and nut, and detach the hose pressure suction.

 

  • Do not apply excessive force to the hose.

  • Seal the engaging part of disconnected hose, compressor assembly, and expansion valve with a plug or vinyl tape to prevent foreign matter from entering.

2. HIGH-PRESSURE HOSE
1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3.

Remove the air intake duct. INTAKE (INDUCTION)(H4DO)>Air Intake Duct>REMOVAL

4.

Remove the bracket grille front.

(1)

Apply the protective tapes on the bracket grille front and the grille assembly front UPR.

(2)

Remove the clips, and remove the bracket grille front.

5.

Remove the reservoir tank. COOLING(H4DO)>Reservoir Tank>REMOVAL

6.

Remove the radiator upper bracket.

(1)

Remove the bolts and remove the radiator upper bracket.

7.

Remove the hose pressure discharge.

 

  • Do not apply excessive force to the hose.

  • Seal the disconnected hose, compressor assembly and engaging part of condenser assembly with a plug or vinyl tape to prevent foreign matter from entering.

(1)

Disconnect the connector of the pressure sensor.

(2)

Remove the bolts, and remove the hose pressure discharge.

 

Push the condenser assembly and radiator toward the engine side to secure working space.

3. A/C PIPE
1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Remove the battery and battery tray. STARTING/CHARGING SYSTEMS(H4DO)>Battery>REMOVAL

3.

Remove the hose pressure suction. AIR CONDITIONER>Hose and Pipe>REMOVAL > LOW-PRESSURE HOSE

4.

Remove the hose pressure discharge. AIR CONDITIONER>Hose and Pipe>REMOVAL > HIGH-PRESSURE HOSE

5.

Remove the pipe evaporator cooling.

 

  • Do not apply excessive force to the pipe.

  • Seal the engaging parts of disconnected pipe, expansion valve and condenser assembly with a plug or vinyl tape to prevent foreign matter from entering.

  • Do not pull the harness and cable forcibly.

(1)

Disconnect the ECM upper connector. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>REMOVAL

(2)

Disconnect the main fuse box connector, and detach the harness from the clip.

(3)

Release the claws, and remove the battery cable bracket and engine harness bracket.

(4)

Disconnect the connector of the pressure sensor.

(5)

Remove the bolt, and detach the pipe evaporator cooling.

(6)

Remove the pipe evaporator cooling from the clip and clamp.

AIR CONDITIONER > Hose and Pipe　
INSTALLATION
1. LOW-PRESSURE HOSE
 

  • Do not start the engine before charging refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • If the hose and pipe has been replaced, add an appropriate amount of compressor oil to the compressor. AIR CONDITIONER>Compressor Oil>ADJUSTMENT

  • Replace the O-rings with new parts, and then apply compressor oil to install completely.

  • When connecting hoses, do not apply an excessive force to them. After installing, check that no torsion or excessive tension applied to the hoses.

  • If the lock spring of the pipe evaporator cooling is damaged, replace it with a new part.

1.

Install the hose pressure suction.

(1)

If the pipe evaporator cooling is reused, install the indicator ring (a) as shown in the figure.

(2)

Engage the hose pressure suction and the pipe evaporator cooling, and press them in until a click sound is heard and the indicator ring jumps out.

 

If the aforementioned phenomenon cannot be confirmed, it is considered that the fastening of the pipe evaporator cooling was not successful. In this case, perform the installation work again by following the procedure.

(3)

Install the hose pressure suction.

Tightening torque:

Air conditioning unit: AIR CONDITIONER>General Description>COMPONENT > AIR CONDITIONING UNIT

2.

Install the vacuum hose COMPL and vacuum pipe assembly. BRAKE>Brake Booster>INSTALLATION > BRAKE VACUUM HOSE

3.

Charge refrigerant. AIR CONDITIONER>Refrigerant Charging Procedure>PROCEDURE

2. HIGH-PRESSURE HOSE
 

  • Do not start the engine before charging refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • If the hose and pipe has been replaced, add an appropriate amount of compressor oil to the compressor. AIR CONDITIONER>Compressor Oil>ADJUSTMENT

  • Replace the O-rings with new parts, and then apply compressor oil to install completely.

  • When connecting hoses, do not apply an excessive force to them. After installing, check that no torsion or excessive tension applied to the hoses.

1.

Install the hose pressure discharge.

(1)

Install the hose pressure discharge.

Tightening torque:

Air conditioning unit: AIR CONDITIONER>General Description>COMPONENT > AIR CONDITIONING UNIT

(2)

Connect the connector of the pressure sensor.

2.

Install the radiator upper bracket.

Tightening torque:

12 N·m (1.2kgf-m, 8.9ft-lb)

3.

Install the reservoir tank. COOLING(H4DO)>Reservoir Tank>INSTALLATION

4.

Install the bracket grille front.

5.

Install the air intake duct. INTAKE (INDUCTION)(H4DO)>Air Intake Duct>INSTALLATION

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

7.

Charge refrigerant. AIR CONDITIONER>Refrigerant Charging Procedure>PROCEDURE

3. A/C PIPE
 

  • Do not start the engine before charging refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • If the hose and pipe has been replaced, add an appropriate amount of compressor oil to the compressor. AIR CONDITIONER>Compressor Oil>ADJUSTMENT

  • Replace the O-rings with new parts, and then apply compressor oil to install completely.

  • When connecting pipes, do not apply an excessive force to them. After installation, check that the pipes are not damaged.

  • If the lock spring of the pipe evaporator cooling is damaged, replace it with a new part.

1.

Install the pipe evaporator cooling.

(1)

Install the pipe evaporator cooling.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

(2)

Connect the connector of the pressure sensor.

(3)

Install the battery cable bracket and engine harness bracket.

(4)

Connect the connector and harness of the main fuse box.

(5)

Connect the ECM upper connector. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>INSTALLATION

2.

Install the hose pressure discharge. AIR CONDITIONER>Hose and Pipe>INSTALLATION > HIGH-PRESSURE HOSE

3.

Install the hose pressure suction. AIR CONDITIONER>Hose and Pipe>INSTALLATION > LOW-PRESSURE HOSE

4.

Install the battery and battery tray. STARTING/CHARGING SYSTEMS(H4DO)>Battery>INSTALLATION

5.

Charge refrigerant. AIR CONDITIONER>Refrigerant Charging Procedure>PROCEDURE

AIR CONDITIONER > Hose and Pipe　
INSPECTION
1.

Check the hoses for cracks, damage and expansion. If there is a malfunction, replace the hose pressure suction or the hose pressure discharge.

2.

Check the pipes for crack or damage. If there is a malfunction, replace the pipe evaporator cooling.

AIR CONDITIONER > Pressure Sensor　
REMOVAL
1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3.

Remove the pressure sensor.

(1)

Disconnect the connector.

(2)

Remove the pressure sensor as shown in the figure.

 

  • Do not deform the pipe.

  • Seal the engaging sections of the disconnected pipe and the sensor with a plug or vinyl tape to prevent foreign matter from entering.

  • Do not reuse the sensor.

AIR CONDITIONER > Pressure Sensor　
INSTALLATION
 

  • Do not start the engine before charging refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • O-rings are included in the pressure sensor. Apply compressor oil to new O-rings and install it to the pressure sensor completely.

1.

Install a new pressure sensor and new O-rings.

Tightening torque:

9.8±1.5N·m (1.0±0.2kgf-m, 7.2±1.1ft-lb)

2.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3.

Charge refrigerant. AIR CONDITIONER>Refrigerant Charging Procedure>PROCEDURE

AIR CONDITIONER > Pressure Sensor　
INSPECTION
1.

Perform a diagnosis code (DTC) check by connecting the Subaru Select Monitor. AIR CONDITIONER(DIAGNOSTICS)>Diagnostic Trouble Code (DTC)>OPERATION

2.

If the following diagnosis code (DTC) is displayed, refer to “Diagnostic Procedure with Diagnostic Trouble Code (DTC)” in “AIR CONDITIONER (DIAGNOSTICS)” section.

AIR CONDITIONER > Ambient Sensor　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Lift up the vehicle.

3.

Turn over the mud guard front.

(1)

Remove the screw and clips, and turn over the mud guard front.

4.

Remove the ambient sensor.

(1)

Disconnect the connector.

(2)

Release the claws and remove the ambient sensor.

AIR CONDITIONER > Ambient Sensor　
INSTALLATION
 

Install the mud guard front so that the front end of the mud guard (b), except for the clip fixing point, comes inside the bumper face (a).

1.

Install the ambient sensor.

2.

Install the mud guard front.

3.

Lower the vehicle.

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > Ambient Sensor　
INSPECTION
1.

Visually check the ambient sensor for dirt or damage, and clean or replace as necessary.

2.

Measure the resistance between connector terminals.

 

During inspection, be careful not to touch the sensor end in order to avoid misjudgment due to body temperature.

Preparation tool:

Circuit tester

AC-10423 2 1 (140) (122) (104) (86) (68) (50) 60 50 40 30 (32) 10 0 20 6.50 6.00 5.50 5.00 4.50 4.00 3.50 3.00 2.50 2.00 1.50 1.00 0.50 : STANDARD (MAX TOLERANCE) : STANDARD (MIN TOLERANCE) RESISTANCE VALUE TEMPERATURE

Terminal No.

Inspection conditions

Standard

1 — 2

10°C (50°F)

5.82 — 6.18 kΩ

15°C (59°F)

4.58 — 4.87 kΩ

20°C (68°F)

3.64 — 3.86 kΩ

25°C (77°F)

2.91 — 3.09 kΩ

30°C (86°F)

2.35 — 2.49 kΩ

35°C (95°F)

1.9 — 2.02 kΩ

40°C (104°F)

1.56 — 1.65 kΩ

45°C (113°F)

1.28 — 1.36 kΩ

50°C (122°F)

1.06 — 1.12 kΩ

55°C (131°F)

0.88 — 0.93 kΩ

60°C (140°F)

0.74 — 0.78 kΩ
3.

Replace the ambient sensor if the inspection result is not within the standard value.

AIR CONDITIONER > Sunload Sensor (Auto A/C Model)　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the grille ventilation assembly center. AIR CONDITIONER>Air Vent Grille>REMOVAL > CENTER GRILLE

3.

Remove the panel center UPR, and remove the audio assembly or navigation assembly. ENTERTAINMENT & MONITORING>Audio>REMOVAL

4.

Remove the multi-function display assembly. INSTRUMENTATION/DRIVER INFO>Multi-function Display (MFD)>REMOVAL

5.

Remove the grille front defroster.

(1)

Release the clips.

(2)

Disconnect the connector and remove the grille front defroster.

6.

Remove the sunload sensor.

(1)

Release the claws and remove the sunload sensor.

AIR CONDITIONER > Sunload Sensor (Auto A/C Model)　
INSTALLATION
1.

Install the sunload sensor.

2.

Install the grille front defroster.

3.

Install the multi-function display. INSTRUMENTATION/DRIVER INFO>Multi-function Display (MFD)>INSTALLATION

4.

Install the audio assembly or navigation assembly and install the panel center UPR. ENTERTAINMENT & MONITORING>Audio>INSTALLATION

5.

Install the grille ventilation assembly center. AIR CONDITIONER>Air Vent Grille>INSTALLATION > CENTER GRILLE

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > Sunload Sensor (Auto A/C Model)　
INSPECTION
1.

Check if there is anything that affects sensing, around the sunload sensor.

(1)

Is the sunload sensor free from any object that disturbs sensing?

(2)

Is the windshield glass free from any object such as sticker or film that disturbs sensing?

  • Yes → Go to step 2.

  • No → Remove everything that affects sensing.

2.

Check the sunload sensor using the Subaru Select Monitor.

(1)

Connect the Subaru Select Monitor.

(2)

On [Start] screen, select [Diagnosis].

(3)

On [Select Vehicle] screen, enter vehicle information and select [OK].

(4)

On [Select System] screen, select [Air Conditioner], and then select [Next].

(5)

On [Select Function] screen, select [Data Monitor].

(6)

From the data monitor item list, select [Quantity of Sunload].

(7)

Cover the sunload sensor with cloth and the like to avoid direct light. Does [Quantity of Sunload] indicate [0 W/m2]?

  • Yes → Go to step 3.

  • No → Replace the sunload sensor.

3.

From step 2), expose the sunload sensor to light.

(1)

Place intense light such as incandescent light at 300 mm (11.81in) or less from the sunload sensor.

(2)

Does [Quantity of Sunload] indicate [2,000 W/m2] or less?

 

The value changes depending on the angle of light.

  • Yes → The sunload sensor is normal.

  • No → Replace the sunload sensor.

AIR CONDITIONER > Temperature and Humidity Sensor　
REMOVAL
 

Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the cover assembly instrument panel side LH and the cover LWR driver. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>REMOVAL

3.

Remove the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>REMOVAL

4.

Remove the temperature and humidity sensor.

(1)

Disconnect the aspirator hose and connector.

(2)

Release the claws and then remove the temperature and humidity sensor.

AIR CONDITIONER > Temperature and Humidity Sensor　
INSTALLATION
 

Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Install the temperature and humidity sensor.

2.

Install the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>INSTALLATION

3.

Install the cover LWR driver and the cover assembly instrument panel side LH. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > Temperature and Humidity Sensor　
INSPECTION
1.

Set the vehicle to the following conditions.

Item

Condition

Ambient temperature

Approx. 25°C (77°F)

Ignition switch

ON

A/C switch

ON

Temperature adjustment dial

HI (MAX HOT)

Air flow control switch

DEF

Fan dial

HI (MAX)
2.

Check the suction port (a) for the temperature and humidity sensor of the cover LWR driver.

(1)

Put a strip of paper close to the front side of the suction port (a).

(2)

Can you see the paper moving towards the port and the air being sucked into the port?

 

Be careful not to let the paper get sucked into the port.

  • Yes → Go to step 5.

  • No → Go to step 3.

3.

Remove the cover LWR driver, and check the aspirator hose (a).

(1)

Are the aspirator hoses on both sides of the case and sensor connected securely?

(2)

Is the aspirator hose free from any kinks or cracks?

  • Yes → Go to step 4.

  • No → Repair or replace the aspirator hose if necessary.

4.

Check if there is anything that affects sensing around the temperature and humidity sensor.

(1)

Is the temperature and humidity sensor hole free from clogging?

(2)

Is the peripheral area of the temperature and humidity sensor free from any heat-producing parts (such as audio, navigation system etc.)?

  • Yes → Go to step 5.

  • No → Remove everything that affects sensing.

5.

Perform the inspection of temperature and humidity sensor unit.

(1)

Is the voltage between terminals of humidity sensor within standard value?

 

During inspection, be careful not to touch the sensor end in order to avoid misjudgment due to body temperature.

Preparation tool:

Circuit tester

20 10 0 30 40 50 60 70 80 90 2 1 4 3 AC-10891 3.50 3.00 2.50 2.00 1.50 1.00 0.50 0.00 HUMIDITY % OUTPUT VOLTAGE V : STANDARD (MIN TOLERANCE) : STANDARD (MAX TOLERANCE)

Terminal No.

Inspection conditions

Standard

2 — 3

10%

0.46 — 0.94 V

20%

0.90 — 1.35 V

30%

1.35 — 1.78 V

40%

1.78 — 2.11 V

50%

2.11 — 2.36 V

60%

2.34 — 2.59 V

70%

2.55 — 2.78 V

80%

2.73 — 2.96 V

90%

2.90 — 3.15 V
 

Perform the check from the backside with the connectors connected and with the ignition switch ON.

(2)

Is the resistance between terminals of temperature sensor within standard value?

 

During inspection, be careful not to touch the sensor end in order to avoid misjudgment due to body temperature.

  1. Turn the ignition switch to OFF, then disconnect the ground terminal from the battery sensor. REPAIR CONTENTS>NOTE > BATTERY

  2. Disconnect the temperature and humidity sensor connector.

  3. Is the resistance between terminals of temperature sensor within standard value?

    Preparation tool:

    Circuit tester

    2 1 4 3 AC-10884 (140) (122) (104) (86) (68) (50) (32) 20 10 0 30 40 50 60 0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 TEMPERATURE RESISTANCE VALUE : STANDARD (MAX TOLERANCE) : STANDARD (MIN TOLERANCE)

    Terminal No.

    Inspection conditions

    Standard

    1 — 2

    10°C (50°F)

    3.772 — 4.101 kΩ

    15°C (59°F)

    3.096 — 3.338 kΩ

    20°C (68°F)

    2.556 — 2.734 kΩ

    25°C (77°F)

    2.121 — 2.251 kΩ

    30°C (86°F)

    1.756 — 1.878 kΩ

    35°C (95°F)

    1.462 — 1.574 kΩ

    40°C (104°F)

    1.223 — 1.326 kΩ

    45°C (113°F)

    1.028 — 1.122 kΩ

    50°C (122°F)

    0.868 — 0.9542 kΩ

    55°C (131°F)

    0.7363 — 0.8147 kΩ

    60°C (140°F)

    0.6273 — 0.6984 kΩ

  • Yes → The temperature and humidity sensor is normal.

  • No → Replace the temperature and humidity sensor.

AIR CONDITIONER > Evaporator Sensor　
REMOVAL
 

Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Using the refrigerant recovery system, discharge refrigerant. AIR CONDITIONER>Refrigerant Recovery Procedure>PROCEDURE

2.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • For the power seat model, remove the console box before removing the ground terminal from the battery sensor.

3.

Drain the coolant from the radiator. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

4.

Remove the instrument panel assembly and the beam steering COMPL. EXTERIOR/INTERIOR TRIM>Instrument Panel Assembly>REMOVAL

5.

Remove the expansion valve. AIR CONDITIONER>Expansion Valve>REMOVAL

6.

Remove the heater and cooling unit assembly. AIR CONDITIONER>Heater and Cooling Unit>REMOVAL

7.

Remove the heater unit assembly. AIR CONDITIONER>Heater Core>REMOVAL

8.

Remove the evaporator assembly. AIR CONDITIONER>Evaporator>REMOVAL

9.

Remove the evaporator sensor.

(1)

Remove the evaporator sensor as shown in the figure.

AIR CONDITIONER > Evaporator Sensor　
INSTALLATION
 

  • Do not start the engine before charging refrigerant.

  • If the engine is started with no refrigerant charge, replace the compressor assembly.

  • Replace the O-rings with new parts, and then apply compressor oil to install completely.

  • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Install the evaporator sensor at the position shown in the figure below.

(a)

Evaporator ASSY

(b)

Evaporator sensor

(c)

57 mm (2.24in)

(d)

48 mm (1.89in)

(e)

32.6 mm (1.28in)
2.

Install the evaporator assembly. AIR CONDITIONER>Evaporator>INSTALLATION

3.

Install the heater unit assembly. AIR CONDITIONER>Heater Core>INSTALLATION

4.

Install the heater and cooling unit assembly. AIR CONDITIONER>Heater and Cooling Unit>INSTALLATION

5.

Install the expansion valve. AIR CONDITIONER>Expansion Valve>INSTALLATION

6.

Install the instrument panel assembly and the beam steering COMPL. EXTERIOR/INTERIOR TRIM>Instrument Panel Assembly>INSTALLATION

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

8.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

AIR CONDITIONER > Evaporator Sensor　
INSPECTION
1.

Prepare the vehicle.

 

Check that the ambient temperature is 25 — 40°C (77 — 104°F) and that the humidity is 30 — 80%.

  • Place the vehicle in the workshop or in the shade and windless condition.

  • Open all windows.

2.

Set the vehicle to the following conditions.

Item

Condition

Engine

Idling

Air vent grille

Full open

A/C switch

OFF

Temperature setting

LO (MAX COOL)

FRESH/RECIRC position

RECIRC

Air flow control position

VENT

Fan speed

HI (MAX)
3.

Using the Subaru Select Monitor, check the evaporator sensor.

(1)

Connect the Subaru Select Monitor.

(2)

On [Start] screen, select [Diagnosis].

(3)

On [Select Vehicle] screen, enter vehicle information and select [OK].

(4)

On [Select System] screen, select [Air Conditioner], and then select [Enter].

(5)

On [Select Function] screen, select [Data Monitor].

(6)

From the data monitor item list, select [Evaporator Temperature Target].

(7)

Idle the engine for 15 minutes, and then compare the air flow outlet temperature with [Evaporator Temperature Target].

Preparation tool:

Thermometer and hygrometer

 

For outlet opening temperature, measure the average temperature of center grille assembly and side grille assembly.

(8)

Is the difference between outlet opening temperature and [Evaporator Temperature Target] by 3°C (5.4°F) or more?

  • Yes → Go to step 4.

  • No → Evaporator sensor is normal.

4.

Check the evaporator sensor.

(1)

Disconnect the connector.

(2)

Measure the resistance between connector terminals.

Preparation tool:

Circuit tester

(14) 0 (32) 10 (50) 20 (68) 30 (86) 40 (104) 50 (122) 2 1 AC-03060 16.00 14.00 12.00 10.00 8.00 6.00 4.00 2.00 0.00 (-22) -30 (-4) -20 -10 : STANDARD (MIN TOLERANCE) RESISTANCE VALUE : STANDARD (MAX TOLERANCE) TEMPERATURE

Terminal No.

Inspection conditions

Standard

1 — 2

−20°C (-4°F)

13.584 — 14.541 kΩ

−15°C (5°F)

10.34 — 10.946 kΩ

−10°C (14°F)

7.938 — 8.313 kΩ

−5°C (23°F)

6.143 — 6.366 kΩ

0°C (32°F)

4.79 — 4.914 kΩ

5°C (41°F)

3.718 — 3.829 kΩ

10°C (50°F)

2.889 — 3.031 kΩ

15°C (59°F)

2.247 — 2.435 kΩ

20°C (68°F)

1.785 — 1.952 kΩ

25°C (77°F)

1.427 — 1.574 kΩ

30°C (86°F)

1.149 — 1.278 kΩ

35°C (95°F)

0.931 — 1.044 kΩ

40°C (104°F)

0.759 — 0.858 kΩ
(3)

Is the resistance within the standard?

  • Yes → Evaporator sensor is normal.

  • No → Replace the evaporator sensor.

AIR CONDITIONER > Heater Core Sensor　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>REMOVAL

3.

Remove the duct foot passenger. AIR CONDITIONER>Air Vent Duct>REMOVAL > FOOT DUCT

4.

Remove the motor actuator air mix RH. AIR CONDITIONER>Air Mix Door Actuator>REMOVAL > PASSENGER’S SIDE

5.

Remove the heater core sensor.

(1)

Disconnect the connector.

(2)

Remove the screw and detach the heater core sensor.

AIR CONDITIONER > Heater Core Sensor　
INSTALLATION
1.

Attach the heater core sensor.

2.

Install the motor actuator air mix RH. AIR CONDITIONER>Air Mix Door Actuator>INSTALLATION > PASSENGER’S SIDE

3.

Install the duct foot passenger. AIR CONDITIONER>Air Vent Duct>INSTALLATION > FOOT DUCT

4.

Install the panel instrument passenger and pocket COMPL. EXTERIOR/INTERIOR TRIM>Glove Box>INSTALLATION

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > Heater Core Sensor　
INSPECTION
1.

Check heater core sensor.

(1)

Measure the resistance between connector terminals.

 

During inspection, be careful not to touch the sensor end in order to avoid misjudgment due to body temperature.

Preparation tool:

Circuit tester

AC-10361 0 20 40 60 80 40 0 120 160 200 (32) (68) (104) (140) 80 (176) 100 (212) 120 (248) 2 1 (-4) (-40) -40 -20 RESISTANCE VALUE : STANDARD (MIN TOLERANCE) : STANDARD (MAX TOLERANCE) TEMPERATURE

Terminal No.

Inspection conditions

Standard

1 — 2

−40°C (−40°F)

151.6 — 201.1 kΩ

−35°C (−-31°F)

109.9 — 142.7 kΩ

−30°C (−22°F)

80.55 — 102.4 kΩ

−25°C (−13°F)

59.69 — 74.44 kΩ

−20°C (−4°F)

44.69 — 54.69 kΩ

−15°C (5°F)

33.79 — 40.61 kΩ

−10°C (14°F)

25.79 — 30.45 kΩ

−5°C (23°F)

19.86 — 23.06 kΩ

0°C (32°F)

15.42 — 17.61 kΩ

5°C (41°F)

12.05 — 13.55 kΩ

10°C (50°F)

9.497 — 10.52 kΩ

15°C (59°F)

7.538 — 8.229 kΩ

20°C (68°F)

6.026 — 6.487 kΩ

25°C (77°F)

4.85 — 5.15 kΩ

30°C (86°F)

3.877 — 4.172 kΩ

35°C (95°F)

3.12 — 3.4 kΩ

40°C (104°F)

2.527 — 2.788 kΩ

45°C (113°F)

2.059 — 2.299 kΩ

50°C (122°F)

1.687 — 1.905 kΩ

55°C (131°F)

1.39 — 1.588 kΩ

60°C (140°F)

1.152 — 1.33 kΩ

65°C (149°F)

0.9587 — 1.119 kΩ

70°C (158°F)

0.8021 — 0.9457 kΩ

75°C (167°F)

0.6743 — 0.8029 kΩ

80°C (176°F)

0.5693 — 0.6846 kΩ

85°C (185°F)

0.4828 — 0.586 kΩ

90°C (194°F)

0.4112 — 0.5036 kΩ

95°C (203°F)

0.3516 — 0.4345 kΩ

100°C (212°F)

0.3017 — 0.3761 kΩ

105°C (221°F)

0.26 — 0.3268 kΩ

110°C (230°F)

0.2248 — 0.2849 kΩ

115°C (239°F)

0.195 — 0.2491 kΩ

120°C (248°F)

0.1697 — 0.2186 kΩ
(2)

Replace the heater core sensor if the inspection result is not within the standard value.

AIR CONDITIONER > FRESH/RECIRC Door Actuator　
REMOVAL
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>REMOVAL

3.

Remove the motor actuator intake.

(1)

Disconnect the connector.

(2)

Remove the screws, and remove the motor actuator intake.

AIR CONDITIONER > FRESH/RECIRC Door Actuator　
INSTALLATION
1.

Install the motor actuator intake.

2.

Install the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>INSTALLATION

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > FRESH/RECIRC Door Actuator　
INSPECTION
1. ACTUATOR LINK
1.

Visually check the operating range of the link, and remove the foreign matter if any.

2.

Operate the FRESH/RECIRC switch, and check that the link operates normally.

3.

If it does not operate normally as the result of inspection, perform a unit inspection of motor actuator intake.

2. CHECK ACTUATOR.
1.

Check the actuator operation when battery voltage is applied between the connector terminals.

 

Disconnect the battery immediately after the actuator stops operation. Otherwise, the motor may be damaged.

Terminal No.

Inspection conditions

Operating position

1 (+) — 2 (−)

Apply battery voltage.

FRESH

2 (+) — 1 (−)

RECIRC
2.

If it is found defective as a result of inspection, replace the motor actuator intake.

AIR CONDITIONER > Mode Door Actuator　
REMOVAL
 

Before handling the airbag system components, always refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the cover LWR driver. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>REMOVAL

3.

Remove the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>REMOVAL

4.

Remove the motor actuator mode.

(1)

Disconnect the connector.

(2)

Release the lock by turning as shown in the figure, and remove the motor actuator mode.

5.

Remove the bracket actuator mode.

(1)

Remove the screws, and remove the bracket actuator mode.

(2)

Remove the levers.

AIR CONDITIONER > Mode Door Actuator　
INSTALLATION
 

Before handling the airbag system components, always refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

When replacing the lever mode with a new part, apply a thin coat of grease evenly to the contact area inside the rail of lever mode by using approx. 5 mm (0.2in) width and approx. 0.1 g (0.004 oz) of grease squeezed out from a tube.

 

After installing the actuator, perform 3 — 5 times of adaptation for the grease to fit in.

Preparation items:

Genuine part: SUBARU genuine grease (72129AJ000)

2.

Install each lever and the bracket actuator mode.

3.

Install the motor actuator mode.

4.

Install the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>INSTALLATION

5.

Install the cover LWR driver. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>INSTALLATION

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > Mode Door Actuator　
INSPECTION
1. ACTUATOR LINK
1.

Visually check the operating range of the link, and remove the foreign matter if any.

2.

Operate the mode change switch, and check that the link operates normally.

3.

If it does not operate normally as the result of inspection, perform a unit inspection of motor actuator mode.

2. CHECK ACTUATOR OPERATION
1.

Measure the resistance between connector terminals.

Terminal No.

Inspection conditions

Standard

3 − 1

Always

80 — 100 Ω

3 − 2

3 − 5

3 − 6
2.

Replace the motor actuator mode if the inspection result is not within the standard value.

AIR CONDITIONER > Air Mix Door Actuator　
REMOVAL
1. DRIVER’S SIDE
 

Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the cover LWR driver. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>REMOVAL

3.

Remove the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>REMOVAL

4.

Remove the duct foot driver. AIR CONDITIONER>Air Vent Duct>REMOVAL > FOOT DUCT

5.

Remove the motor actuator air mix.

(1)

Disconnect the connector.

(2)

Release the lock by turning as shown in the figure, and remove the motor actuator air mix.

2. PASSENGER’S SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>REMOVAL

3.

Remove the duct foot passenger. AIR CONDITIONER>Air Vent Duct>REMOVAL > FOOT DUCT

4.

Remove the motor actuator air mix.

(1)

Disconnect the connector.

(2)

Remove the screws and remove the motor actuator air mix.

 

Put the alignment marks on the engaging portion of the lever mix and motor actuator air mix.

AIR CONDITIONER > Air Mix Door Actuator　
INSTALLATION
1. DRIVER’S SIDE
1.

Install the motor actuator air mix.

2.

Install the duct foot driver. AIR CONDITIONER>Air Vent Duct>INSTALLATION > FOOT DUCT

3.

Install the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>INSTALLATION

4.

Install the cover LWR driver. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>INSTALLATION

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2. PASSENGER’S SIDE
1.

Install the motor actuator air mix.

 

Align the alignment mark of the lever with that of the motor actuator air mix.

2.

Install the duct foot passenger. AIR CONDITIONER>Air Vent Duct>INSTALLATION > FOOT DUCT

3.

Install the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > Air Mix Door Actuator　
INSPECTION
1. ACTUATOR LINK
1.

Visually check the operating range of the link, and remove the foreign matter if any.

2.

Operate the temperature setting to check that the link operates normally.

3.

If it does not operate normally as the result of inspection, perform a unit inspection of motor actuator air mix.

2. CHECK ACTUATOR OPERATION
1.

Measure the resistance between connector terminals.

Terminal No.

Inspection conditions

Standard

3 − 1

Always

80 — 100 Ω

3 − 2

3 − 5

3 − 6
2.

Replace the motor actuator air mix if the inspection result is not within the standard value.

AIR CONDITIONER > Air Vent Grille　
REMOVAL
1. CENTER GRILLE
1.

Remove the grille ventilation assembly center.

(1)

Attach the protective tape (a).

(2)

Release the clips, and then remove the grille ventilation assembly center RH and LH.

 

Wrap a remover, etc. with protective tape or cloth. Use a remover, etc. by pressing it in the instrument panel side so that the grille ventilation assembly center should not be damaged.

2. SIDE GRILLE
1.

Remove the grille ventilation side.

(1)

Attach the protective tape (a).

(2)

Release the claws and clips, then detach the grille ventilation side.

 

Wrap a remover, etc. with protective tape or cloth. Insert a remover, etc. from inside the grille ventilation side. Be careful not to damage the grille ventilation side.

  • Driver’s side

  • Passenger’s side

3. CONSOLE GRILLE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • On power seat models, move the front seat all the way forward before disconnecting the ground terminal from the battery sensor.

2.

Remove the console box assembly. EXTERIOR/INTERIOR TRIM>Console Box>REMOVAL

3.

Remove the grille assembly console rear. EXTERIOR/INTERIOR TRIM>Console Box>DISASSEMBLY

AIR CONDITIONER > Air Vent Grille　
INSTALLATION
1. CENTER GRILLE
 

Make sure that the grille assembly is inserted into the air vent duct correctly.

1.

Install the grille ventilation assembly center.

2. SIDE GRILLE
 

Make sure that the grille assembly is inserted into the air vent duct correctly.

1.

Install the grille ventilation side.

3. CONSOLE GRILLE
 

Make sure that the air vent duct is inserted into the grille assembly correctly.

1.

Install the grille assembly console rear. EXTERIOR/INTERIOR TRIM>Console Box>ASSEMBLY

2.

Install the console box assembly. EXTERIOR/INTERIOR TRIM>Console Box>INSTALLATION

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > Air Vent Grille　
INSPECTION
1.

Check that the direction and the amount of air can be adjusted smoothly. Replace the grille assembly if faulty.

2.

Check that the adjustment can be maintained in each position. Replace the grille assembly if faulty.

AIR CONDITIONER > Air Vent Duct　
REMOVAL
1. FRONT DUCT
 

  • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

  • Be careful not to damage the airbag system harness when servicing the instrument panel. Damage may cause the system to malfunction.

1.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • For the power seat model, remove the console box before removing the ground terminal from the battery sensor.

2.

Remove the instrument panel assembly. EXTERIOR/INTERIOR TRIM>Instrument Panel Assembly>REMOVAL

3.

Remove the duct center ventilation front and the duct side ventilation.

(1)

Remove the screws and remove the duct side ventilation LH and RH (a).

(2)

Remove the duct center ventilation front (b).

2. REAR DUCT
•
FRONT
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • For the power seat model, remove the console box before removing the ground terminal from the battery sensor.

2.

Remove the cover assembly front and the console box assembly. EXTERIOR/INTERIOR TRIM>Console Box>REMOVAL

3.

Remove the cover center side. EXTERIOR/INTERIOR TRIM>Center Console>REMOVAL

4.

Remove the duct rear heater front.

(1)

Remove the slide lock.

(2)

Release the claws, and remove the duct rear heater front.

•
REAR
 

Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Prior to starting work, check “Precautions” in the “SEATS” section. SEATS>General Description>CAUTION

2.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • For the power seat model, remove the console box before removing the ground terminal from the battery sensor.

3.

Remove the duct rear heater front. AIR CONDITIONER>Air Vent Duct>REMOVAL > REAR DUCT

4.

Remove the front seats. SEATS>Front Seat>REMOVAL

5.

Turn over the floor mat. EXTERIOR/INTERIOR TRIM>Floor Mat>REMOVAL

 

For models with amplifier, remove the duct extension.

6.

Remove the duct rear heater rear.

(1)

Release the claws, and then remove the duct rear heater rear.

3. CONSOLE DUCT
•
FRONT
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • For the power seat model, remove the console box before removing the ground terminal from the battery sensor.

2.

Remove the heater control assembly. AIR CONDITIONER>Control Panel>REMOVAL

3.

Remove the cover assembly front and the console box assembly. EXTERIOR/INTERIOR TRIM>Console Box>REMOVAL

4.

Remove the cover center side. EXTERIOR/INTERIOR TRIM>Center Console>REMOVAL

5.

Remove the duct console center. AIR CONDITIONER>Air Vent Duct>REMOVAL > CONSOLE DUCT

6.

Remove the duct console front. EXTERIOR/INTERIOR TRIM>Center Console>REMOVAL

•
CENTER
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • For the power seat model, remove the console box before removing the ground terminal from the battery sensor.

2.

Remove the cover assembly front and the console box assembly. EXTERIOR/INTERIOR TRIM>Console Box>REMOVAL

3.

Remove the cover center side. EXTERIOR/INTERIOR TRIM>Center Console>REMOVAL

4.

Remove the duct console center.

(1)

Remove the clips, and remove the duct console center.

•
REAR
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

 

  • Release the shift lock and shift the select lever to the “N” position. CONTROL SYSTEMS>Select Lever>REMOVAL

  • For the power seat model, remove the console box before removing the ground terminal from the battery sensor.

2.

Remove the cover assembly front and the console box assembly. EXTERIOR/INTERIOR TRIM>Console Box>REMOVAL

3.

Remove the duct console rear. EXTERIOR/INTERIOR TRIM>Console Box>DISASSEMBLY

4. FOOT DUCT
RH SIDE
1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>REMOVAL

3.

Remove the duct foot passenger.

(1)

Remove the harness clip and screws, and remove the duct foot passenger.

LH SIDE
 

Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Disconnect the ground terminal from the battery sensor, and wait for at least 60 seconds before starting work. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the cover LWR driver. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>REMOVAL

3.

Remove the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>REMOVAL

4.

Remove the duct foot driver.

(1)

Remove the screws securing the spacer foot and release the claws, then detach the duct foot driver together with the spacer foot.

 

If the duct foot driver is detached from the spacer foot, replace the duct foot driver with a new part. If the duct foot driver is reused, the holding force of the claws and clips is reduced and the part may come off.

AIR CONDITIONER > Air Vent Duct　
INSTALLATION
1. FRONT DUCT
 

  • Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

  • Be careful not to damage the airbag system harness when servicing the instrument panel. Damage may cause the system to malfunction.

1.

Install the duct side ventilation and the duct center ventilation front.

2.

Install the instrument panel assembly. EXTERIOR/INTERIOR TRIM>Instrument Panel Assembly>INSTALLATION

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2. REAR DUCT
•
FRONT
1.

Install the duct rear heater front.

2.

Install the cover center side. EXTERIOR/INTERIOR TRIM>Center Console>INSTALLATION

3.

Install the console box assembly and the cover assembly front. EXTERIOR/INTERIOR TRIM>Console Box>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

•
REAR
 
1.

Install the duct rear heater rear.

2.

Install the floor mat. EXTERIOR/INTERIOR TRIM>Floor Mat>INSTALLATION

 

For models with amplifier, install the duct extension.

3.

Install the front seat. SEATS>Front Seat>INSTALLATION

4.

Install the duct rear heater front. AIR CONDITIONER>Air Vent Duct>INSTALLATION > REAR DUCT

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3. CONSOLE DUCT
•
FRONT
1.

Install the duct console front. EXTERIOR/INTERIOR TRIM>Center Console>INSTALLATION

2.

Install the duct console center. AIR CONDITIONER>Air Vent Duct>INSTALLATION > CONSOLE DUCT

3.

Install the cover center side. EXTERIOR/INTERIOR TRIM>Center Console>INSTALLATION

4.

Install the console box assembly and the cover assembly front. EXTERIOR/INTERIOR TRIM>Console Box>INSTALLATION

5.

Install the heater control assembly. AIR CONDITIONER>Control Panel>INSTALLATION

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

•
CENTER
1.

Install the duct console center.

2.

Install the cover center side. EXTERIOR/INTERIOR TRIM>Center Console>INSTALLATION

3.

Install the console box assembly and the cover assembly front. EXTERIOR/INTERIOR TRIM>Console Box>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

•
REAR
1.

Install the duct console rear. EXTERIOR/INTERIOR TRIM>Console Box>ASSEMBLY

2.

Install the cover assembly front and the console box assembly. EXTERIOR/INTERIOR TRIM>Console Box>INSTALLATION

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4. FOOT DUCT
RH SIDE
1.

Install the duct foot passenger.

2.

Install the pocket COMPL and the panel instrument passenger. EXTERIOR/INTERIOR TRIM>Glove Box>INSTALLATION

3.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

LH SIDE
 

Before handling the airbag system components, refer to “CAUTION” of “General Description” in “AIRBAG SYSTEM”. AIRBAG SYSTEM>General Description>CAUTION

1.

Install the duct foot driver.

 

If the duct foot driver is detached from the spacer foot, replace the duct foot driver with a new part. If the duct foot driver is reused, the holding force of the claws and clips is reduced and the part may come off.

2.

Install the knee airbag module. AIRBAG SYSTEM>Knee Airbag Module>INSTALLATION

3.

Install the cover LWR driver. EXTERIOR/INTERIOR TRIM>Instrument Panel Lower Cover>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

AIR CONDITIONER > Air Vent Duct　
INSPECTION
1.

Check installation condition of duct. Connect the duct properly if defective.

2.

Check that no foreign matter is mixed in the duct. Remove the foreign matter if any.

AIR CONDITIONER > A/C Filter　
REPLACEMENT
1.

Remove the pocket COMPL.

(1)

Remove the damper assembly.

(2)

Release the stoppers and remove the pocket COMPL by pulling it toward you.

2.

Remove the filter.

(1)

Release the lock and remove the filter as shown in the figure.

 

Slowly pull out while tilting the front side of the filter downward to prevent dirt or dust from falling inside the case.

3.

Install a new filter.

4.

Install the pocket COMPL.

AIR CONDITIONER > A/C Filter　
INSPECTION

Check the A/C filter for dust or dirt, and clean or replace as necessary.

AIR CONDITIONER > Diagnostics with Phenomenon　
INSPECTION

For the diagnostics with phenomenon, refer to “Diagnostics with Phenomenon” of “AIR CONDITIONER (DIAGNOSTICS)”. AIR CONDITIONER(DIAGNOSTICS)>Diagnostics with Phenomenon