2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

BODY SECTION

HVAC SYSTEM AC
(HEATER, VENTILATOR AND A/C)

HVAC SYSTEM (AUTO A/C) AC

(DIAGNOSTICS)

AIRBAG SYSTEM AB

AIRBAG SYSTEM (DIAGNOSTICS) AB

This service manual has been prepared
to provide SUBARU service personnel
SEAT BELT SYSTEM SB
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles. LIGHTING SYSTEM LI
This manual includes the procedures
for maintenance, disassembling, reas-
sembling, inspection and adjustment of WIPER AND WASHER SYSTEMS WW
components and diagnostics for guid-
ance of experienced mechanics.
Please peruse and utilize this manual ENTERTAINMENT ET
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition. COMMUNICATION SYSTEM COM
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts. GLASS/WINDOWS/MIRRORS GW

BODY STRUCTURE BS

INSTRUMENTATION/DRIVER INFO IDI

SEATS SE

SECURITY AND LOCKS SL

IMMOBILIZER (DIAGNOSTICS) IM

SUNROOF/T-TOP/CONVERTIBLE TOP SR
(SUNROOF)
All information, illustration and specifi-
cations contained in this manual are EXTERIOR/INTERIOR TRIM EI
based on the latest product information
available at the time of publication
approval.

FUJI HEAVY INDUSTRIES LTD. G1830GE6

2001 IMPREZA SERVICE MANUAL QUICK REFERENCE INDEX

BODY SECTION

EXTERIOR BODY PANELS EB

CRUISE CONTROL SYSTEM CC

CRUISE CONTROL SYSTEM CC

(DIAGNOSTICS)

G1830GE6
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)

AC
Page
1. General Description ....................................................................................2
2. Refrigerant Pressure with Manifold Gauge Set.........................................15
3. Refrigerant Recovery Procedure...............................................................16
4. Refrigerant Charging Procedure ...............................................................17
5. Refrigerant Leak Check ............................................................................20
6. Compressor Oil .........................................................................................22
7. Blower Motor Unit Assembly .....................................................................23
8. Power Transistor (Heater Blower Resistor)...............................................24
9. Heater Core...............................................................................................25
10. Control Unit ...............................................................................................26
11. Compressor...............................................................................................27
12. Condenser.................................................................................................28
13. Heater and Cooling Unit............................................................................29
14. Evaporator.................................................................................................30
15. Hose and Tube..........................................................................................31
16. Relay and Fuse .........................................................................................32
17. Pressure Switch (Dual Switch)..................................................................33
18. Ambient Sensor (Auto A/C).......................................................................34
19. Sun-load Sensor (Auto A/C)......................................................................35
20. Air Vent Grille ............................................................................................36
21. Heater Duct ...............................................................................................37
22. Heater Vent Duct.......................................................................................38
23. General Diagnostics..................................................................................39
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

1. General Description
A: SPECIFICATIONS
1. HEATER SYSTEM

Item Specifications Condition

• Mode selector switch: HEAT
• Temperature control switch: FULL HOT
5.0 kW (4,300 kcal/h, 17,062 BTU/ • Temperature difference between hot water
Heating capacity
h) or more and inlet air: 65°C (149°F)
• Hot water flow rate: 360 2 (95.1 US gal,
79.2 Imp gal)/h
Air flow rate 280 m3 (9,888 cu ft)/h Heat mode (FRESH), FULL HOT at 12.5 V
• Temperature control switch: FULL COLD
Max air flow rate 450 m3 (15,892 cu ft)/h • Blower fan speed: 4th position
• Mode selector lever: RECIRC
163.9 × 200 × 25.0 mm
LHD model
Heater core size (6.45 × 7.87 × 0.984 in)
—
(height × length × width) 181.5 × 160 × 27 mm
RHD model
(7.15 × 6.30 × 1.06 in)
Type Magnet motor 200 W or less at 12 V
Blower
motor Fan type and size Sirocco fan type
—
(diameter × width) 150 × 75 mm (5.91 × 2.95 in)

AC-2
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

2. A/C SYSTEM
• LHD Model:

Item Specifications
Type of air conditioner Reheat air-mix type
5.1 kW
Cooling capacity
(4,385 kcal/h, 17,402 BTU/h)
HFC-134a (CH2FCF3)
Refrigerant
[0.5±0.05 kg (0.99±0.11 lb)]
Type Vane rotary, fix volume (CR-14)
Compressor Discharge 144 cm3 (8.79 cu in)/rev
Max. permissible speed 7,000 rpm
Type Dry, single-disc type
Power consumption 47 W
Magnet clutch Type of belt V-Ribbed 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Type Corrugated fin (Sub cool type)
Core face area 0.21 m2 (2.26 sq ft)
Condenser
Core thickness 16 mm (0.63 in)
Radiation area 6.52 m2 (70 sq ft)
Receiver drier Effective inner capacity 250 cm3 (15.26 cu in)
Expansion valve Type Internal equalizing
Type Single tank
Evaporator 255 × 200 × 48 mm
Dimensions (W × H × T)
(10 × 7.87 × 1.89 in)
Fan type Sirocco fan
Blower fan Outer diameter × width 150 × 75 mm (5.91 × 2.95 in)
Power consumption 200 W at 12 V
Motor type Magnet
Condenser fan (Sub fan) Power consumption 70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
Motor type Magnet
Radiator fan (Main fan) Power consumption 70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
Idling speed (A/C ON) MPFI model 850±100 rpm
278±29 kPa
ON → OFF
Low-pressure switch (2.83±0.3 kg/cm2, 40.3±4.2 psi)
operating pressure 287+39/−25 kPa
OFF → ON
Dual switch (2.9+0.4/−0.25 kg/cm2, 42+5.7/−3.6 psi)
(Pressure switch) 2,800±100 kPa
ON → OFF
High-pressure switch (29±1 kg/cm2, 406±15 psi)
operating pressure 600±200 kPa
DIFF
(6.12±2 kg/cm2, 87±29 psi)

Thermo control amplifier working temperature

ON
(Evaporator outlet air)
OFF
HV0045

AC-3
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

• RHD Model:

Item Specifications
Type of air conditioner Reheat air-mix type
Cooling capacity 5.1 kW (4,385 kcal/h, 17,402 BTU/h)
HFC-134a (CH2FCF3)
Refrigerant
[0.5±0.05 kg (1.10±0.11 lb)]
Type Vane rotary, fix volume (CR-14)
Compressor Discharge 144 cm3 (8.79 cu in)/rev
Max. permissible speed 7,000 rpm
Type Dry, single-disc type
Power consumption 47 W
Magnet clutch Type of belt V-Ribbed 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
Type Corrugated fin (Sub cool type)
Core face area 0.21 m2 (2.26 sq ft)
Condenser
Core thickness 16 mm (0.63 in)
Radiation area 5.34 m2 (57.48 sq ft)
Receiver drier Effective inner capacity 250 cm3 (15.26 cu in)
Expansion valve Type Externally equalizing
Type Single tank
Evaporator 255 × 200 × 48 mm
Dimensions (W × H × T)
(10 × 7.87 × 1.89 in)
Fan type Sirocco fan
Blower fan Outer diameter × width 150 × 75 mm (5.91 × 2.95 in)
Power consumption 200 W at 12 V
Motor type Magnet
Condenser fan (Sub fan) Power consumption 70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
Motor type Magnet
Radiator fan (Main fan) Power consumption 70 W at 12 V
Fan outer diameter 320 mm (12.6 in)
Idling speed (A/C ON) MPFI model 850±100 rpm
278±29 kPa
ON → OFF
Low-pressure switch (2.83±0.3 kg/cm2, 40.3±4.2 psi)
operating pressure 287+39/−25 kPa
OFF → ON
Dual switch (2.9+0.4/−0.25 kg/cm2, 42+5.7/−3.6 psi)
(Pressure switch) 2,800±100 kPa
ON → OFF
High-pressure switch (29±1 kg/cm2, 406±15 psi)
operating pressure 600±200 kPa
DIFF
(6.12±2 kg/cm2, 87±29 psi)

Thermo control amplifier working temperature

(Evaporator outlet air)

G4M0938

AC-4
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

B: COMPONENT
1. HEATER COOLING UNIT

(25)

(21)
(22)

(24)
(27) T

(26) (17)
(18)
(23) (16)
(8)
(7)

(6)
(5) (20)
(4)
(14) (15)
(3)

(2) (19)

(17)

(20)
T

(20)

(1) (13)
(10)
(11) (12)

(9)

HV0047

(1) Unit cover (11) Heater core clamp (21) Packing

(2) Mode acutuator (12) Heater core (22) Cooling unit block
(3) Side link (13) Drain hose (23) O-ring
(4) Mode acutuator lever (14) Mix acutuator (24) Expansion valve
(5) Foot lever (15) Mix acutuator lever (25) Evaporator
(6) Spring (16) Unit assembly (26) Evaporator cover
(7) Mode acutuator link (17) Aspirator hose (27) Thermistor
(8) Defroster lever (18) Aspirator
(9) Foot nozzle (19) Foot duct Tightening torque: N·m (kgf-m, ft-lb)
(10) Unit duct cover (20) Clip T: 7.35 (0.750, 5.421)

AC-5
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

2. BLOWER MOTER UNIT

(4)
(10)
(3)

(6)
(2)

(5)

(7)
(8)
T
(11)
(1) (12)

(13)

(9)

HV0048

(1) Upper case (7) Clip (13) Power transister cover

(2) Servo motor (8) Filter cover
(3) Blower link (9) Filter Tightening torque: N·m (kgf-m, ft-lb)
(4) Blower link lever A (10) Blower motor assembly T: 7.35 (0.750, 5.421)
(5) Blower link lever B (11) Hose
(6) Blower link lever C (12) Power transistor

AC-6
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

3. CONTROL UNIT

(9)

(7)

(6)

(10)

(8)

(2)
(4)

(5)
(1) (3)

(2)
HV0049

(1) Switch (6) Switch assembly

(2) Control lever (7) Control base
(3) Control panel (8) Electronic control unit
(4) Incar sensor (9) Bulb
(5) Hose (10) Control case

AC-7
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

4. AIR CONDITIONING UNIT

(5)

T2

(6)

(6) (2)

(6) (6) (6)

(3)
T2

T2
T2
T2
(1)

(4)
(6)

T1

HV0050

(1) Condenser (4) Tube Tightening torque: N·m (kgf-m, ft-lb)

(2) Hose (High — pressure) (5) Compressor T1: 7.4 (0.75, 5.4)
(3) Hose (Low — pressure) (6) O-ring T2: 15 (1.5, 10.8)

AC-8
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

5. COMPRESSOR

T5

(4)

(5)
T5
T3
T5

(9)
(3)
(2)

T2 (1)

T1

(6)

(7)
T1
(8) T4

HV0051

(1) Idler pulley bracket (7) V-belt Tightening torque: N·m (kgf-m, ft-lb)
(2) Idler pulley adjuster (8) Compressor belt cover T1: 7.4 (0.75, 5.4)
(3) Idler pulley T2: 22.6 (2.3, 16.6)
(4) Compressor bracket upper T3: 23.0 (2.35, 17.0)
(5) Compressor T4: 28.9 (2.95, 21.3)
(6) Compressor bracket lower T5: 35 (3.6, 26)

AC-9
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

C: CAUTION 4. HANDLING OF REFRIGERANT

1. HFC-134A A/C SYSTEM • The refrigerant boils at approx. −30°C (−22°F).
When handling it, be sure to wear safety goggles
• Unlike the old conventional HFC-12 system com- and protective gloves. Direct contact of the refriger-
ponents, the cooling system components for the ant with skin may cause frostbite.
HFC-134a system such as the refrigerant and com- If the refrigerant gets into your eye, avoid rubbing
pressor oil are incompatible. your eyes with your hands. Wash your eye with
• Vehicles with the HFC-134a system can be iden- plenty of water, and receive medical treatment from
tified by the label “A” attached to the vehicle. an eye doctor.
Before maintenance, check which A/C system is in- • Do not heat a service can. If a service can is di-
stalled in the vehicle. rectly heated, or put into boiling water, the inside
pressure will become extremely high. This may
cause the can to explode. If a service can must be
warmed up, use hot water in 40°C (104°F) max.
• Do not drop or impact a service can. (Observe
the precautions and operation procedure described
on the refrigerant can.)
• When the engine is running, do not open the
high-pressure valve of the manifold gauge. The
high-pressure gas will back-flow resulting in an ex-
B4M1817A
plosion of the can.
• The refrigerant is non-toxic and harmless under
2. COMPRESSOR OIL normal operating circumstance, but it may change
• HFC-134a compressor oil has no compatibility to phosgene (a noxious fume) under open flames
with that for R12 system. or high temperatures (caused by a cigarette or
• Use only the manufacturer-authorized compres- heater).
sor oil for the HFC-134a system; only use DH-PR. • Provide good ventilation and do not work in a
• Do not mix multiple compressor oils. closed area.
If HFC-12 compressor oil is used in a HFC-134a A/ • Never perform a gas leak test using a halide
C system, the compressor may become stuck due torch-type leak tester.
to poor lubrication, or the refrigerant may leak due • In order to avoid destroying the ozone layer, pre-
to swelling of rubber parts. vent HFC-134a from being released into the atmo-
On the other hand, if HFC-134a compressor oil is sphere. Using a refrigerant recovery system,
used in a HFC-12 A/C system, the durability of the discharge and reuse it.
A/C system will be lowered.
• HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from the atmosphere us-
ing a plug or tape. In order to avoid moisture, store
the oil in a container with its cap tightly closed.
3. REFRIGERANT
• The HFC-12 refrigerant cannot be used in the
HFC-134a A/C system. The HFC-134a refrigerant,
also, cannot be used in the HFC-12 A/C system.
• If an incorrect or no refrigerant is used, poor lu-
brication will result and the compressor itself may
be damaged.

G4M0979

AC-10
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

5. O-RING CONNECTIONS Apply the oil to the area including the O-rings and
tube beads.
• Use new O-rings.
• In order to keep the O-rings free of lint which will
cause a refrigerant gas leak, perform operations
without gloves and shop towels.
• Apply the compressor oil to the O-rings to avoid
sticking, then install them.
• Use a torque wrench to tighten the O-ring fittings:
Over-tightening will damage the O-ring and tube
end distortion.
• If the operation is interrupted before completing a
pipe connection, recap the tubes, components, and
fittings with a plug or tape to prevent contamination
from entering.

G4M0583
G4M0581 • When connecting hoses or pipes, use 2 wrench-
• Visually check the surfaces and mating surfaces es (a torque wrench for tightening). While securing
of O-rings, threads, and connecting points. If a fail- one side with a wrench, tighten the other side to the
ure is found, replace the applicable parts. specified torque with a torque wrench.
• Install the O-rings at right angle to the tube If only one wrench is used to tighten, the tightening
beards. torque will be excessive or insufficient. This may
O-ring
cause a pipe distortion or gas leak, resulting in
damage to hoses and pipes.
• After tightening, using a clean shop towel to re-
O.K. Bead
move excess oil from the connections and any oil
which may have run on the vehicle body or other
Not O.K.
parts.
• If any leakage is suspected after tightening, do
not retighten the connections, Disconnect the con-
Not O.K.
nections, remove the O-rings, and check the O-
rings, threads, and connections.
HV0046
• Use the oil specified in the service manual to lu-
bricate the O-rings.
Apply the oil to the top and sides of the O-rings be-
fore installation.

AC-11
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

D: PREPARATION TOOL In order to help prevent mixing HFC-134a and

CFC-12 parts and liquid, the tool and screw
CAUTION: type and the type of service valves used are dif-
When working on vehicles with the HFC-134a ferent. The gas leak detectors for the HFC-134a
system, only use HFC-134a specified tools and and CFC-12 systems must also not be inter-
parts. Do not mix with CFC-12 tools and parts. If changed.
HFC-134a and CFC-12 refrigerant or compres-
sor oil is mixed, poor lubrication will result and HFC-134a CFC-12
the compressor itself may be destroyed. Tool & screw type Millimeter size Inch size
Valve type Quick joint type Screw-in type

Tools and Equipment Description

Wrench
Various WRENCHES will be required to service any A/C system. A 7 to
40 N·m (0.7 to 4.1 kg-m, 5 to 30 ft-lb) torque wrench with various crow-
foot wrenches will be needed. Open end or flare nut wrenches will be
needed for back-up on the tube and hose fittings.

G4M0571
Applicator bottle
A small APPLICATOR BOTTLE is recommended to apply refrigerant
oil to the various parts. They can be obtained at a hardware or drug
store.

G4M0572
Manifold gauge set
A MANIFOLD GAUGE SET (with hoses) can be obtained from either a
commercial refrigeration supply house or from an auto shop equipment
supplier.

G4M0573

AC-12
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Tools and Equipment Description

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

G4M0574
Syringe
A graduated plastic SYRINGE will be needed to add oil back into the
system. The syringe can be found at a pharmacy or drug store.

G4M0575
Vacuum pump
A VACUUM PUMP (in good working condition) is necessary, and may
be obtained from either a commercial refrigeration supply house or an
automotive equipment supplier.

G4M0576
Can tap
A CAN TAP for the 397 g (14 oz) can is available from an auto supply
store.

G4M0577

AC-13
 GENERAL DESCRIPTION
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Tools and Equipment Description

Thermometer
Pocket THERMOMETERS are available from either industrial hard-
ware store or commercial refrigeration supply houses.

G4M0578
Electronic leak detector
An ELECTRONIC LEAK DETECTOR can be obtained from either a
specialty tool supply or an A/C equipment supplier.

G4M0579
Weight scale
A WEIGHT SCALE such as an electronic charging scale or a bath-
room scale with digital display will be needed if a 13.6 kg (30 lb) refrig-
erant container is used.

G4M0580

AC-14
 REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

2. Refrigerant Pressure with Manifold Gauge Set

A: OPERATION
1) Place the vehicle in the shade and draftless condition.
2) Connect the manifold gauge set.
3) Open the front windows and close all doors.
4) Open the hood.
5) Increase engine rpm to 1,500.
6) Turn ON the A/C switch.
7) Turn the temperature control switch to MAX COOL.
8) Put in RECIRC position.
9) Turn the blower control switch to HI.
10) Read the gauge.
Standard:
Low pressure: 127 - 196 kPa (1.3 - 2.0 kg/cm2, 18 - 28 psi)
High pressure: 1,471 - 1,667 kPa (15 - 17 kg/cm2, 213 - 242 psi)
Ambient temperature: 30 - 35 °C (86 - 95 °F)

B: INSPECTION
Symptom Probable cause Repair order
• Defective condenser fan motor • Replace the fan motor.
• Clogged condenser fan • Clean the condenser fin.
High-pressure side is unusually high. • Too much refrigerant • Discharge refrigerant.
• Air inside the system • Replace the receiver dryer.
• Defective receiver dryer
• Defective compressor • Replace the compressor.
• Not enough refrigerant • Check for leaks.
High-pressure side is unusually low. • Clogged expansion valve • Replace the expansion valve.
• Expansion valve frozen temporarily by
moisture
• Defective compressor • Replace the compressor.
Low-pressure side is unusually high. • Defective expansion valve • Replace the expansion valve.
• Too much refrigerant • Discharge refigerant.
• Not enough refrigerant • Check for leaks.
• Clogged expansion valve • Replace the expansion valve
Low-pressure side is unusually low. • Expansion valve frozen temporarily by • Replace the receiver dryer.
moisture
• Saturated receiver dryer

AC-15
 REFRIGERANT RECOVERY PROCEDURE
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

3. Refrigerant Recovery Proce-

dure
A: OPERATION
CAUTION:
• During operation, be sure to wear safety gog-
gles and protective gloves.
• Connect the refrigerant recovery system with
the manifold gauge set to discharge the refrig-
erant from the A/C system and reuse it.
• When reusing the discharged refrigerant,
keep service cans on hand. Because the dis-
charge rate with the recovery system is approx.
90%, service cans are necessary to charge the
refrigerant.
• Follow the detailed operation procedure de-
scribed in the operation manual attached to the
refrigerant recovery system.
1) Turn the A/C switch ON.
Leave the engine running for approx. 5 minutes to
activate the compressor. Perform the refrigerating
cycle with the refrigerant to discharge the compres-
sor oil remaining on the functional parts into the
compressor as much as possible.
2) Stop the engine.
3) Close the valves on the low-/high-pressure sides
of the manifold gauge set.

G4M0585
4) Install the low-/high-pressure hoses to the ser-
vice ports on the low-/high-pressure sides of the
vehicle respectively.

G4M0586
5) Connect the center hose to the refrigerant recov-
ery system.
6) Follow the operation manual to activate the re-
frigerant recovery system.

AC-16
 REFRIGERANT CHARGING PROCEDURE
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

4. Refrigerant Charging Proce- 4) Carefully open the valves on the low-/high-pres-

sure sides to activate the vacuum pump.
dure
A: OPERATION
CAUTION:
• During operation, be sure to wear safety gog-
gles and protective gloves.
• Before charging the refrigerant, evacuate the
system to remove small amounts of moisture
remaining in the system.
The moisture in the system can be completely
G4M0597
evacuated only under the minimum vacuum
level. The minimum vacuum level affects the 5) After the low-pressure gauge reaches 100.0 kPa
temperature in the system. (750 mmHg, 29.5 inHg) or higher, evacuate the
• The list below shows the vacuum values nec- system for approx. 15 minutes.
essary to boil water in various temperature. In
addition, the vacuum levels indicated on the
gauge are approx. 3.3 kPa (25 mmHg, 0.98 inHg)
lower than those measured at 304.8 m (1,000 ft)
above sea level.
Vacuum level required to boil water (at sea level)
Temperature Vacuum
1.7°C (35°F) 100.9 kPa (757 mmHg, 29.8 inHg)
7.2°C (45°F) 100.5 kPa (754 mmHg, 29.7 inHg) G4M0598
12.8°C (55°F) 99.8 kPa (749 mmHg, 29.5 inHg) 6) After 15 minutes of evacuation, if the reading
18.3°C (65°F) 99.2 kPa (744 mmHg, 29.3 inHg) shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher,
23.9°C (75°F) 98.5 kPa (739 mmHg, 29.1 inHg) close the valves on the both sides to stop the vac-
29.4°C (85°F) 97.2 kPa (729 mmHg, 28.7 inHg) uum pump.
35°C (95°F) 95.8 kPa (719 mmHg, 28.3 inHg)

1) Close the valves on low-/high-pressure sides of

the manifold gauge.

G4M0599
7) Note the low-pressure gauge reading.

G4M0596
2) Install the low-/high-pressure hoses to the corre-
sponding service ports on the vehicle respectively.
3) Connect the center hose of the manifold gauge
set with the vacuum pump.

G4M0600

AC-17
 REFRIGERANT CHARGING PROCEDURE
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

8) Leave it at least 5 minutes, and then check the CAUTION:

low-pressure gauge reading for any changes. Do not open the low-pressure valve.
When a gauge indicator shows near to zero point,
this is a sign of leakage. Check pipe connector
points, repair them, make sure there is no leakage
by air bleeding.
9) Following the can tap operation manual instruc-
tions, install it to the refrigerant can.

G4M0604

CAUTION:
Never run the engine during charging from the
high-pressure side.
16) Close the high-pressure valve when the low-
G4M0980
pressure gauge reaches 98 kPa (1 kg/cm2, 14 psi).
10) Disconnect the center manifold hose from the Using a leak tester, check the system for leaks.
vacuum pump, and connect the hose to the tap If any leakage is found after the refrigerant recov-
valve. ery is completed, repair the applicable area.
11) When a 13.6 kg (30 lb) refrigerant container is 17) After confirming that there are no leaks with the
used, measure the refrigerant amount in use using leak test, charge the required amount of refrigerant.
a weighting scale. CAUTION:
Never run the engine during charging from the
high-pressure side.
18) Close the high-pressure valve when;
• the readings of low- and high-pressure gauges
become almost equal, after the charging speed is
reduced,
• the HFC-134a source becomes empty, or
• the system is filled with the gas.

G4M0981
12) Confirm that all the 3 hoses are tightly connect-
ed to the manifold gauge set.

G4M0605

G4M0603
13) Open the valve on the HFC-134a source.
14) Loosen the center hose connection on the
manifold gauge set (if applicable, press a purge
valve on the manifold gauge set) only for a couple
of seconds to allow the air in the center hose to es-
cape by the refrigerant.
15) Carefully open the high-pressure valve with the
engine stopping.

AC-18
 REFRIGERANT CHARGING PROCEDURE
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

19) If the HFC-134a source is empty, close the 27) Disconnect the hose from the service port, and
high-pressure valve, close the valve on the can tap, install the service port cap.
and replace the HFC-134a source with a new one
to restart the operation.

G4M0606
20) Confirm that both the low- and high-pressure
valves can be closed. Start the engine with the A/C
switch OFF.
21) Quickly repeat ON-OFF cycles a few times to
prevent initial compressor damage.
22) Set up the vehicle to the following status:
• A/C switch ON
• Engine running at 1,500 rpm
• Blower speed setting to “HI”
• Temperature setting to “MAX COOL”
• Air inlet setting to “RECIRC”
• Windows open
23) While reading the low-pressure gauge, careful-
ly open the low-pressure valve with the refrigerant
source connected and the service hose purged.
CAUTION:
Never open the high-pressure valve with the en-
gine running.

G4M0608
24) Adjust the refrigerant flow to maintain the pres-
sure on the low-pressure side at 276 kPa (2.81 kg/
cm2, 40 psi) max.
25) After the system is fully charged, close the low-
pressure valve.
26) Close the valve on the refrigerant source.
Refrigerant amount
Refrigerant Minimum Maximum
LHD 0.6 kg (1.3 lb) 0.7 kg (1.5 lb)
HFC-134a
RHD 0.4 kg (0.9 lb) 0.5 kg (1.1 lb)

AC-19
 REFRIGERANT LEAK CHECK
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

5. Refrigerant Leak Check 7) Check the thermal limiter (if equipped) on the
compressor housing.
A: INSPECTION 8) Check the compressor shaft seal at the area
1) Operate the A/C system for approx. 10 minutes, near the center of compressor clutch pulley.
and confirm that the high-side pressure shows at Some shaft seals show a slight amount of leakage
least 690 kPa (7.03 kg/cm2, 100 psi). Then stop the about 28 g (1.0 oz) per year. This is not a problem.
engine to start the leak test. 9) Starting from the connection between the low-
2) Starting from the connection between the high- pressure tube and evaporator, check the system
pressure tube and evaporator, check the system for leakage along the high-pressure side through
for leaks along the high-pressure side through the the compressor. The following items must be
compressor. The following items must be checked checked thoroughly.
thoroughly. • Connection between the tube and tube fitting
• Connection between the tube and tube fitting • Connection between 2 parts
• Connection between the tube and nut

G4M0612
• Connection between 2 parts S4M0038
10) Visually check the rubber area of the flexible
hose for cracks.
Check the entire length of the flexible hose, espe-
cially the connection with the metal hose end.
CAUTION:
Carefully check the external surface of hoses
and tubes at approx. 25 mm (0.98 in) per sec-
ond.

G4M0613
• Connection between the tube and nut

G4M0617
11) Disconnect the drain hose from the evaporator
case, and check the hose end for at least 10 sec-
G4M0614 onds.
3) Check the joint and seam between the pressure After the test is finished, reconnect the drain hose.
switch (dual switch) and receiver dryer.
4) Check the connections between the condenser
and tubes, and welded joints on the condenser.
The leak tester may detect the oil on the condenser
fins as a leak.
5) Check the joint between the compressor and
hoses.
6) Check the machined area of compressor and
other joints on the compressor.

AC-20
 REFRIGERANT LEAK CHECK
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

12) Turn the ignition key to ON position, and run the

blower at high speed for 1 minute. Stop the blower
to check the ventilation grill on the instrument pan-
el. While moving the tester closer to the grill, run the
blower for 1 or 2 seconds, then stop it. Check the
grill at that point for at least 10 seconds.

G4M0618
13) Check the valve in the service port.
14) Visually check the rubber seal in the service
port cap.

G4M0619

AC-21
 COMPRESSOR OIL
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

6. Compressor Oil B: REPLACEMENT

NOTE:
A: OPERATION • If a component is replaced, add an appropriate
NOTE: amount of compressor oil.
Before making repairs, conduct the oil return oper- • When replacing the compressor, the new com-
ation to return the compressor oil in circulation with pressor will already have the specified amount of
the refrigerant to the compressor. oil in it. Install the new compressor after removing
1) Increase engine rpm to 1,500. the same amount of oil that is remaining in the com-
2) Turn ON the A/C switch. pressor removed.
3) Turn the temperature control switch to MAX
Replacement parts Amount of oil replenishment
COOL.
Evaporator 114 m2 (3.9 US fl oz, 4.0 Imp fl oz)
4) Put in RECIRC position.
5) Turn the blower control switch to HI. Condenser 7 m2 (0.24 US fl oz, 0.25 Imp fl oz)
6) Leave in this condition for 10 minutes. Hose 1 m2 (0.03 US fl oz, 0.04 Imp fl oz)

AC-22
 BLOWER MOTOR UNIT ASSEMBLY
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

7. Blower Motor Unit Assembly B: INSTALLATION

Install in the reverse order of removal.
A: REMOVAL
1) Disconnect ground cable from battery. C: INSPECTION
2) Remove glove box. <Ref. to EI-22, REMOVAL, Connect motor connector terminal 1 from the bat-
Glove Box.> tery to the positive (+) lead and terminal 2 to the
3) Loosen nut to remove support beam stay. negative (−) lead. Make sure the motor runs
smoothly.

HV0006
4) Disconnect motor connector. B4M2404

HV0014
5) Disconnect resistor connector.

HV0009
6) Loosen bolt and nut to remove blower motor unit
assembly.

HV0013

AC-23
 POWER TRANSISTOR (HEATER BLOWER RESISTOR)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

8. Power Transistor (Heater

Blower Resistor)
A: REMOVAL
1) Remove glove box. <Ref. to EI-22, REMOVAL,
Glove Box.>
2) Disconnect power transistor connector.
3) Loosen 2 screws to remove power transistor.

HV0009

B: INSTALLATION
Install in the reverse order of removal.

AC-24
 HEATER CORE
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

9. Heater Core
A: REMOVAL
1) Remove heater and cooling unit. <Ref. to AC-29,
REMOVAL, Heater and Cooling Unit.>
2) Loosen screws to remove heater core cover.

HV0001
3) Remove heater core.

HV0002

B: INSTALLATION
Install in the reverse order of removal.

AC-25
 CONTROL UNIT
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] Unit
A: REMOVAL
1) Disconnect Battery ground cable.
2) Remove center console panel.
3) Disconnect connector and aspirator hose (A).

(A)

HV0010

B: INSTALLATION
Install in the reverse order of removal.

AC-26
 COMPRESSOR
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] 9) Loosen bolts to remove compressor bracket.

A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
1) Check the clearance of the entire circumference
around the drive plate and pulley.
Standard:
0.45±0.15 mm (0.0177±0.0059 in)
2. MAGNETIC CLUTCH OPERATION B4M2311
1) Disconnect the compressor connector. 10) Remove bolts and then separate compressor
2) Connect the battery positive terminal to the NO.3 and bracket.
terminal of the compressor connector.

HV0011

B4M2407
3) Make sure the magnet clutch engages.
C: INSTALLATION
If NG, replace the compressor. 1) Install in the reverse order of removal.
2) Replace O-rings on low-/high-pressure hoses
B: REMOVAL with new ones, then apply compressor oil.
1) Perform compressor oil return operation. <Ref. 3) When replacing compressor, adjust amount of
to AC-22, OPERATION, Compressor Oil.> compressor oil. <Ref. to AC-22, OPERATION,
2) Turn A/C switch OFF and stop the engine. Compressor Oil.>
3) Using refrigerant recovery system, discharge re- 4) Charge refrigerant. <Ref. to AC-17, OPERA-
frigerant. <Ref. to AC-16, OPERATION, Refriger- TION, Refrigerant Charging Procedure.>
ant Recovery Procedure.>
4) Disconnect ground cable from battery.
5) Remove V-belt. <Ref. to ME(SOHC)-42, RE-
MOVAL, V-belt.> or <Ref. to ME(DOHC TURBO)-
43, REMOVAL, V-belt.>
6) Remove generator. <Ref. to SC-12, REMOVAL,
Generator.>
7) Remove low-pressure hose and high-pressure
hose.

HV0012
8) Disconnect compressor harness from body har-
ness.

AC-27
 CONDENSER
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] B: INSTALLATION
1) Install in the reverse order of removal.
A: REMOVAL
CAUTION:
1) Using refrigerant recovery system, discharge re-
Replace O-rings on hoses or pipes with new
frigerant. <Ref. to AC-16, OPERATION, Refriger-
ones, and then apply compressor oil. Confirm
ant Recovery Procedure.>
that lower guide of condenser has been fitted
2) Disconnect ground cable from battery. into holes on radiator panel.
3) Disconnect pressure hose and pipe from con-
denser.

B4M1822A

HV0003 2) Charge refrigerant. <Ref. to AC-17, OPERA-

4) Remove radiator bracket (A). TION, Refrigerant Charging Procedure.>
C: INSPECTION
1) Confirm that no dust or insects are found on the
condenser fins. Air-blow or flush fins with water as
needed.
2) Confirm that no oil leaks from condenser. If a fail-
ure is found, replace condenser with a new one.

B4M1820A
5) Remove two bolts. While lifting condenser, pull it
out through space between the radiator and the ra-
diator panel.

HV0004

CAUTION:
Be careful not to damage condenser fins. If a
damaged fin is found, repair it using a thin
screwdriver.
If condenser is replaced, add appropriate
amount of compressor oil to the compressor.
<Ref. to AC-22, REPLACEMENT, Compressor
Oil.>

AC-28
 HEATER AND COOLING UNIT
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] and Cooling Unit

A: REMOVAL
1) Disconnect ground cable from battery.
2) Using refrigerant recovery system, discharge re-
frigerant. <Ref. to AC-16, OPERATION, Refriger-
ant Recovery Procedure.>
3) Drain LLC from radiator.
4) Removes bolt securing expansion valve and
pipe in engine compartment. Release heater hose
clamps in engine compartment to remove the hos-
es.

HV0015
5) Remove instrument panel. <Ref. to EI-25, RE-
MOVAL, Instrument Panel Assembly.>
6) Remove support beam.
7) Remove blower motor unit assembly. <Ref. to
AC-23, REMOVAL, Blower Motor Unit Assembly.>
8) Disconnect servo motor connectors.
9) Loosen bolt and nuts to remove heater and cool-
ing unit.

HV0016

B: INSTALLATION
1) Install in the reverse order of removal.
2) Charge refrigerant. <Ref. to AC-17, OPERA-
TION, Refrigerant Charging Procedure.>

AC-29
 EVAPORATOR
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link]
A: REMOVAL
1) Remove heater and cooling unit. <Ref. to AC-29,
REMOVAL, Heater and Cooling Unit.>
2) Loosen screws and clip to remove evaporator
cover.

HV0024
3) Remove evaporator.

HV0025
4) Loosen two bolts to remove expansion valve.

HV0026

CAUTION:
If evaporator is replaced, add appropriate
amount of compressor oil to evaporator. <Ref.
to AC-22, REPLACEMENT, Compressor Oil.>
B: INSTALLATION
Install in the reverse order of removal.

AC-30
 HOSE AND TUBE
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] and Tube B: INSTALLATION

A: REMOVAL CAUTION:
When disconnecting/connecting hoses, do not
CAUTION: apply an excessive force them. Confirm that no
• When disconnecting/connecting hoses, do torsion and excessive tension exist after in-
not apply excessive force them. Confirm that stalling. Seal the disconnected hose with a plug
no torsion and excessive tension exist after in- or vinyl tape to prevent contamination from en-
stalling. tering.
• Seal the disconnected hose with a plug or vi- 1) Install in the reverse order of removal.
nyl tape to prevent contamination from enter- 2) Charge refrigerant. <Ref. to AC-17, OPERA-
ing. TION, Refrigerant Charging Procedure.>
1) Disconnect ground cable from battery.
2) Using refrigerant recovery system, discharge re- C: INSPECTION
frigerant. <Ref. to AC-16, OPERATION, Refriger- NOTE:
ant Recovery Procedure.> If cracking, damage, or swelling is found on a hose,
3) Remove evaporator unit mounting bolt (A). replace it with a new one.
4) Remove low-pressure hose attaching bolts (B).
5) Disconnect low-pressure hose from evaporator
unit.
6) Disconnect low-pressure hose from compressor.
7) Remove low-pressure hose from the vehicle.
8) Remove high-pressure hose attaching bolts (C).
9) Disconnect high-pressure hose from compres-
sor.
10) Disconnect high-pressure hose from condens-
er.
11) Remove high-pressure hose from the vehicle.
12) Remove high-pressure tube attaching bolt (D).
13) Remove high-pressure tube from the vehicle.

(A)

(C)

(B)

(C)

(D)

HV0023

AC-31
 RELAY AND FUSE
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] and Fuse B: INSPECTION

A: LOCATION

(H)

Joint box

(A)
(B)
(C)

(D)
(E)
(F)
(G)

B4M2308A
Main fuse box
(3) — (4): Continuity exists.
HV0022
(1) — (2): No continuity
Main Fan Relay 1 A While applying battery voltage to the cable be-
Main Fan Relay 2 B
tween (3) and (4), check continuity between (1) and
(2).
Sub Fan Relay 1 C
If no continuity exists, replace the relay with a new
Sub Fan Relay 2 E
one.
A/C Relay D
Main Fan Fuse F
Sub Fan Fuse G
A/C Fuse H

AC-32
 PRESSURE SWITCH (DUAL SWITCH)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] Switch (Dual 2) Remove the pressure switch harness connector.

Using a circuit tester, inspect the ON-OFF opera-
Switch) tion of the pressure switch.
A: INSPECTION
1) Connect the manifold gauge to the service valve
on the high-pressure side.

2 1

HV0021

Tester con- Specified condition

Operation
nection kPa (kg/cm2, psi)
Increasing to
2,800±100 (29±1, 406±15)
Turns OFF.
Decreasing to
278±29 (2.83±0.3, 40.3±4.2)
High and low pressure switch 1—2
Increasing to
287+39/−25 (2.9+0.4/−0.25, 42+5.7/−3.6)
Turns ON.
Decreasing to
2,200±200 (22.4±2, 319±29)

AC-33
 AMBIENT SENSOR (AUTO A/C)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] Sensor (Auto A/C)

A: REMOVAL
1) Open front hood.
2) Disconnect ground cable from battery.
3) Disconnect ambient sensor connector.
4) Remove ambient sensor from radiator lower
panel.

HV0020

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
<Ref. to AC-36, AMBIENT SENSOR, Diagnostic
Procedure for Sensors.>

AC-34
 SUN-LOAD SENSOR (AUTO A/C)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link]-load Sensor (Auto A/C)

A: REMOVAL
1) Disconnect ground cable from battery.
2) Remove front defroster grille.
3) Disconnect sunload sensor connector (A).
(A)

HV0005

CAUTION:
Be careful not to damage sensors and interior
trims when removing them.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
<Ref. to AC-43, SUNLOAD SENSOR, Diagnostic
Procedure for Sensors.>

AC-35
 AIR VENT GRILLE
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] Vent Grille

A: REMOVAL
1. CENTER GRILLE
1) Disconnect ground cable from battery.
2) Remove center console panel (A).
3) Loosen two screws to remove center air vent
grille (B).

(B)

(A)

HV0018

2. SIDE GRILLE
1) Disconnect ground cable from battery.
2) Remove heater vent duct. <Ref. to AC-38, RE-
MOVAL, Heater Vent Duct.>
3) Loosen screws to remove side air vent grille.

HV0019

B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
The direction and amount of air should be adjusted
smoothly.
The adjustment should be kept in each position.

AC-36
 HEATER DUCT
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] Duct
A: REMOVAL
1) Remove heater unit. <Ref. to AC-29, Removal.>
2) Remove front seat. <Ref. to SE-6, REMOVAL,
Front Seat.>
3) Remove front side sill cover.
4) Pull off floor mat to remove heater duct.

B4M2309

B: INSTALLATION
Install in the reverse order of removal.

AC-37
 HEATER VENT DUCT
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] Vent Duct

A: REMOVAL
1) Remove instrument panel. <Ref. to EI-25, RE-
MOVAL, Instrument Panel Assembly.>
2) Remove screws.
3) Remove heater vent duct.

HV0017

B: INSTALLATION
Install in the reverse order of removal.

AC-38
 GENERAL DIAGNOSTICS
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

[Link] Diagnostics
A: INSPECTION
Symptom Repair order
Fuse
Blower motor relay
Blower motor
Doesn't move.
Blower motor Blower motor resister
Blower switch
Wire harness
Strange noise. Blower motor
Refrigerant
Fuse
Air conditioning relay
Magnet clutch
Doesn't move. Compressor
Pressure switch
Compressor
A/C switch
Blower switch
Wire harness
V-Belt
Strange noise Magnet clutch
Compressor
Refrigerant
V-Belt
Magnet clutch
Compressor
Pressure switch
Cold air not emitted.
A/C switch
Blower switch
Wire harness
Heater duct
Heater vent duct
Engine coolant
Warm air not emitted. Blower switch
Heater core
Engine coolant
Temperature of air from vents does not change. Mode actuator
Wire harness
Mode actuator
Unable to switch blow vents. Air flow switch
Wire harness
Air inlet select switch
Unable to switch suction vents. FRESH/RECIRC actuator
Wire harness

AC-39
 GENERAL DIAGNOSTICS
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

AC-40