1999 SUBARU LEGACY Service Repair Manual

Tools and Equipment Description
IREFRIGERANT RECOVERY SYSTEM
AREFRIGERANT RECOVERY SYSTEMis used for the
recovery and reuse of A/C system refrigerant after contami-
nants and moisture have been removed from the refrigerant.
G4M0574
ISYRINGE
A graduated plasticSYRINGEwill be needed to add oil back
into the system. The syringe can be found at a pharmacy or
drug store.
G4M0575
IVACUUM PUMP
AVACUUM PUMP(in good working condition) is necessary,
and may be obtained from either a commercial refrigeration
supply house or an automotive equipment supplier.
G4M0576
ICAN TAP
ACAN TAPfor the 397 g (14 oz) can is available from an
auto supply store.
G4M0577
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3. Tools and Equipment

Tools and Equipment Description
ITHERMOMETER
PocketTHERMOMETERSare available from either industrial
hardware store or commercial refrigeration supply houses.
G4M0578
IELECTRONIC LEAK DETECTOR
AnELECTRONIC LEAK DETECTORcan be obtained from
either a specially tool supply or an A/C equipment supplier.
G4M0579
IWEIGHT SCALE
AWEIGHT SCALEsuch 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.
G4M0580
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[W300]4-7SERVICE PROCEDURE
3. Tools and Equipment

4. O-ring Connections
A: GENERAL
The following points should be kept in mind when
assembling O-ring connections.
1) Avoid unnecessary handling and contact of
O-rings with your hands, since even clean fingers
contain body acids, which can contaminate the
O-ring surface.
2) Do not handle O-rings with gloves, shop towels,
etc., since lint particles may cling to the O-ring,
possibly causing a leak upon assembly.
3) Always lubricate O-rings before assembly to
allow the O-ring to seat itself properly.
4) Be certain to use torque wrenches when tight-
ening O-ring fittings, because overtightening can
not only damage the O-ring, but it can distort the
tube end as well.
B: REMOVE PROTECTIVE SEALS
1) Just prior to making the connection, remove the
protective seals.
CAUTION:
If for any reason you have to stop before mak-
ing a connection, recap the tube, component or
fitting.
G4M0581
2) Visually inspect the O-ring surface, the O-ring
mating surface, the threads and the connection
points. If a defective part is found, replace it.
The O-ring must sit square against the tube bead.
If necessary, slide the O-ring into proper position
with clean hands.
G4M0582
C: LUBRICATE THE COMPONENTS
For lubrication of the components, use only refrig-
erant oil as described in the appropriate service
manual. Apply oil from an oil squirt gun or other
closed container. Do not use your finger to spread
the oil over the O-ring.
Apply a small amount of refrigerant oil to the top
and sides of the O-ring. The area covered by oil
should include the O-ring and the tube bead.
G4M0583
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4-7[W4A0]SERVICE PROCEDURE
4. O-ring Connections

D: TORQUE THE FITTING
Using a back-up wrench in conjunction with a cali-
brated torque wrench, torque the connection to the
midrange of the specification.
After completion of torquing, use a clean shop
towel to remove any excess oil from the connection
or any oil that may have dripped on the vehicle
body or other parts.
CAUTION:
If a leak is suspected after torquing, do not
retighten or retorque the connection. Instead,
disassemble the connection, remove the
O-ring, and inspect the O-ring, threads, joints
and seating surfaces.
G4M0584
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4. O-ring Connections

5. Refrigerant Service Procedure
A: WORK FLOW
B4M1097A
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4-7[W5A0]SERVICE PROCEDURE
5. Refrigerant Service Procedure

6. Discharge the System
CAUTION:
The following points should be kept in mind
when discharging the system.
IBe certain that goggles and gloves are worn.
IConnect refrigerant recovery system to
manifold gauge set and remove recycle refrig-
erant from A/C system.
NOTE:
Refer to appropriate refrigerant recovery system
instruction manual for operation.
A: CONNECTING THE MANIFOLD
GAUGE SET
1) Close the high and low side manifold valves.
G4M0585
2) Turn the A/C system ON and turn the IG switch
OFF.
3) Attach the high- and low-pressure manifolds to
the high and low services port on the vehicle.
G4M0586
B: PREPARE FOR DISCHARGING
Connect the center manifold hose to the refrigerant
recovery system to recycle refrigerant.
7. Evacuating and Charging
The following points should be kept in mind when
evacuating and charging with a manifold gauge
set.
1) Be certain that goggles and gloves are worn.
2) If bulk refrigerant [13.6 kg (30 lb) canister] is
used, be certain to weigh the charge amount
carefully, using the correct equipment, to avoid
overcharging the system.
3) The charging procedure described in this sec-
tion begins by charging liquid refrigerant into the
high- pressure side of the system with the engine
off. The procedure is completed by charging refrig-
erant vapor into the low-pressure side of the sys-
tem with the engine running.
CAUTION:
Never open the high-pressure manifold valve
when the engine is running.
A: CONNECT THE GAUGE SET
1) Close the high- and low-pressure manifold
valves.
G4M0596
2) Attach the low-pressure manifold hose to the
low- pressure service port on the vehicle. Check
the low- pressure gauge. If more than 68.6 kPa
(0.70 kg/cm
2, 10 psi) is indicated, discharge the
system prior to charging.
3) Attach the high-pressure manifold hose to the
high- pressure service port on the vehicle.
4) Connect the center hose from the manifold to
the vacuum pump.
5) Turn on the vacuum pump.
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[W7A0]4-7SERVICE PROCEDURE
7. Evacuating and Charging

6. Discharge the System
CAUTION:
The following points should be kept in mind
when discharging the system.
IBe certain that goggles and gloves are worn.
IConnect refrigerant recovery system to
manifold gauge set and remove recycle refrig-
erant from A/C system.
NOTE:
Refer to appropriate refrigerant recovery system
instruction manual for operation.
A: CONNECTING THE MANIFOLD
GAUGE SET
1) Close the high and low side manifold valves.
G4M0585
2) Turn the A/C system ON and turn the IG switch
OFF.
3) Attach the high- and low-pressure manifolds to
the high and low services port on the vehicle.
G4M0586
B: PREPARE FOR DISCHARGING
Connect the center manifold hose to the refrigerant
recovery system to recycle refrigerant.
7. Evacuating and Charging
The following points should be kept in mind when
evacuating and charging with a manifold gauge
set.
1) Be certain that goggles and gloves are worn.
2) If bulk refrigerant [13.6 kg (30 lb) canister] is
used, be certain to weigh the charge amount
carefully, using the correct equipment, to avoid
overcharging the system.
3) The charging procedure described in this sec-
tion begins by charging liquid refrigerant into the
high- pressure side of the system with the engine
off. The procedure is completed by charging refrig-
erant vapor into the low-pressure side of the sys-
tem with the engine running.
CAUTION:
Never open the high-pressure manifold valve
when the engine is running.
A: CONNECT THE GAUGE SET
1) Close the high- and low-pressure manifold
valves.
G4M0596
2) Attach the low-pressure manifold hose to the
low- pressure service port on the vehicle. Check
the low- pressure gauge. If more than 68.6 kPa
(0.70 kg/cm
2, 10 psi) is indicated, discharge the
system prior to charging.
3) Attach the high-pressure manifold hose to the
high- pressure service port on the vehicle.
4) Connect the center hose from the manifold to
the vacuum pump.
5) Turn on the vacuum pump.
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7. Evacuating and Charging

6) Slowly open the low-pressure manifold valve.
G4M0597
7) When the low-pressure gauge reaches approxi-
mately 66.43 kPa (498.3 mmHg, 19.62 inHg),
slowly open the high- pressure manifold valve.
8) Maintain a minimum vacuum level of 100.56
kPa (754.4 mmHg, 29.70 inHg) for a minimum of
15 minutes on a new system or 30 minutes for an
in-service system.
NOTE:
The gauge will read 4 kPa (25 mmHg, 1 inHg) less
for every 304.8 m (1,000 ft) above sea level.
G4M0598
B: PERFORM A VACUUM LEAK
TEST
1) After 15 minutes (or more) of evacuation, close
the high-pressure manifold valve.
2) Close the low-pressure manifold valve.
G4M0599
3) Turn off the vacuum pump.4) Note the low side gauge reading.
G4M0600
5) After 5 minutes, re-check the low-pressure
gauge reading.
If the vacuum level has changed more than 4 kPa
(25 mmHg, 1 inHg), perform an HFC-134a leak
test.
If the vacuum reading is about the same as noted
in step 4), continue on to next step.
6) Carefully attach the can tap to the refrigerant
can by following the can tap manufacturer's
instructions.
G4M0980
7) Disconnect the center manifold hose from the
vacuum pump and connect the hose to the tap
valve.
8) If a 13.6 kg (30 lb) container of refrigerant is
used a weight scale will be needed. This scale is
to determine the amount of refrigerant that is used.
Connect the center hose from the manifold to the
valve. Place the 13.6 kg (30 lb) container on the
scale, valve end down.
G4M0981
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4-7[W7B0]SERVICE PROCEDURE
7. Evacuating and Charging