1999 SUBARU LEGACY cooling

(4) Clutch return spring (Models without hill
holder only)
CAUTION:
After connecting each cable, adjust them.
14) Install chamber stay.
15) Install air intake system.
(1) Install air cleaner element.
(2) Install air intake chamber and air intake duct
with air cleaner upper cover. (Except 2200 cc
California spec. vehicles)
(3) Connect connector to mass air flow sensor.
B2M2018
(4) Install air intake duct with air cleaner case.
(2200 cc California spec. vehicles) [W1A0].> and
16) Install A/C flexible hoses. (With A/C)

CAUTION:
Use new O-rings.
Tightening torque:
25
±7 N´m (2.5±0.7 kg-m, 18.1±5.1 ft-lb)
B2M2774
17) Install cooling system.(1) Attach radiator mounting cushions to body.
B2M0307A
(2) Install radiator while fitting radiator pins to
cushions.
B2M2323
(3) Install radiator brackets and tighten bolts.
Tightening torque:
13.7
±1.5 N´m (1.4±0.15 kg-m, 10.1±1.1
ft-lb)
B2M0320
(4) Connect radiator fan motor connector.
H2M2515
19
[W1C0]2-11SERVICE PROCEDURE
1. Engine

Automatic
transmis-
sionTransmis-
sionSelector positionP (Park)Transmission in
neutral, output mem-
ber immovable, and
engine start possible
R (Reverse)Transmission in
reverse for backing
N (Neutral)Transmission in
neutral, and engine
start possible
D (Drive)Automatic gear
change
1st
¬
®2nd¬
®3rd¬
®4th
3 (3rd)Automatic gear
change
1st
¬
®2nd¬
®3rd
¬4th
2 (2nd)2nd gear locked
(Deceleration pos-
sible 4th®3rd®
2nd)
1 (1st)1st gear locked
(Deceleration pos-
sible 4th®3rd®
2nd®1st)
Control method Hydraulic remote control
Oil pumpType Trochoid constant-displacement pump
Driving method Driven by engine
Number of teethInner rotor 9
Outer rotor 10
Hydraulic
controlTypeElectronic/hydraulic control [Four forward speed changes by electri-
cal signals of vehicle speed and accelerator (throttle) opening]
Fluid Dexron II or Dexron III type Automatic transmission fluid
Fluid capacity2200 cc 8.4 Ð 8.7(8.9 Ð 9.2 US qt, 7.4 Ð 7.7 Imp qt)
2500 cc 9.3 Ð 9.6(9.8 Ð 10.1 US qt, 8.2 Ð 8.4 Imp qt)
Lubrica-
tionLubrication system Forced feed lubrication with oil pump
Oil Automatic transmission fluid (above mentioned.)
Cooling Cooling system Liquid-cooled cooler incorporated in radiator
HarnessInhibitor switch 12 poles
Transmission harness 17 poles
TransferTransfer clutch Hydraulic multi-plate clutch
Plate number of transfer clutchDrive plate & driven
plate2200 cc 4
2500 cc 5
Control method Electronic, hydraulic type
LubricantThe same Automatic Transmission
Fluid used in automatic transmission.
1st reduction gear ratio 1.000 (53/53)
3
[S1A0]3-2SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

Final
reductionFinal gear
ratioFront drive2200 cc 4.111 (37/9)
2500 cc 4.444 (40/9)
Lubrication oil
H3M1235A
Oil capacity Front drive 1.2(1.3 US qt, 1.1 Imp qt)
ATF cooling system Radiation capacity 1.977 kW (1,700 kcal/h, 6,746 BTU/h)
4
3-2[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Automatic Transmission and Differential

F: CLEARANCE TABLE
CAUTION:
This table lists various clearances that must be
correctly adjusted to ensure normal vehicle
driving without interfering noise, or any other
faults.
LocationMinimum
allowance
mm (in)LocationMinimum
allowance
mm (in)
(1) Crossmember Ð Pipe 5 (0.20) (6) Exhaust pipe Ð Pipe 15 (0.59)
(2) DOJ Ð Shaft or joint 14 (0.55) (7) Exhaust pipe Ð Gearbox bolt 15 (0.59)
(3) DOJ Ð Valve housing 11 (0.43) (8) Side frame Ð Hose A and B 15 (0.59)
(4) Pipe Ð Pipe 2 (0.08) (9) Cruise control pump Ð Hose A and B 15 (0.59)
(5) Stabilizer Ð Pipe 5 (0.20) (10) Pipe portion of hose A Ð Pipe portion of
hose B1.5 (0.059)
(11)AT cooling hose Ð Joint 20 (0.79)
B4M0565B
G: BREAKAGE OF HOSES
CAUTION:
Although surface layer materials of rubber
hoses have excellent weathering resistance,
heat resistance and resistance for low tem-
perature brittleness, they are likely to be dam-
aged chemically by brake fluid, battery
electrolyte, engine oil and automatic transmis-
sion fluid and their service lives are to be very
shortened. It is very important to keep thehoses free from before mentioned fluids and to
wipe out immediately when the hoses are
adhered with the fluids.
Since resistances for heat or low temperature
brittleness are gradually declining according to
time accumulation of hot or cold conditions for
the hoses and their service lives are shortening
accordingly, it is necessary to perform careful
inspection frequently when the vehicle is used
in hot weather areas, cold weather area and/or
a driving condition in which many steering
operations are required in short time. Particu-
76
4-3[K1F0]DIAGNOSTICS
1. Power Steering

1. Air Conditioning System
A: SPECIFICATIONS
Item Specifications
Type of air conditioner Reheat air-mix type
Cooling capacity (IMACA)4.885 kW
(4,200 kcal/h, 16,666 BTU/h)
RefrigerantHFC-134a (CH
2FCF3)
[0.55 Ð 0.65 kg
(1.21 Ð 1.43 lb)]
CompressorType 5-vane rotary, fix volume (DKV-14G)
Discharge 140 cm
3(8.54 cu in)/rev
Max. permissible speed 7,000 rpm
Magnet clutchType Dry, single-disc type
Power consumption 45 W
Type of belt V-Ribbed 4 PK
Pulley dia. (effective dia.) 125 mm (4.92 in)
Pulley ratio 1.064
CondenserType Corrugated fin (Multi-flow)
Core face area 0.215 m
2(2.31 sq ft)
Core thickness 19 mm (0.75 in)
Radiation area 4.7 m
2(51 sq ft)
Receiver drier Effective inner capacity 290 cm3(17.70 cu in)
Expansion valve Type Internal equalizing
EvaporatorType A-laminate
Dimensions (W´H´T)60´224´235 mm
(2.36´8.82´9.25 in)
Blower fanFan type Sirocco fan
Outer diameter´width 150´75 mm (5.91´2.95 in)
Power consumption 230 W at 12 V
Condenser fan
(Sub fan)Motor type Magnet
Power consumption 120 W at 12 V
Fan outer diameter 320 mm (12.60 in)
Radiator fan
(Main fan)Motor type Magnet
Power consumption 120 W at 12 V
Fan outer diameter 320 mm (12.60 in)
Idling speed with
F.I.C.D. in operationMPFI model850±100 rpm (700±100 rpm ªDº range in AT
model)
Dual switch
(Pressure switch)
High-pressure line
B4M0755A
Compressor relief valve
blow-out pressure
B4M0084A
2
4-7[S1A0]SPECIFICATIONS AND SERVICE DATA
1. Air Conditioning System

2. Evaporator Unit
B4M0086B
(1) Thermo control amplifier
(2) Case upper
(3) Cooling module
(4) Pipe
(5) Seat
(6) Expansion valve(7) Drain hose
(8) Case lower
(9) Resistor
(10) Resistor bracketTightening torque: N´m (kg-m, ft-lb)
T1:
7.4±2.0 (0.75±0.2, 5.4±1.4)
T2:10±3 (1.0±0.3, 7.2±2.2)
T3:15±5 (1.5±0.5, 10.8±3.6)
T4:20±5 (2.0±0.5, 14.5±3.6)
5
[C200]4-7COMPONENT PARTS
2. Evaporator Unit

1. Safety Precautions
A: HFC-134a AIR CONDITIONING
SYSTEM
Component parts of the cooling system,
refrigerant, compressor oil, and other parts are not
the same for the HFC- 134a system and the older
CFC-12 system. Do not interchange parts or liquid.
Vehicles with HFC-134a air conditioning systems,
use only HFC-134a parts that are indicated on a
label attached to the vehicle. Before performing
any maintenance, verify the type of air conditioning
system installed in the vehicle.
B4M0780
B: COMPRESSOR OIL
Do not use any compressor oil that is not specifi-
cally designated for the HFC-134a air conditioning
system; only use ZXL200PG. Also, do not use
HFC-134a compressor oil in the CFC-12 air condi-
tioning system. If compression oils are mixed, poor
lubrication will result and the compressor itself may
be damaged.
Because HFC-134a compressor oil is very hygro-
scopic (easily absorbs moisture), when parts of the
air conditioning system are being removed, quickly
install a blind plug to prevent contact with the out-
side air. Also, always make sure that the service
container for compressor oil is tightly closed except
when in use. Store compressor oil in a tightly
closed steel container.
C: REFRIGERANT
Do not put CFC-12 refrigerant into a HFC-134a air
conditioning system. Also, do not put HFC-134a
refrigerant into a CFC-12 air conditioning system.
If the wrong refrigerant is used, poor lubrication willresult and the compressor itself may be destroyed.
7
[W1C0]4-7SERVICE PROCEDURE
1. Safety Precautions

2. Performance Test Diagnosis
If various conditions caused to other air conditioning system, the characteristics revealed on manifold gauge
reading are shown in the following:
As to the method of a performance test, refer to the item of ªPerformance Testº.
Each shaded area on the following tables indicates a reading of the normal system when the temperature
of outside air is 32.5ÉC (91ÉF).
Condition Probable cause Corrective action
INSUFFICIENT REFRIGERANT CHARGE
G4M0673
Insufficient cooling Refrigerant is small, or
leaking a little.(1) Perform leak test.
(2) Repair leak.
(3) Charge system.
Evacuate, as
necessary, and
recharge system.
ALMOST NO REFRIGERANT
G4M0674
No cooling action Serious refrigerant leak.Stop compressor
immediately.
(1) Perform leak test.
(2) Discharge system.
(3) Repair leak(s).
(4) Replace receiver
drier if necessary.
(5) Check oil level.
(6) Evacuate and
recharge system.
FAULTY EXPANSION VALVE
G4M0675
Slight cooling;
Sweating or frosted
expansion valve inlet.Expansion valve
restricts refrigerant flow.
IExpansion valve is
clogged.
IExpansion valve is
inoperative.
IValve stuck closed.
IThermal bulb has lost
charge.If valve inlet reveals
sweat or frost:
(1) Discharge system
(2) Remove valve and
clean it. Replace it if
necessary.
(3) Evacuate system
(4) Charge system.
If valve does not oper-
ate:
(1) Discharge system.
(2) Replace valve.
(3) Evacuate and
charge system.
35
[K200]4-7DIAGNOSTICS
2. Performance Test Diagnosis