Subaru Legacy (2005 year). Manual - part 863

 

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Subaru Legacy (2005 year). Manual - part 863

 

 

AC-21

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Refrigerant Charging Procedure

4. Refrigerant Charging Proce-

dure

A: PROCEDURE

CAUTION:
• During operation, be sure to wear protective
goggles 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
evacuated only under the minimum vacuum
level. The minimum vacuum level affects the
temperature in the system.
• The list below shows the vacuum values nec-
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.

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

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.

4) Carefully open the valves on the low-/high-pres-
sure sides to activate the vacuum pump.

5) After the low-pressure gauge reaches 100.0 kPa
(750 mmHg, 29.5 inHg) or higher, evacuate the
system for approx. 15 minutes. (Continue evacua-
tion).

6) After 15 minutes of evacuation, if the reading
shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher,
close the valves on the both sides to stop the vac-
uum pump.

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)

12.8

°C (55°F)

99.8 kPa (749 mmHg, 29.5 inHg)

18.3

°C (65°F)

99.2 kPa (744 mmHg, 29.3 inHg)

23.9

°C (75°F)

98.5 kPa (739 mmHg, 29.1 inHg)

29.4

°C (85°F)

97.2 kPa (729 mmHg, 28.7 inHg)

35

°C (95°F)

95.8 kPa (719 mmHg, 28.3 inHg)

(A) Low-pressure gauge (Compound pressure 

gauge)

(B) High-pressure gauge

(C) Close

AC-00023

(A)

(B)

(C)

(C)

(A) Low-pressure gauge (Compound pressure 

gauge)

(B) High-pressure gauge

(C) Slowly open

(D) Vacuum pump turn on

(A) Low-pressure gauge (Compound pressure 

gauge)

(B) High-pressure gauge

(C) Close

(D) Vacuum pump turn off

AC-00024

(A)

(B)

(D)

(C)

(C)

AC-00025

AC-00026

(A)

(B)

(D)

(C)

(C)

AC-22

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Refrigerant Charging Procedure

7) Note the low-pressure gauge reading.

8) Leave it at least 5 minutes, and then check the
low-pressure gauge reading for any changes.
When a gauge indicator shows near to zero point, it
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.

10) Disconnect the center manifold hose from the
vacuum pump, and connect the hose to the tap
valve.
11) When a 13.6 kg (30 lb) refrigerant container is
used, measure the refrigerant amount in use using
a weight scale.

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

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.

CAUTION:
Do not open the low-pressure valve.

CAUTION:
Never run the engine during charging from the 
high-pressure side.
16) Close the high-pressure valve when the low-
pressure gauge reaches 98 kPa (1 kgf/cm

2

, 14 psi).

Using a leak tester, check the system for leaks.
If any leakage is found after the refrigerant recov-
ery is completed, repair the applicable area.

(A) Tap valve

(B) Center manifold hose

(A) Refrigerant container (HFC-134a)

(B) Weight scale

AC-00027

AC-00028

(A)

(B)

AC-00029

(A)

(B)

(A) Low-pressure gauge (Compound pressure 

gauge)

(B) High-pressure gauge

(C) Close

(A) Low-pressure gauge (Compound pressure 

gauge)

(B) High-pressure gauge

(C) Close

(D) Ignition switch OFF

(E) Slowly open

AC-00030

(A)

(B)

(C)

(C)

AC-00031

(A)

(B)

(E)

(D)

(C)

AC-23

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Refrigerant Charging Procedure

17) After confirming that there are no leaks with the
leak test, charge the required amount of refrigerant.

CAUTION:
Never run the engine during charging from the 
high-pressure side.
18) Close the high-pressure valve when;
• the readings of low- / high-pressure gauges be-
come almost equal, after the charging speed is re-
duced,
• the HFC-134a source becomes empty, or the
system is filled with the gas.

19) If the HFC-134a source is empty, close the
high-pressure valve, close the valve on the can tap,
and replace the HFC-134a source with a new one
to restart the operation.

20) Confirm that both the low-/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”
• Window 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. The high-pressure gas will back-
flow resulting in an explosion of the can.

24) Adjust the refrigerant flow to maintain the pres-
sure on the low-pressure side at 276 kPa (2.81 kgf/
cm

2

, 40 psi) max.

25) After the system is fully charged, close the low-
pressure valve.
26) Close the valve on the refrigerant source.

27) Disconnect the hose from the service port, and
install the service port cap.

(A) Low-pressure gauge (Compound pressure 

gauge)

(B) High-pressure gauge

(C) Close

AC-00032

AC-00033

(A)

(B)

(C)

(C)

Refrigerant amount

Refrigerant

Minimum

Maximum

HFC-134a

370 g (0.82 lb)

430 g (0.95 lb)

AC-00034

AC-24

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Refrigerant Leak Check

5. Refrigerant Leak Check

A: INSPECTION

1) Operate the A/C system for approx. 10 minutes,
and confirm that the high-side pressure shows at
least 690 kPa (7.03 kgf/cm

2

, 100 psi). Then stop

the engine to start the leak test.
2) Starting from the connection between high-pres-
sure pipe and evaporator, check the system for
leaks along the high-pressure side through the
compressor. The following items must be checked
thoroughly.
3) Check the joint and seam between pressure
switch (triple pressure switch) and high-pressure
pipe.
4) Check the connections between condenser and
pipes, 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 compressor and hoses.
6) Check the machined area of compressor and
other joints on the compressor.
7) Check the compressor shaft seal at the area
near the center of compressor clutch pulley.
Some shaft seals show a slight amount of leakage
about 3 g (0.1 oz.) per year. This is not a problem.
8) Starting from the connection between low-pres-
sure pipe and evaporator, check the system for
leakage along the low-pressure side through the
compressor. The following items must be checked
thoroughly.
• Connection between 2 parts
• Connection between pipe and plate

9) 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.

10) Disconnect the drain hose from heater case,
and check the hose end for at least 10 seconds.
After the test is finished, reconnect the drain hose.
11) Turn the ignition key to ON position, and run
the blower at high speed for approx. 1 minute. Stop
the blower to check the ventilation grille on the in-
strument 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 point for at least 10
seconds.

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

AC-00035

(A) Flexible hose

AC-00036

(A)

AC-00037

AC-00038

 

 

 

 

 

 

 

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