Subaru Car 1998-05

Removal & Installation

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Baja



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the air intake system.
  6.  
  7. Release the heater hose clamps in the engine compartment to remove the heater hoses.
  8.  
  9. Remove the A/C unit.
  10.  
  11. Using a Torx® wrench, remove the airbag control unit.
  12.  
  13. Disconnect the connector of the air bag main wiring harness near the steering support beam.
  14.  
  15. Loosen the bolts and nuts of the support beam to remove the support beam.
  16.  
  17. Disconnect the servo connector.
  18.  
  19. Loosen the bolts and nuts of the heater unit to remove.
  20.  
  21. Separate the heater unit case to remove the heater core.
  22.  
  23. Installation is the reverse of removal.
  24.  
  25. Fill the cooling system to the correct level.

    Click image to see an enlarged view

    Fig. Removing the heater core from the heater unit-Baja

  26.  

Impreza



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
If equipped with an air bag system, wait 10 minutes after disconnecting the negative battery cable before performing any further work while the system fully de-energizes in order to avoid accidental deployment. All air bag system wiring is yellow. Do not use electrically powered test equipment on these circuits.

  1. Drain the cooling system into a clean container for reuse.
  2.  
  3. Remove or disconnect the following:

    Heater hoses from the heater core. Plug the heater core and heater hoses.
     
    Radio box or console
     

  4.  
  5. Remove the instrument panel as follows:
    1. Remove the rear console box.
    2.  
    3. Pull the cup holder.
    4.  
    5. Turn over the shift lever boot (manual transaxle models) or remove select lever cover (automatic transaxle models).
    6.  
    7. Remove the console cover.
    8.  
    9. Remove the audio assembly and disconnect the antenna cable and connectors.
    10.  
    11. Remove the lower cover and then disconnect the seat belt timer connector.
    12.  
    13. Remove the glove box.
    14.  
    15. Remove the instrument panel console.
    16.  
    17. Remove the 2 bolts and lower the steering column.
    18.  
    19. Remove the column cover.
    20.  
    21. Remove the hood opening lever.
    22.  
    23. Set the temperature control switch to MAX COLD, and mode selector switch to the defroster position.
    24.  
    25. Disconnect both the temperature control cable and the mode selector cable from the link.
    26.  

  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and center console-Impreza



NOTE
Do not move the switch and link when installing.

  1. Tag or match mark the wiring connectors, then disconnect by holding the connectors and not the wiring.
  2.  
  3. Remove the 6 instrument panel retaining bolts and nuts.
  4.  
  5. Remove the front defroster grille and 2 bolts.
  6.  
  7. Carefully remove the instrument panel from the body and then disconnect the speedometer cable from the back of the combination meter.
  8.  

  1. Remove or disconnect the following:

    Heater control cables and the fan motor wiring harness
     
    Duct between the heater unit and the blower heater unit. Lift up and out on the heater unit and remove it.
     

  2.  
  3. With the heater assembly out of the vehicle, remove the heater core tube retaining clamps and lift the core from the heater case.
  4.  
  5. Remove the heater core.
  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the heater assembly-Impreza


To install:

  1. Install or connect the following:

    Heater core into the heater case. Secure it in place with the retaining clamps and screws.
     
    Heater assembly to its mounting position under the dash. Torque the mounting bolts to 48-84 inch lbs. (5-9 Nm).
     
    Heater control cables and fan motor wiring harness connectors
     
    Instrument panel
     
    Radio and console assemblies
     
    Heater hoses in the engine compartment
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Evacuate, charge and leak test the air conditioning system.
  8.  
  9. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  10.  

1997 Model
  1. If equipped, discharge the A/C system using an approved recovery/recycling machine.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Tag and disconnect the heater hoses from the firewall.
  8.  
  9. Remove the center console box and cup holder.
  10.  
  11. Remove the radio. Refer to the procedure in this section.
  12.  
  13. Remove the drivers side lower instrument trim panel, then disconnect the seat belt timer harness.
  14.  
  15. Remove the glove box.
  16.  
  17. Remove the bolts and lower the steering column.
  18.  
  19. Remove the steering column covers.
  20.  
  21. Remove the hood release handle.
  22.  
  23. Set the temperature control switch to MAX. COLD, and mode selector switch to the DEFROSTER position.
  24.  
  25. Unfasten the following underdash connectors:
    1. 15-pin gray
    2.  
    3. 5-pin natural
    4.  
    5. 20-pin white
    6.  
    7. 20-pin blue
    8.  
    9. 12-pin black
    10.  
    11. 8-pin natural
    12.  
    13. 1-pin blue
    14.  
    15. 6-pin black
    16.  
    17. 20-pin natural
    18.  

  26.  
  27. Remove the instrument panel nuts and bolts then the defroster grilles.
  28.  
  29. Pull the instrument panel outward carefully, disconnect the speedometer cable from the instrument cluster and remove the instrument panel.
  30.  
  31. Remove the steering support beam.
  32.  
  33. Disconnect the discharge pipe, suction pipe and grommets from the evaporator. Cap the hoses to prevent moisture from entering the system.
  34.  
  35. Disconnect the harness and drain hose from the evaporator.
  36.  
  37. Remove the mounting nut, bolt and evaporator.
  38.  
  39. Remove the bolt, nuts and the heater unit.
  40.  
  41. Separate the heater unit housing and remove the heater core.
  42.  
  43. Install all the components in the reverse order of removal. Tighten the components to specifications.

    Install the heater unit. Attach the retainer bolts, and tighten the bolt and nuts to 6 ft. lbs. (8 Nm).
     

  44.  
  45. Connect the heater hoses to the firewall.
  46.  
  47. Connect the negative battery cable. Fill and bleed the cooling system.
  48.  
  49. If equipped, evacuate and charge the A/C system using an approved recovery/recycling machine.
  50.  
  51. Check for coolant leaks at the core and hose connections.
  52.  

1998-01 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant from the heater unit.
  4.  
  5. Remove the heater hoses from the heater unit in the engine compartment.
  6.  
  7. Remove the instrument panel
  8.  
  9. Remove the evaporator as follows:
    1. Disconnect the discharge pipe, suction pipe and grommets.
    2.  
    3. Remove the glove box and pocket back panel.
    4.  
    5. Disconnect the evaporator wiring harness.
    6.  
    7. Disconnect the drain hose.
    8.  
    9. Remove the evaporator.
    10.  

  10.  
  11. Remove the heater unit mounting bolts.
  12.  
  13. Remove the heater unit.
  14.  
  15. Separate the heater unit case to remove the heater core.
  16.  
  17. Installation is the reverse order of removal.
  18.  
  19. Fill the cooling system to the correct level.
  20.  

2002-05 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Discharge the air conditioning system.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the bolts securing the expansion valve and pipe in the engine compartment. Release the heater hose clamps in the engine compartment to remove the heater hoses.
  8.  
  9. Remove the instrument panel.
  10.  
  11. Remove the support beam.
  12.  
  13. Remove the blower motor assembly.
  14.  
  15. Loosen the bolts and nuts to remove the heater and cooling unit.
  16.  
  17. Loosen the screws to remove the heater core cover.
  18.  
  19. Remove the heater core.
  20.  
  21. Installation is the reverse order of removal.

    Click image to see an enlarged view

    Fig. Removing the heater core from the heater and cooling unit-2002-05 Impreza

  22.  

Removal And Installation
  1. Disconnect the negative battery cable.
    CAUTION
    If equipped with an air bag system, wait 10 minutes after disconnecting the negative battery cable before performing any further work while the system fully de-energizes in order to avoid accidental deployment. All air bag system wiring is yellow. Do not use electrically powered test equipment on these circuits.

  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core. Plug the heater core and heater hoses.
  6.  
  7. Remove the radio box or console.

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and center console-Impreza

  8.  
  9. Remove the instrument panel by:
    NOTE
    Do not move the switch and link when installing.



    Remove the rear console box.
     
    Pull the cup holder.
     
    Turn over the shift lever boot (manual transaxle models) or remove select lever cover (automatic transaxle models).
     
    Remove the console cover.
     
    Remove the audio assembly and disconnect the antenna cable and connectors.
     
    Remove the lower cover and then disconnect the seat belt timer connector.
     
    Remove the glove box.
     
    Remove the instrument panel console.
     
    Remove the 2 bolts and lower the steering column.
     
    Remove the column cover.
     
    Remove the hood opening lever.
     
    Set the temperature control switch to MAX. COLD, and mode selector switch to the defroster position.
     
    Disconnect both the temperature control cable and the mode selector cable from the link.
     



    Tag or match mark the wiring connectors, then disconnect by holding the connectors and not the wiring.
     
    Remove the 6 instrument panel retaining bolts and nuts.
     
    Remove the front defroster grille and 2 bolts.
     
    Carefully remove the instrument panel from the body and then disconnect the speedometer cable from the back of the combination meter.
     

  10.  
  11. Disconnect the heater control cables and the fan motor wiring harness.
  12.  
  13. Disconnect the duct between the heater unit and the blower heater unit. Lift up and out on the heater unit and remove it.
  14.  
  15. With the heater assembly out of the vehicle, remove the heater core tube retaining clamps and lift the core from the heater case.
  16.  
  17. Remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the heater assembly-Impreza

  18.  

To install:

  1. Install the heater core into the heater case. Secure it in place with the retaining clamps and screws.
  2.  
  3. Install the heater assembly to its mounting position under the dash.
  4.  
  5. Install the mounting bolts. Torque the mounting bolts to 48-84 inch lbs. (5-9 Nm).
  6.  
  7. Connect the heater control cables and fan motor wiring harness connectors.
  8.  
  9. Install the instrument panel.
  10.  
  11. Install the radio and console assemblies.
  12.  
  13. Connect the heater hoses in the engine compartment.
  14.  
  15. Refill the cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Evacuate, charge and leak test the air conditioning system.
  20.  
  21. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  22.  

Legacy



Removal And Installation
  1. Disconnect the negative battery cable.
    CAUTION
    If equipped with an air bag system, wait 10 minutes after disconnecting the negative battery cable before performing any further work while the system fully de-energizes in order to avoid accidental deployment. All air bag system wiring is yellow. Do not use electrically powered test equipment on these circuits.

  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core. Plug the heater core and heater hoses.
  6.  
  7. Remove the radio box or console.
  8.  
  9. Remove the instrument panel by:
    NOTE
    When removing the instrument panel, check that all wiring and cables are disconnected before pulling it completely away from the firewall.



    Remove the center console retaining screws and remove the center console assembly.
     
    Remove the instrument panel retaining bolt covers by prying them from the panel.
     
    Remove the lower part of the front A pillar trim. Remove the instrument panel under covers from the driver-s and passenger's sides.
     
    Remove the hood release cable from the hood release lever.
     
    Disconnect the wiring harness connectors under the instrument panel.
     
    Remove the instrument cluster assembly. Remove the glove box assembly
     
    Disconnect the ventilation control cables and electrical connectors at the heater unit. Disconnect the vacuum line at the blower housing.
     
    Disconnect the radio antenna feeder wire. Disconnect the main harness connector at the fuse box.
     
    Remove the lower steering column covers. Remove the steering column retaining bolts and allow the column to hang down.
     
    Remove the instrument panel retaining bolts.
     



    With the help of an assistant, lift and remove the instrument panel from the vehicle.
     

  10.  
  11. Disconnect the heater control cables and the fan motor wiring harness.
  12.  
  13. Disconnect the duct between the heater unit and the blower heater unit. Lift up and out on the heater unit and remove it.
  14.  
  15. Remove the evaporator case assembly by performing the following procedure:

    Discharge and recover the air conditioning system refrigerant.
     
    Disconnect the low and high pressure line from the evaporator outlet and cap the fittings.
     
    Remove the inlet and outlet pipe grommets.
     
    Remove the glove box and support bracket.
     
    Disconnect the air conditioning wiring harness from the evaporator. Disconnect the drain hose from the evaporator.
     
    Remove the evaporator mounting nut and bolt.
     
    Remove the evaporator case assembly from the vehicle.
     

  16.  
  17. With the heater assembly out of the vehicle, remove the heater core tube retaining clamps and lift the core from the heater case.
  18.  
  19. Remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the heater assembly-Legacy

  20.  

To install:

  1. Install the heater core into the heater case. Secure it in place with the retaining clamps and screws.
  2.  
  3. Install the heater assembly to its mounting position under the dash.
  4.  
  5. Install the mounting bolts. Torque the mounting bolts to 48-84 inch lbs. (5-9 Nm).
  6.  
  7. Install the evaporator by performing the following procedure:

    Install the evaporator case assembly and the nuts and bolts.
     
    Adjust the position of the evaporator assembly so the inlet and outlet connections are aligned with the heater and blower unit connections.
     
    Install the drain hose. Connect the air conditioning wiring harness.
     
    Install the inlet and outlet pipe grommets.
     
    Install the glove box and the lower support bracket.
     
    Using new O-rings, lubricate them with clean refrigerant oil and install them on the pipe fittings.
     
    Connect the suction hose to the evaporator inlet fitting.
     
    Connect the discharge hose to the evaporator outlet fitting.
     

  8.  
  9. Connect the heater control cables and fan motor wiring harness connectors.
  10.  
  11. Install the instrument panel.
  12.  
  13. Install the radio and console assemblies.
  14.  
  15. Connect the heater hoses in the engine compartment.
  16.  
  17. Refill the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Evacuate, charge and leak test the air conditioning system.
  22.  
  23. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  24.  

Legacy & Outback



1997 Model (Except Outback )
  1. Disconnect the negative battery cable.
  2.  
  3. Disarm the air bag, if equipped.
  4.  
  5. Drain the engine coolant into a suitable container.
  6.  
  7. In the engine compartment, tag and disconnect the heater hoses at the firewall. Plug the openings to prevent spillage inside the vehicle.
  8.  
  9. Remove the front side sill cover and disconnect the air bag connector (AB9) and (AB10).
  10.  
  11. Remove the shift knob, if equipped with a manual transaxle.
  12.  
  13. Remove the center console assembly.
  14.  
  15. Remove the front pillar lower trim panel from the body.
  16.  
  17. Remove the trim panel that secures the hood release cable in place.
  18.  
  19. Remove the trim cover below the steering column.
  20.  
  21. Remove the instrument panel, disconnecting the speedometer cable and wire harnesses. Refer to Section 10 for removal and installation steps.
  22.  
  23. Remove the glove box and back panel assembly.
  24.  
  25. Disconnect the blower motor harness.
  26.  
  27. Remove the bolts and lower the steering column. Tag and disconnect the necessary wire harnesses.
  28.  
  29. Disconnect the temperature control cable from the link of the heater case.
  30.  
  31. Remove ash tray, radio and temperature control unit from the dash.
  32.  
  33. Disconnect the dashboard harness connectors.
  34.  
  35. Remove the dashboard mounting bolts.
  36.  
  37. Remove the front defroster grille and 2 mounting bolts.
  38.  
  39. Remove the dashboard from the body. Refer to Section 10 for removal and installation steps.
    NOTE
    When storing the removed dashboard, place in an upright position on a workbench or floor.

  40.  
  41. Remove the steering support beam.
  42.  
  43. Properly evacuate the A/C refrigerant from the system using an approved recovery/recycling machine.
  44.  
  45. Disconnect the discharge pipe, suction pipe and grommets. Cap the openings of the A/C pipes to prevent contamination of the system.
  46.  
  47. Disconnect the harness from the evaporator.
  48.  
  49. Disconnect the drain hose.
  50.  
  51. Remove the evaporator unit mounting nut and bolt, remove the evaporator unit.
  52.  
  53. Remove the heater unit and separate the case halves. Remove the heater core from the heater unit.
  54.  

To install:

  1. Install the heater core into the heater unit. Connect the case halves. Install the heater unit to the vehicle.
  2.  
  3. Install the evaporator unit and secure.
  4.  
  5. Connect the drain hose and the harness to the evaporator.
  6.  
  7. Connect the grommets, suction pipe and discharge pipe to the evaporator. Be sure to use new O-rings for the A/C connections
  8.  
  9. Install the remaining components and secure them to specifications.
  10.  
  11. Fill the cooling system with coolant. Properly charge the A/C system, using an approved recovery/recycling machine.
  12.  
  13. Run vehicle to normal operating temperature and check for leaks. Check the heating and A/C system for proper operation.
  14.  

1998-01 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Discharge the air conditioning system.
  4.  
  5. Drain the coolant from the heater unit.
  6.  
  7. Remove the heater hoses from the heater unit in the engine compartment.
  8.  
  9. Remove the instrument panel.
  10.  
  11. Remove the steering support beam.
  12.  
  13. Remove the evaporator as follows:
    1. Disconnect the discharge pipe, suction pipe and grommets.
    2.  
    3. Remove the glove box and pocket back panel.
    4.  
    5. Disconnect the evaporator wiring harness.
    6.  
    7. Disconnect the drain hose.
    8.  
    9. Remove the evaporator.
    10.  

  14.  
  15. Remove the heater unit mounting bolts.
  16.  
  17. Remove the heater unit.
  18.  
  19. Separate the heater unit case to remove the heater core.
  20.  
  21. Installation is the reverse order of removal.
  22.  
  23. Fill the cooling system to the correct level.
  24.  

2002-04 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the air intake system.
  6.  
  7. Release the heater hose clamps in the engine compartment to remove the heater hoses.
  8.  
  9. Remove the A/C unit.
  10.  
  11. Using a Torx® wrench, remove the airbag control unit.
  12.  
  13. Disconnect the connector of the air bag main wiring harness near the steering support beam.
  14.  
  15. Loosen the bolts and nuts of the support beam to remove the support beam.
  16.  
  17. Disconnect the servo connector.
  18.  
  19. Loosen the bolts and nuts of the heater unit to remove.
  20.  
  21. Separate the heater unit case to remove the heater core.
  22.  
  23. Installation is the reverse of removal.
  24.  
  25. Fill the cooling system to the correct level.
  26.  

2005 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Discharge the air conditioning system.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the bolts securing the expansion valve and pipe in the engine compartment. Release the heater hose clamps in the engine compartment to remove the heater hoses.
  8.  
  9. Remove the instrument panel.
  10.  
  11. Remove the support beam.
  12.  
  13. Remove the blower motor assembly.
  14.  
  15. Disconnect the actuator connector.
  16.  
  17. Loosen the bolts and nuts of the heater unit to remove.
  18.  
  19. Separate the heater unit case to remove the heater core.
  20.  
  21. Installation is the reverse of removal.
  22.  
  23. Fill the cooling system to the correct level.
  24.  
  25. Charge the air conditioning system.

    Click image to see an enlarged view

    Fig. Remove the bolt securing the expansion valve (left) and disconnect the heater hoses (right).

  26.  

Legacy And Baja



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
If equipped with an air bag system, wait 10 minutes after disconnecting the negative battery cable before performing any further work while the system fully de-energizes in order to avoid accidental deployment. All air bag system wiring is yellow. Do not use electrically powered test equipment on these circuits.

  1. Drain the cooling system into a clean container for reuse.
  2.  
  3. Remove or disconnect the following:

    Heater hoses from the heater core. Plug the heater core and heater hoses.
     
    Radio box or console
     

  4.  
  5. Remove the instrument panel as follows:
    1. Remove the center console retaining screws and remove the center console assembly.
    2.  
    3. Remove the instrument panel retaining bolt covers by prying them from the panel.
    4.  
    5. Remove the lower part of the front A pillar trim. Remove the instrument panel under covers from the driver-s and passenger's sides.
    6.  
    7. Remove the hood release cable from the hood release lever.
    8.  
    9. Disconnect the wiring harness connectors under the instrument panel.
    10.  
    11. Remove the instrument cluster assembly. Remove the glove box assembly
    12.  
    13. Disconnect the ventilation control cables and electrical connectors at the heater unit. Disconnect the vacuum line at the blower housing.
    14.  
    15. Disconnect the radio antenna feeder wire. Disconnect the main harness connector at the fuse box.
    16.  
    17. Remove the lower steering column covers. Remove the steering column retaining bolts and allow the column to hang down.
    18.  
    19. Remove the instrument panel retaining bolts.
    20.  

  6.  


NOTE
When removing the instrument panel, check that all wiring and cables are disconnected before pulling it completely away from the firewall.

  1. With the help of an assistant, lift and remove the instrument panel from the vehicle.
  2.  

  1. Remove or disconnect the following:

    Heater control cables and the fan motor wiring harness
     
    Duct between the heater unit and the blower heater unit. Lift up and out on the heater unit and remove it.
     

  2.  
  3. Remove the evaporator case assembly by performing the following procedure:
    1. Discharge and recover the air conditioning system refrigerant.
    2.  
    3. Disconnect the low and high pressure line from the evaporator outlet and cap the fittings.
    4.  
    5. Remove the inlet and outlet pipe grommets.
    6.  
    7. Remove the glove box and support bracket.
    8.  
    9. Disconnect the air conditioning wiring harness from the evaporator. Disconnect the drain hose from the evaporator.
    10.  
    11. Remove the evaporator mounting nut and bolt.
    12.  
    13. Remove the evaporator case assembly from the vehicle.
    14.  

  4.  
  5. With the heater assembly out of the vehicle, remove the heater core tube retaining clamps and lift the core from the heater case.
  6.  
  7. Remove the heater core.
  8.  


    Click image to see an enlarged view

    Fig. Exploded view of the heater assembly-Legacy


To install:

  1. Install or connect the following:

    Heater core into the heater case. Secure it in place with the retaining clamps and screws.
     
    Heater assembly to its mounting position under the dash Torque the mounting bolts to 48-84 inch lbs. (5-9 Nm).
     

  2.  
  3. Install the evaporator by performing the following procedure:
    1. Install the evaporator case assembly and the nuts and bolts.
    2.  
    3. Adjust the position of the evaporator assembly so the inlet and outlet connections are aligned with the heater and blower unit connections.
    4.  
    5. Install the drain hose. Connect the air conditioning wiring harness.
    6.  
    7. Install the inlet and outlet pipe grommets.
    8.  
    9. Install the glove box and the lower support bracket.
    10.  
    11. Using new O-rings, lubricate them with clean refrigerant oil and install them on the pipe fittings.
    12.  
    13. Connect the suction hose to the evaporator inlet fitting.
    14.  
    15. Connect the discharge hose to the evaporator outlet fitting.
    16.  
    17. Connect the heater control cables and fan motor wiring harness connectors.
    18.  

  4.  
  5. Install or connect the following:

    Instrument panel
     
    Radio and console assemblies
     
    Heater hoses in the engine compartment
     

  6.  
  7. Refill the cooling system.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Evacuate, charge and leak test the air conditioning system.
  12.  
  13. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  14.  

Outback



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
If equipped with an air bag system, wait 10 minutes after disconnecting the negative battery cable before performing any further work while the system fully de-energizes in order to avoid accidental deployment. All air bag system wiring is yellow. Do not use electrically powered test equipment on these circuits.

  1. Drain the cooling system into a clean container for reuse.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    LLC
     
    Heater hoses from the heater core. Plug the heater core and heater hoses.
     
    Bolts attaching the expansion valve and pipe in the engine compartment
     

  4.  
  5. Remove the instrument panel as follows:
    1. Remove the lower cover.
    2.  
    3. Remove the lower column cover and disconnect the harness.
    4.  
    5. Set the tires in the straight ahead position.
    6.  
    7. Using a T30 Torx® bit, remove the Torx bolts from either side of the steering wheel.
    8.  
    9. Slide the airbag module forward and disconnect the electrical connection. Remove the module and store in a safe area.
    10.  

  6.  


NOTE
Matchmark the steering wheel to shaft location, prior to removal.

  1. Steering wheel nut and use a puller to draw the wheel off of the shaft.
  2.  
  3. Remove the universal joint bolts and remove the joint.
  4.  
  5. If not already removed, remove the trim from under the instrument panel.
  6.  
  7. Remove the lower steering column cover screw.
  8.  
  9. Disconnect all electrical connectors from the column.
  10.  
  11. Remove the 2 bolts that secure the column to the instrument panel.
  12.  
  13. Remove the steering column.
  14.  
  15. Remove the glove box stopper and the glove box.
  16.  
  17. Remove the side panels from both sides.
  18.  
  19. Disconnect passenger air bag module from the support beam.
  20.  
  21. Remove the 3 bolts securing the passenger air bag module and remove the module.
  22.  
  23. Remove the shift knob.
  24.  
  25. Remove the tray the console box cover and the console box.
  26.  
  27. Remove the front trim pillar from both sides.
  28.  
  29. Remove the front pillar lower trim from the passenger side.
  30.  
  31. Set the temperature control switch toFULL HOT
  32.  
  33. Remove the instrument panel bolts, harness connectors and the panel.
  34.  

  1. Remove or disconnect the following:

    Keyless and CRU units
     
    Sunroof connector
     
    Servo motor connector
     
    Heater blower transistor connector
     
    Blower motor and in-vehicle temperature sensor connectors
     
    Intake unit bolts and nuts
     
    Drain hose from the intake unit
     
    Intake unit
     
    Heater unit case screws
     
    Heater core from the case
     

  2.  

To install:

  1. Install or connect the following:

    Heater core into the heater case. Secure it in place with the retaining screws.
     
    Drain hose to the intake unit
     
    Intake unit to its mounting position. Torque the mounting bolts to 48-84 inch lbs. (5-9 Nm).
     
    Blower motor and in-vehicle temperature sensor connectors
     
    Heater blower transistor connector
     
    Servo motor connector
     
    Sunroof connector
     
    Keyless and CRU units
     

  2.  
  3. Install the instrument panel as follows:
    1. Install the instrument panel, tighten the bolts and connect the harness connectors
    2.  
    3. Connect the control cable to the bottom of the heater unit. Do not move the switch and link during installation.
    4.  
    5. Install the front pillar lower trim to the passenger side.
    6.  
    7. Install the front trim pillar on both sides.
    8.  
    9. Install the console box, box cover and tray.
    10.  
    11. Install the shift knob.
    12.  
    13. Passenger side airbag module and tighten the 3 bolts securing the module.
    14.  
    15. Connect passenger air bag module to the support beam.
    16.  
    17. Install the side panels on both sides.
    18.  
    19. Install the glove box and stopper.
    20.  
    21. Install the steering column.
    22.  
    23. Install the 2 bolts that secure the column to the instrument panel. Tighten the bolts to 18 ft. lbs. (25 Nm).
    24.  
    25. Connect all electrical connectors to the column.
    26.  
    27. Install the lower steering column cover with the tilt lever held in the lowered position.
    28.  
    29. Install the universal joint. Align the bolt hole on the long yoke side of the joint with the cutout at the serrated section of the shaft end and insert the joint. Align the bolt hole on the short yoke side of the joint at the serrated section of the gearbox assembly and lower the joint completely. Temporarily tighten the bolt on the short yoke side and raise the joint to ensure the bolt is passing properly through the cutout. Tighten the bolt on the long yoke side, then the short yoke side to 17 ft. lbs. (24 Nm).
    30.  

  4.  


CAUTION
Make sure the joint bolt is tightened through the notch in the shaft serration. Do not over tighten the joint bolts as this can lead to heavy steering wheel operation. Make sure the clearance between the gearbox is over 0.59 inch (15mm).

  1. Making sure the wheels are still in the straight ahead position, turn the roll connector (A) clockwise until it stops. Then turn the roll connector pin (A) counterclockwise approximately 2.65 turns until the marks are aligned. Refer to the accompanying illustration for more detail.
  2.  
  3. Steering wheel, align the matchmarks made during removal and install the nut. Tighten the nut to 32 ft. lbs. (45 Nm). make sure the column cover-to- steering wheel clearance is 0.08-0.16 inch (2-4mm).
  4.  


    Click image to see an enlarged view

    Fig. Make sure the roll pin is properly aligned-Outback

  5. Drivers side airbag, engage the connector and tighten the fasteners.
  6.  


CAUTION
Insert the roll connector guide pin into the guide hole on the lower end of the surface of the steering wheel to prevent any damage. Draw out the airbag, horn and cruise control connectors from the guide hole of the steering wheel lower end.

  1. Connect any remaining connections and install the lower column cover.
  2.  
  3. Install the lower cover.
  4.  

  1. Install or connect the following:

    Bolts attaching the expansion valve and pipe in the engine compartment
     
    Heater hoses to the heater core after removing the plugs.
     
    LLC
     
    Negative battery cable
     

  2.  
  3. Refill the cooling system.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Evacuate, charge and leak test the air conditioning system.
  8.  
  9. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  10.  

SVX



  1. Disconnect the negative battery cable.
  2.  
  3. Disarm the air bag.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Tag and disconnect the heater hoses from the heater core in the engine compartment.
  8.  
  9. Remove the center console box assembly.
  10.  
  11. Remove the front pillar upper trim.
  12.  
  13. Remove the radio grounding wire.
  14.  
  15. Remove the remote controlled rearview mirror switch and internal bolt.
  16.  
  17. Remove the lower trim cover by removing the clips and bolts.
  18.  
  19. Disconnect the air bag harness at the harness spool.
  20.  
  21. Remove the plastic trim caps from both ends of the instrument panel, and remove the bolts.
  22.  
  23. Remove, tag and disconnect the instrument panel switches.
  24.  
  25. Unscrew and remove the visor. Disconnect the clock harness.
  26.  
  27. Remove the combination switch assembly.
  28.  
  29. Remove the glove box assembly.
  30.  
  31. Disconnect the instrument and body harnesses, as well as the antenna lead.
  32.  
  33. Cover the automatic transaxle select lever with cloth to avoid damage, if equipped with an automatic transaxle.
  34.  
  35. Remove the instrument panel by pulling it forward. Refer to Section 10 for removal and installation steps.
  36.  
  37. Remove the steering support beam.
  38.  
  39. Disconnect the door motor joint harnesses (mode, air mix door and sensor) from the heater unit.
  40.  
  41. Remove the aspirator hose.
  42.  
  43. Remove the evaporator and heater unit. Extract the heater core from the case.
  44.  
  45. Install the heater core to the heater unit, and install the case assembly.
  46.  
  47. Install the evaporator and the evaporator hose.
  48.  
  49. Install the remaining components in the reverse order of removal.
  50.  
  51. Connect the heater hoses.
  52.  
  53. Fill the cooling system with coolant, check for leaks.
  54.  
  55. Connect the negative battery cable.
  56.  

Removal And Installation
  1. Disconnect the negative battery cable.
    CAUTION
    If equipped with an air bag system, wait 10 minutes after disconnecting the negative battery cable before performing any further work while the system fully de-energizes in order to avoid accidental deployment. All air bag system wiring is yellow. Do not use electrically powered test equipment on these circuits.

  2.  
  3. Drain the cooling system into a clean container for reuse.
  4.  
  5. Disconnect the heater hoses from the heater core. Plug the heater core and heater hoses.
  6.  
  7. Remove the instrument panel by:

    Remove the center console assembly retaining screws and remove the center console.
     
    Remove the front A pillar upper trim pieces.
     
    Remove the radio grounding wire, which is screwed to the floor just behind the shifter assembly.
     
    Remove the power mirror switch and remove the bolt located behind it.
     
    Remove the lower driver's side instrument panel cover by removing the 6 clips and disconnecting the 3 connectors.
     
    Remove the instrument cluster lower cover by removing the retaining bolts.
     
    Disconnect the air bag assembly connector (YELLOW coated wires) at the bottom of the steering column.
     
    Remove the lower steering column cover. Remove the steering column-to-bracket bolts and lower the column.
     
    Remove the small bolt caps from both ends of the instrument panel and remove the bolts.
     
    Remove the 2 sets of instrument panel switches by pulling them from their mountings. Disconnect the electrical leads from the switches.
     
    Remove the instrument cluster visor assembly and remove the instrument cluster.
     
    Remove the 4 bolts from behind where the instrument cluster was. Remove the 5 bolts from inside the glove box.
     
    Disconnect the main harness connectors under the driver's side (6 connectors). Disconnect the 2 radio antenna leads.
     
    With the help of an assistant, remove the instrument panel by pulling it sharply forward, this will release the retaining pins from the top of the panel. Remove the panel from the vehicle.
     

  8.  
  9. Remove the steering support beam.
  10.  
  11. Disconnect the door actuator connectors from the heater unit.
  12.  
  13. Remove the aspirator hose.
  14.  
  15. Remove the evaporator case assembly by performing the following procedure:

    Discharge and recover the air conditioning system refrigerant.
     
    Disconnect the low and high pressure line from the evaporator outlet and cap the fittings.
     
    Remove the inlet and outlet pipe grommets.
     
    Remove the glove box and support bracket.
     
    Remove the time control unit and detach the fan control amplifier harness connector.
     
    Disconnect the air conditioning wiring harness from the evaporator. Disconnect the drain hose from the evaporator.
     
    Remove the evaporator mounting nut and bolt.
     
    Remove the evaporator case assembly from the vehicle.
     

  16.  
  17. Remove the heater core.
  18.  

To install:

  1. Install the heater core.
  2.  
  3. Install the evaporator by performing the following procedure:

    Install the evaporator case assembly and the nuts and bolts.
     
    Adjust the position of the evaporator assembly so the inlet and outlet connections are aligned with the heater and blower unit connections.
     
    Connect the fan control amplifier harness and install the time control unit.
     
    Install the drain hose. Connect the air conditioning wiring harness.
     
    Install the inlet and outlet pipe grommets.
     
    Install the glove box and the lower support bracket.
     
    Using new O-rings, lubricate them with clean refrigerant oil and install them on the pipe fittings.
     
    Connect the suction hose to the evaporator inlet fitting.
     
    Connect the discharge hose to the evaporator outlet fitting.
     

  4.  
  5. Install the aspirator hose.
  6.  
  7. Connect the door actuator connectors to the heater unit.
  8.  
  9. Install the steering support beam.
  10.  
  11. Install the instrument panel.
  12.  
  13. Connect the heater hoses to the heater core.
  14.  
  15. Refill the cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Evacuate, charge and leak test the air conditioning system.
  20.  
  21. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  22.  

Wrx



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  


CAUTION
If equipped with an air bag system, wait 10 minutes after disconnecting the negative battery cable before performing any further work while the system fully de-energizes in order to avoid accidental deployment. All air bag system wiring is yellow. Do not use electrically powered test equipment on these circuits.

  1. Drain the cooling system into a clean container for reuse.
  2.  
  3. Remove or disconnect the following:

    Bolts retaining the expansion valve and pipe
     
    Heater hoses from the heater core. Plug the heater core and heater hoses.
     
    Lower cover from the instrument panel
     
    Glove box
     

  4.  
  5. Remove the center console panel as follows:
    1. Remove lower panel and control wires.
    2.  
    3. Pull the control panel out and disconnect the connections.
    4.  

  6.  
  7. Remove the passenger side air bag module as follows:
    1. Disconnect the airbag connector from the support beam bracket and then unplug the connector.
    2.  
    3. Unfasten the 3 airbag module bolts and remove the module.
    4.  

  8.  
  9. Remove or disconnect the following:

    4 screws and two nuts then remove the lower console panel
     
    Hooks that retain the defroster panel
     
    Nuts and remove the electrical connections as shown in the illustration
     
    Instrument panel bolts and remove the panel
     
    Support beam
     
    Blower motor
     
    Heater core retainers
     
    Heater core
     

  10.  


    Click image to see an enlarged view

    Fig. Location of the lower cover retainers-WRX models



    Click image to see an enlarged view

    Fig. Location of the control unit control wires-WRX models



    Click image to see an enlarged view

    Fig. Location of the lower console panel retainers-WRX models



    Click image to see an enlarged view

    Fig. Loosen the hooks that retain the defroster panel-WRX models



    Click image to see an enlarged view

    Fig. Disconnect the two electrical connections after removing the console panel-WRX models



    Click image to see an enlarged view

    Fig. Location of the instrument panel bolts-WRX models



    Click image to see an enlarged view

    Fig. Location of the heater core retainers-WRX models


To install:

  1. Install or connect the following:

    Heater core
     
    Heater core retainers
     
    Blower motor
     
    Support beam
     
    Instrument panel and tighten the bolts
     
    Electrical connections and tighten the nuts
     
    Hooks to the defroster panel
     
    Lower console panel and tighten the 4 screws and two nuts
     

  2.  
  3. Install the passenger side air bag module as follows:
    1. Install the module and tighten the 3 airbag module bolts.
    2.  
    3. Connect the airbag connector and then attach it to the support beam bracket.
    4.  

  4.  
  5. Install the center console panel as follows:
    1. Attach the control panel connections and insert the panel into position.
    2.  
    3. Install the lower panel and control wires.
    4.  

  6.  
  7. Install or connect the following:

    Glove box
     
    Lower cover to the instrument panel
     
    Heater hoses to the heater core
     
    Bolts retaining the expansion valve and pipe
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Evacuate, charge and leak test the air conditioning system.
  14.  
  15. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  16.  


    Click image to see an enlarged view

    Fig. When installing the instrument panel, push the hook into grommet (A) on the body panel-WRX models


 
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