Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Evaporator Core

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REMOVAL & INSTALLATION



Justy

Consult an authorized Subaru dealer for Justy A/C service. Because the air conditioner on the Justy is dealer installed as opposed to factory installed, there are several different A/C systems in these vehicles, each requiring a different removal and installation technique.

Sedan, Coupe, Loyale, XT, Wagon and Brat

See Figures 1, 2 asnd 3

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Fig. Fig. 1: Evaporator assembly and case-Sedan, Coupe, Loyale, XT, Wagon and Brat



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Fig. Fig. 2: Disconnecting the suction and discharge lines-Sedan, Coupe, Loyale, XT, Wagon and Brat



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Fig. Fig. 3: To separate the case halves, remove the metal clips from around the assembly-Sedan, Coupe, Loyale, XT, Wagon and Brat

  1. Open the hood and remove the spare tire, if necessary.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly discharge the air conditioning system using an approved recovery/recycling machine.
  6.  
  7. Tag and disconnect the evaporator discharge pipe, suction pipe and grommets. Remove and discard the rubber O-rings.
  8.  
  9. Remove the evaporator core under cover.
  10.  
  11. Remove the pocket assembly from the dash.
  12.  
  13. Disconnect the wire harness from the evaporator case.
  14.  
  15. Remove the 2 retaining bands and remove the evaporator case.
  16.  
  17. Using a suitable prytool, remove the retainer clips around the evaporator case halves, then separate the sections to access the evaporator assembly.
  18.  

To install:
  1. Position the evaporator core in one of the halves of the case assembly. Close the evaporator case halves, and install the retainer clips around the assembly to secure the sections together.
  2.  
  3. Install the evaporator case in the vehicle, and secure in place using the retainer bands.
  4.  

When installing the evaporator into the car body, make sure the wiring harness and any vacuum hoses do not get caught between the body parts.

  1. Attach the wire harness to the evaporator case.
  2.  
  3. Install the pocket to the dash panel.
  4.  
  5. Install the suction and discharge pipes, using new O-rings coated with clean refrigerant oil. Tighten the discharge pipe to 7-14 ft. lbs. (10-20 Nm), the nut on the suction side to 14-22 ft. lbs. (20-29 Nm).
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Properly charge the A/C system using an approved recovery/recycling machine.
  10.  

Legacy, Impreza and SVX

See Figures 4, 5 and 6

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Fig. Fig. 4: Evaporative case and core assembly-Legacy, Impreza and SVX



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Fig. Fig. 5: Evaporative case and retainer nut and bolt under dash panel-Legacy and Impreza



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Fig. Fig. 6: Evaporative case and retainer nut and bolts-SVX

  1. Disconnect the negative battery cable.
  2.  


CAUTION
Properly disarm the air bag on vehicles equipped with the SRS system.

  1. On models equipped with an air bag, properly disarm the air bag. This is necessary because the air bag harness is routed in front of the evaporative case, and must be disconnected for case removal and installation.
  2.  
  3. Properly discharge the refrigerant system using an approved recovery/recycling machine.
  4.  
  5. Disconnect and plug the discharge and suction pipes in the engine compartment. Remove the grommets and rubber O-rings. Discard the O-rings
  6.  
  7. Disconnect the air bag harness routed in front of the evaporator case.
  8.  
  9. Remove the glove box assembly and remove the bolts retaining the metal glove box support bracket.
  10.  
  11. Disconnect the electrical leads from the evaporator case.
  12.  
  13. Disconnect the drain hose from the case.
  14.  
  15. Remove the evaporator case mounting nut and bolts, then remove the evaporator case from the vehicle.
  16.  
  17. Separate the case using a small prytool to remove the metal clips that retain the case halves.
  18.  
  19. Open the case halves and remove the core assembly.
  20.  

To install:
  1. Install the core assembly in 1 / 2 of the case. Attach the other 1 / 2 of the case, and secure together with the retainer clips.
  2.  
  3. Position the evaporator case assembly into the vehicle and install the mounting nut and bolts. Tighten the nut and bolts to 7 ft. lbs. (10 Nm).
  4.  
  5. Reconnect the electrical leads and the drain tube.
  6.  
  7. Install the glove box assembly support and the glove box.
  8.  
  9. Connect the suction and discharge lines in the engine compartment. Coat the new O-rings lightly with refrigerant oil and tighten the connections. Tighten the nut on the discharge side to 18 ft. lbs. (25 Nm) and the nut on the suction side to 7 ft. lbs. (10 Nm).
  10.  
  11. Connect the negative battery cable and properly charge the air conditioning system. Using an approve recovery/recycling machine.
  12.  

 
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