HEATER AND VENTILATOR SUBARU. 1992 SERVICE MANUAL M. MECHANISM AND FUNCTION 1, Outline 2, Control Unit 3, Mode Door Control... 4, Intake Door Control 5, Blower System... S$ SPECIFICATIONS AND SERVI © COMPONENT PARTS 1. Heater System 2. Heater Unit 3. Intake Unit 4, Control Unit W SERVICE PROCEDURE . 1. Heater Unit 2, Blower Motor Assembly 3, Control Unit 4,Mode Door Motor 5. Intake Door Motor 6, Temperature Control Cable .IM100} HEATER AND VENTILATOR M MECHANISM AND FUNCTION 1. Outline The heater control unit is located in the middle portion of the instrument panel. The heater unit is provided with mode doors and an air mix door, The intake unit is provided with an intake door and blower motor. The heater unit and the intake unit are regulated by their control units. Fresh outside air is introduced into the compartment through the center and side ventilator grilles when the Fresh outside air can also be introduced through the side vents on the driver's and passenger's sides by the ram pressure produced while the vehicle is running. Ahigh performance heater system is adopted. All mod- els are equipped with the front side window defroster and some models are further equipped with the rear heater duct. ventilator fan is operated. FRESH AA tate RecrRcuanoN > A Vent door an B Heater door © Detroster door D. Air mix door E By-pese doar F Intake door Blowor ten Side ventlator leat a TI outer & (oiver's sce) ‘Sia ventator ov, enter outst outlet (Passenger side) Basse Fig. 7HEATER AND VENTILATOR (Mi01]_ 4-6 1. SYSTEM FLOW Push control ype Mode door motor Vent door — Mode switch (Mode lover rf }- Hester door ~ ‘ut Recks. switch L_.| Det. door 4 | intake doer motor |e} intake door | Intake Temp. control lever ‘Outet air Air mix door | verre Ba-15874-6 [M102] HEATER AND VENTILATOR 2. AIR FLOW Switch ‘Swieh position ates, positon HEAT DEF a eiiev > “ oer Wear Heater contol (Push control type) Fig. 3 He O (UD. Tempore conver a Tne ont {lever corto} 9p) Ce sen ‘Ne owen Tempereture controller 24-1868HEATER AND VENTILATOR ' 3, AIR DISTRIBUTION RATIO Figure shows air distribution ratios corresponding to ‘mode selector switch or lever positions. a) bution ratio VENT Biev HEAT —DEFIMEAT per a a ad a @ Sinteh poston (winout rar ove Arden tla te $00, wo. © a. 20 oO 4 ; VENT -GLLEV. EAT —_—_DEFINEAT ber i a a wi a @ Switch portion | perse7.4-6_IM2ay HEATER AND VENTILATOR 2. Control Unit q A: SCHEMATIC 1. PUSH CONTROL TYPE Os Ow [——? Set”? 3 Sl] ever ry Wi switch Fan reiny sour Mey Y) motor Bunion q ier tury edu ery ee oF Cc *®@ ae = h veh | J @ . i t 11E2 i He x | ‘ j j 4] 6) ® | Areal | wruiutuil | fy tli! uJ OF Hi | oe oer | OF, | wear | YET] [vent] wc [h : eee 2 : 7 - a ‘A/C: Air conditioner seiton F/R: Rect switen Fig. 5 ‘HEATER AND VENTILATOR [M2A2]_ 4-6 ase | ' 2, LEVER CONTROL TYPE OB [ Oise ri =i 0 fe He nh oe bail lumination AG bust ine be fo | falls, node ul ey = reas = £ rc nF ney yee | 8 63 3 Tai ieee = am iT 7 | TU j Le! | ¥ ‘AVG: Air eonetloner switch FIR: Reclre ewitcn 84-15604-6 [M280] B: FUNCTION PUSH CONTROL TYPE HEATER AND VENTILATOR Lever control type differs from push control type in that it Is provided with @ MODE fever. Functional features for the two types are the samo. [ror wetasron swe eure | Sp | 5 amen | # | | od | GS] 7 VENT oer ourcer | VENT | wear | NEAT | neat baal ‘When Gol Want ich pu, em ou ot newanxs | veh acute ced by made wheter pach ine enone TEMPERATURE CONTROL LEVER ‘Outlet ae tempacature a variably controled rom (COLO to HOT by air nix door end cole, ‘are SWITCH woiator | +N OFF ‘COMPRESSOR REMARKS | puthed, lndeator fd compramor utr on. ‘Comprasor shay be turned off by thermo contr van though AIC Indicator ight. Fig. 7 INDICATOR ow oFF INTAKE DOOR. Recine FRESH POSITION FAN swITCH POSITION FAN (OPERATION on ‘Fon weed iscontroted REMARKS fom te to 4th spre. 841598) 3, Mode Door Control GENERAL HEATER AND VENTILATOR IM3A0] 4-6 The mode door motor is located .on the right side of the heater unit. It opens and closes the vent, heater and defroster doors through side links. wor HEAT: ere vent ‘Mode door motor VENT Position B/L Position HEAT Position x D 1 a . a 1 fof fo OFT terse © VENT ber b DEF + VENT HID Position Beti59 Fig. 8[M3Bi] B: OPERATION 1, DRIVE CIRCUIT ‘The drive circuit rotates the servo motor in the standard or reverse direction, according to the input of contact plates A or B built into the motor. HEATER AND VENTILATOR 2. SWITCHING FROM THE VENT TO THE DEF MODE When the DEF switch is turned to “ON”, current flows from movable contact A to contact plate A so that input Ais grounded (current = 0). Atthis point, input Bis not grounded (current = 1), As a result, output from the drive circuit is “0” in relation to “C” (grounded) and “1” in relation to “D". Current flows so that the damper moves from the VENT to the DEF mode. After the servo motor has rotated, the movable contact, plate Amoves away from contact plate C. This stops the motor setting the system in the DEF mode. current D Contact plate’ DEF ewiteh jovable contact 4.1160 Fig. 9 3. SWITCHING FROM THE DEF TO THE VENT MODE When the VENT switch is turned to “ON”, current flows from movable contact B to contact plate B so that input Bis grounded (current = 0). At this point, input A is not grounded (current = 1). ‘As a result, output from the drive circult is “1” in relation to “C” and “0” in relation to “D”, Current @ flows so that the damper moves from the DEF to the VENT mode, After the servo motor has rotated the movable contact, plate B moves away from contact plate C. This stops the motor setting the system in the VENT mode. o Batter Fig. 10 104-6 [M500] HEATER AND VENTILATOR 5. Blower System Operation of the blower relay is controlled by turning ‘ON and OFF the ignition switch. When the ignition switch is ON and the fan switch is operated from Tetto 4th speed, electric current from the bettery goos through the blower motor, the resistor, the fan switch and ground. The resistor is switched by the position of tho fan ewitch, and controls the blower motor speed from 1st to 4th. Tenee tl cc ‘BLOWER MOTOR. a @) RESISTOR 68) ow arene 4.1164 Fig. 12 12HEATER AND VENTILATOR {m4oo}_4-6 Ya Intake Door Control Intake door motor is located on the upper part of the intake unit, It opens and closes the intake door with a rod and link. When the RECIRC switch is set to ON (the RECIRC indicator lights), the ground line of the intake door motor is switched to terminal 2 from terminal 1. ‘And the motor starts to rotate because the position switch contacts built into it are set to the current flow ‘rane coon woroR position. The contacts turn slong with the motor. When they reach the non-contacts flow position, the motor bali “sen mina will stop. The motor always turns in the same direction. ittemorar "88807 | When the RECIRC switch is set to OFF (the RECIRC indi- cator does not light), follow the same ope b4.1160| Fig. 17 "13 HEATER AND VENTILATOR [soao} 4-6 A: SPECIFICATIONS tem ‘Spectications Conation [+ Node selector switch a Temp. corirallover_; Full Rot loting ca = Temperature defor. Heating capacity 4.905 wv 200 ken 16.680 Tum [Temperate dtr. water andl inate +360 0h (96.1 US gal Hot water fow rao. * 260, (98.1 US 9 ‘ic fiow rate 300 mh (10,688 ou tur) Mode satoctor switch: HEAT @ Tomperature eon- , Sanne + Full cold Y [Max sie ov rato 480 enh (16,949 cu fn) Blower fan speed: ath postion Mode selector eae 2 VENT Hester core ize 15985 x 180x 32mm {height x long x width x thickness) (6.28 x 7.08 x 1.28 io) a Type [Magnet mator 20 W or less at i28V, Blower motor Fan type & Size (lar-| Sirocco fan type. a tor x with) 140% €5 men (6.51 x 256 in)4-6 [C100] HEATER AND VENTILATOR C COMPONENT PARTS 1. Heater System Fig. 13 44 Hontor hose (let) 5 Honter hose (Outen) 8 Clamp a 9 Roar neater duct 10. Roar ai vert ASSY Qe 4.1537HEATER AND VENTILATOR [e200] 4-6 2. Heater Unit 1 Packing 2 Mode door motor Fig. 144-6 (C300) HEATER AND VENTILATOR 3. Intake Unit Fig. 15 16 4 inser door 2 Lover (For Auto A/C) 3. take lover 4% Iniake camper 5 Shatt 6 Pate 11 lp 12 Blowor moter end fan4. Control Unit & 6 g e 8 5 z Heater contol cable 4.1899 Fig. 16 74-6 [C402] HEATER AND VENTILATOR. 2. LEVER CONTROL TYPE 1 Heater control cable 2 Heater control lover 9 Swlich lover 4 aso 15 Sub hemos Fan switch 7 Outer case 8 Swich ASSY 16. Switch lever Fig. 17 PeeW_ SERVICE PROCEDURE 1. Heater Unit A: REMOVAL 1) Remove heater hoses (inlet, outlet) in engine com- partment, Drain es much coolant from hester unit es possible, ‘nd plug disconnected hose with cloth. 2) Disconnect temperature control cable and door ‘motor joint connectors (mode, intake) from heater unit, and intake unit. 3) Remove instrument panel and console box. (Refer to 6-4.) 4) Remove cooling unit ASSY. (Refer to 4-7.) 5) Remove heater duct. 6) Remove heater unit. 84-1540 Fig. 18 HEATER AND VENTILATOR (W2A0] 4-6 B: INSTALLATION Installation is in the reverse order of removal. Fitted length of heater hose over pipe: 20 ~ 25 mm (0.79 — 0.98 in) Heater unit mounting bolt tightening torque: 5.4 — 9.3 Nem (0.55 — 0.95 kg-m, 4.0 — 6.9 ft-lb) 2. Blower Motor Assembly ‘A: REMOVAL 1) Remove glove box and stay. 2) Remove heater duct. (or cooling unit for A/C equipped vehicles.) 3) Disconnect intake door motor harness connector. 4) Disconnect blower motor harness connector. bati71 Fig. 19 §) Remove blower motor mounting bolts and nuts. 6) Remove blower motor assembly. bat1726 _{W3A0] HEATER AND VENTILATOR Unfasten locks on each side of controt 3. Control Unit ection of the arrow, and remove control base from A: REMOVAL control box, 41) Remove temperature control cable from heater unit. 2) Remove visor A. (Refer to chapter “INSTRUMENT PANEL”) 3) Disconnect push control unit harness connectors. 4) Remove push control unit assembly. Fig. 23 5) Remove fan switch. q 4.1541 B: DISASSEMBLY “Control bsse (Lower! 1) Remove the two control knobs. 2) Remove the switch knobs, ‘While pushing the switch knob locking retainer with a pointed pin driver, remove switch knob in the direction of the arrow. cro Fig. 24 6) Remove temperature control cable and lever. 7) Remove illumination bulbs, Fig. 22 {Warination bua D 3) Disconnect push control sub hamess connector. 4) Remove control base. Fig. 25 20HEATER AND VENTILATOR {wapo]_4-6 SL ’ C: INSPECTION - 2, CONTROL UNIT 4. FAN SWITCH 4) Ignition switch is tumed OFF. - 2) Disconnect connector from control unit. FeeR GR TTNURY betwaen torminale at each switch 5) He ciroult continulty betwaen each terminal, ~ when push contro! switch (mode, recire switch) is Terminal Na, turned ON, Switch poston OF 1 2 a 4 ’ Mae whet awh 2 eae awn | AC, Leo, ‘Terminal cnr Mode | REcinc vewr | YENT | usar | MEAT | oer | lve | pec | racaw | on | sete | SEES | ae coled) “ - © ® Q ® ) © ® 2 3 t © Ec ® 6 g To oT 9 ® 6 ¢ |e T e6 @ o o 6 @ @ 11 Each ewitzh (modo and roi) i turned ON. '*2 Used only push control type, D: ADJUSTMENT Pull 1) Operate temperature control lever to “FULL COLD.” 2) Install control cable to lever, While pulling outer Z cable, secure control cable with a clamp. Y ® ‘control eable 4279]4-6 _[W3E0] HEATER AND VENTILATOR E: ASSEMBLY INSPECTION Assembly i in the reverse order of disassembly. 1) Check the mode door motor operation. When ‘approx. 12V is applied to the mode door motor terminals, mode door motor operates as follows. 3) Remove screws which secure mode door motor to heater unit. 4) Using a screwdriver, remove rod holder 8) While rotating mode door motor, remove it from rod holder. Fig. 27 Ensure mode select or switch is set to “VENT” (to sot side link in the vent position) when removing mode door motor. : \LLATION F: INSTALLATIO! a ar door Installation is in the reverse order of removal. 1 2)slalslel7 motor (Refer to 4-6 [W6A0].) position 4) | +) | VENT 4, Mode Door Motor o erty] OReV ‘A: REMOVAL eel o (1 [ey | Hear supely HEAT -) ye) oer 1) Remove lower cover from instrument panel. 2) Disconnect mode door motor harness connector. i a C: INSTALLATION 1) Connect mode door motor to harness connector. 2) Turn ignition switch to “ACC” and set mode select or switch to “VENT”. Ensure that mode door motor is set in the vent modi 3) Install mode door motor on heater unit. 4) Manually operate side link to the vent mode position, and secure rod to rod holder. 5) Set mode selector switch to “DEF”, and ensure that side link moves over its full stroke range. Fig. 28 22 0HEATER AND VENTILATOR {W6A0] ’ 5. Intake Door Motor 6) Operate mode selector switch to ensure that system changes from Inteke air to “RECIRC” and from A: REMOVAL “RECIRC” to intake air in full-stroke range. 1) Remove glove box. 2) Remove side cover from instrument panel. 3) Remove intake unit ASSY from the vehicle. 4) Remove screws which secure intake door motor to intake unit ASSY. 4283] Fig. 30 6. Temperature Control Cable A: ADJUSTMENT Bie Fig. 28 1) Operate temperature control lever to “FULL COLD”, 5) Remove intake door motor and harness as a unit, 2) Connect control cable to air mix door link, 6) Disconnect harness from intake motor. 3) While pushing outer cable in the direction of the Ensure that RECIRC switch is set to “ON”. arrow, secure control cable to clamp. INSPECTION ‘When approx. 12V is applied to the intake door motor terminals, intake door motor operates as follows. frtsko | Torminal door motor Intake door moter operation or elo position Frosh | @ | @_| Boor motor moved to Rese postion Recire @ | Boor motor moved to Fresh postion Fig. 31 4) Operate temperature control lever to ensure that it C: INSTALLATION and air mix door link complete their full stroke ranges. (Refer to 4-6.) 1) Connect harness to intake door motor. 2) Turn ignition switch to “ACC” and set RECIRC ewitch to"ON" switch to “RECIRC”. Ensure that intake door motor is se! mode. 3) Install intake door motor on intake unit. 4) Secure rod holder to link, and install link to intake unit ASSY. 5) Manually set rod in the “RECIRC” mode, and secure to rod holder. the “RECIRC” 23