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2004 FORESTER SERVICE MANUAL

QUICK REFERENCE INDEX

ENGINE SECTION 1

This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reassembling, inspection and adjustment of
components and diagnostics for guidance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.

FUEL INJECTION (FUEL SYSTEM)

FU(H4SO)

EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICE)

EC(H4SO)

INTAKE (INDUCTION)

IN(H4SO)

MECHANICAL

ME(H4SO)

EXHAUST

EX(H4SO)

COOLING

CO(H4SO)

LUBRICATION

LU(H4SO)

SPEED CONTROL SYSTEM

SP(H4SO)

IGNITION

IG(H4SO)

STARTING/CHARGING SYSTEM

SC(H4SO)

ENGINE (DIAGNOSTIC)

EN(H4SO)

All information, illustration and specifications contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.

G8080GE2

COOLING

CO(H4SO)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Page
General Description ....................................................................................2
Radiator Fan System ................................................................................13
Engine Coolant..........................................................................................19
Water Pump ..............................................................................................21
Thermostat ................................................................................................26
Radiator.....................................................................................................28
Radiator Cap .............................................................................................34
Radiator Main Fan and Fan Motor ............................................................35
Radiator Sub Fan and Fan Motor..............................................................40
Reservoir Tank..........................................................................................41
Coolant Filler Tank ....................................................................................42
Engine Cooling System Trouble in General ..............................................43

General Description
COOLING

1. General Description
A: SPECIFICATION
Model
Cooling system

2(US qt, Imp qt)

Total engine coolant capacity

Type
Discharge performance I

Discharge performance II
Water pump
Discharge performance III

Thermostat

Discharge
Pump speed — Discharge
pressure
Engine coolant temperature
Discharge
Pump speed — Discharge
pressure
Engine coolant temperature
Discharge
Pump speed — Discharge
pressure
Engine coolant temperature

Impeller diameter
Number of impeller vanes
Pump pulley diameter
Standard
Clearance between
impeller and case
Limit
“Thrust” runout of impeller end
Type
Starts to open
Fully opened
Valve lift
Valve bore

Non-turbo
Turbo
Electric fan+Forced engine coolant circulation system
2.0L with ATF warmer:
Approx. 6.9 (7.29, 6.07)
2.0L AT:
AT:
Approx. 6.5 (6.87, 5.72)
Approx. 7.3 (7.71, 6.42)
2.0L MT:
MT with oil cooler:
Approx. 6.6 (6.98, 5.81)
Approx. 7.3 (7.71, 6.42)
2.5L AT:
MT without oil cooler:
Approx. 6.8 (7.19, 5.98)
Approx. 7.4 (7.82, 6.51)
2.5L MT:
Approx. 6.9 (7.29, 6.07)
Centrifugal impeller type
202 (5.3 US gal, 4.4 Imp gal)/min.
760 rpm — 2.9 kPa (0.3 mAq)
85°C (185°F)
1002 (26.4 US gal, 22.0 Imp gal)/min.
3,000 rpm — 49.0 kPa (5.0 mAq)
85°C (185°F)
2002 (52.8 US gal, 44.0 Imp gal)/min.
6,000 rpm — 225.4 kPa (23.0 mAq)
85°C (185°F)
76 mm (2.99 in)
8
60 mm (2.36 in)
0.5 — 0.7 mm (0.020 — 0.028 in)
1.0 mm (0.039 in)
0.5 mm (0.020 in)
Wax pellet type
80 — 84°C (176 — 183°F)
76 — 80°C (169 — 176°F)
95°C (203°F)
91°C (196°F)
9.0 mm (0.354 in) or more
35 mm (1.38 in)

Main fan

70 W

Motor

2.0L AT (K4★1) : 70 W
2.0L AT (EC, EK★1) :
120 W
2.0 L MT: 70 W
2.5 L: 120 W

2.0L AT (K4★1) : 70 W
2.0L AT (EC, EK★1) :
70 W
120 W
2.0 L MT: 70 W
2.5 L: 120 W
320 mm (11.81 in)×5 (main fan)
320 mm (11.81 in)×7 (sub fan)

Radiator fan
Sub fan

Fan diameter×Blade

CO(H4SO)-2

General Description
COOLING
Type
Core dimensions

Width×Height×Thickness

Radiator
Pressure range in which cap valve is open

Fins
Reservoir
tank
★1:

Capacity

Down flow, pressure type
691.5×360×16 mm
(27.22×14.17×0.63 in)
Above: 108±15 kPa
(1.1±0.15 kg/cm2, 16±2 psi)
Below: −1.0 to −4.9 kPa
(−0.01 to −0.05 kg/cm2, −0.1 to −0.7 psi)
Corrugated fin type
0.52 (0.5 US qt, 0.4 Imp qt)

For option code, refer to ID section. <Ref. to ID-2, Identification.>

CO(H4SO)-3

General Description
COOLING

B: COMPONENT
1. WATER PUMP
• NON-TURBO MODEL

(1)

T1

(2)

(3)

T1

(4)

(5)

(6)

T2

CO-00001

(1)
(2)
(3)
(4)

Water pump ASSY
Gasket
Heater by-pass hose
Thermostat

(5)
(6)

Gasket
Thermostat cover

Tightening torque: N⋅m (kgf-m, ft-lb)
T1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T2: 6.5 (0.66, 4.8)

CO(H4SO)-4

General Description
COOLING

• TURBO MODEL

T2

(5)
(8)

(4)
T2
T1

T1
(3)

(7)
(6)

(2)
T2
(1)

CO-00002

(1)
(2)
(3)
(4)

Thermostat cover
Gasket
Thermostat
Water pump ASSY

(5)
(6)
(7)
(8)

Gasket
Heater by-pass hose
Coolant filler tank by-pass hose
Water by-pass pipe

CO(H4SO)-5

Tightening torque: N⋅m (kgf-m, ft-lb)
T1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T2: 6.5 (0.66, 4.8)

General Description
COOLING

• MODEL WITH ATF WARMER

T2

(5)
(8)

(4)

T1

T1
(3)

(7)
(6)

(2)
T2
(1)

CO-02006

(1)
(2)
(3)
(4)

Thermostat cover
Gasket
Thermostat
Water pump ASSY

(5)
(6)
(7)
(8)

Gasket
Heater by-pass hose
Coolant filler tank by-pass hose
Water by-pass pipe

CO(H4SO)-6

Tightening torque: N⋅m (kgf-m, ft-lb)
T1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T2: 6.5 (0.66, 4.8)

General Description
COOLING

2. RADIATOR AND RADIATOR FAN
• NON-TURBO MODEL

A
(8)

T5

T2

(7)
(12)

(6)

(5)
(14)

(5)
T3

(10)

(4)
(9)

T1

(11)

(3)
(23)

(2)

A
(15)

(22)
T4

(17)

T3

T1
(5)
T4

B

(13)
(21)
(15)

C

(16)

T2
(1)

(15)
(19)

(18)

B
(15)

(15)
(15)

C
(20)
CO-00003

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)

Radiator lower cushion
Radiator
Radiator upper cushion
Radiator upper bracket
Clamp
Radiator inlet hose
Engine coolant reservoir tank cap
Overflow hose
Engine coolant reservoir tank
Radiator sub fan shroud

(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)

Radiator sub fan
Radiator sub fan motor
Radiator main fan
Radiator main fan motor
ATF hose clamp (AT model)
ATF inlet hose A (AT model)
ATF outlet hose A (AT model)
ATF pipe (AT model)
ATF inlet hose B (AT model)
ATF outlet hose B (AT model)

CO(H4SO)-7

(21)
(22)
(23)

Radiator outlet hose
Radiator drain plug
Radiator cap

Tightening torque: N⋅m (kgf-m, ft-lb)
T1: 4.4 (0.45, 3.3)
T2: 7.5 (0.76, 5.5)
T3: 18 (1.8, 13.0)
T4: 3.4 (0.35, 2.5)
T5: 4.9 (0.50, 3.6)

General Description
COOLING

• TURBO MODEL
(24)
(27)
(23)

(25)
(5)

(5)

(7)

(8)

T2

(6)
(5)

(5)

T5
(12)

T3

(9)

(10)
(14)

(4)
(11)

(3)

T1

(17)
(15)
T3

T4

(2)
(22)

(18)

T4

(15)

T1

(5)

(16)

T2

(15)

B

B

(13)

(19)
C

(21)
(29)

(5)

C

T3

(28)

(15)
(15)

(26)

(33)
(34)

(20)
T5

(35)
(15)

(1)
B

T2

(30)
(35)

(33)
(34)

(31)
C
(15)

(32)

CO(H4SO)-8

CO-00140

General Description
COOLING
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)

Radiator lower cushion
Radiator
Radiator upper cushion
Radiator upper bracket
Clamp
Radiator inlet hose
Engine coolant reservoir tank cap
Over flow hose
Engine coolant reservoir tank
Radiator fan shroud
Radiator sub fan
Radiator sub fan motor
Radiator main fan
Radiator main fan motor
ATF hose clamp (AT model)
ATF inlet hose A (AT model)
ATF outlet hose A (AT model)

(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)

ATF pipe (AT model)
ATF inlet hose B (AT model)
ATF outlet hose B (AT model)
Radiator outlet hose
Radiator drain plug
Engine coolant filler tank
Engine coolant filler tank cap
Engine overflow hose
Radiator under cover (AT model)
Engine air breather hose
Oil cooler inlet hose A (MT model
with oil cooler)

(29)

Oil cooler outlet hose A (MT
model with oil cooler)

(30)

Oil cooler pipe (MT model with oil
cooler)

CO(H4SO)-9

(31)

Oil cooler inlet hose B (MT model
with oil cooler)

(32)

Oil cooler outlet hose B (MT
model with oil cooler)

(33)
(34)

Spacer (MT model with oil cooler)
Cushion (MT model with oil
cooler)

(35)

Setting washer (MT model with oil
cooler)

Tightening torque: N⋅m (kgf-m, ft-lb)
T1: 4.4 (0.45, 3.3)
T2: 7.5 (0.76, 5.5)
T3: 18 (1.8, 13.0)
T4: 3.4 (0.35, 2.5)
T5: 4.9 (0.50, 3.6)

General Description
COOLING

C: CAUTION
• Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
• Remove contamination including dirt and corrosion before removal, installation or disassembly.
• Keep the disassembled parts in order and protect them from dust or dirt.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
• Be careful not to burn your hands, because each
part in the vehicle is hot after running.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or rigid racks at the specified
points.
• Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.

CO(H4SO)-10

General Description
COOLING

D: PREPARATION TOOL
1. NON-TURBO MODEL
ILLUSTRATION

TOOL NUMBER
499977400
(2.0 L model)

DESCRIPTION
CRANK PULLEY
WRENCH

REMARKS
Used for stopping crank pulley when loosening
and tightening crank pulley bolts.

499977100
(2.5 L model)

CRANK PULLEY
WRENCH

Used for stopping crank pulley when loosening
and tightening crank pulley bolts.

18231AA010

CAM SPROCKET
WRENCH (For left
side)

• Used for removing and installing cam sprocket
(LH).
• Also the CAM SPROCKET WRENCH
(499207100) can be used.

CAM SPROCKET
WRENCH (For right
side)

Used for removing and installing cam sprocket
(RH).

ST-499977400

ST-499977100

ST18231AA010

499207400

ST-499207400

CO(H4SO)-11

General Description
COOLING

2. TURBO MODEL
ILLUSTRATION

TOOL NUMBER
499977400
(2.0 L model)

DESCRIPTION
CRANK PULLEY
WRENCH

REMARKS
Used for stopping crank pulley when loosening
and tightening crank pulley bolts.

499977100
(2.5 L model)

CRANK PULLEY
WRENCH

Used for stopping crank pulley when loosening
and tightening crank pulley bolts.

499977500

CAM SPROCKET
WRENCH

Used for removing and installing cam sprocket.
(Intake)

499207400

CAM SPROCKET
WRENCH

Used for removing and installing cam sprocket.
(Exhaust)

ST-499977400

ST-499977100

ST-499977500

ST-499207400

CO(H4SO)-12

Radiator Fan System
COOLING

2. Radiator Fan System
A: WIRING DIAGRAM
SBF-1
A/C RELAY HOLDER
1

*1

IGNITION SWITCH

SBF-4

NO.17

BATTERY

2

B72

3

*1

NO.18

4
28

SUB
FAN
RELAY

25
27
LHD

RHD

29

*1

31
MAIN
FAN
RELAY-1

: KA TURBO MODEL AND
EC,EK TURBO AT MODEL : 30A
EXCEPT KA TURBO MODEL AND
EC,EK TURBO AT MODEL : 20A

34

*2

32
30

LHD

: LHD MODEL : (GRAY)

RHD
TA

TA

: TURBO AT MODEL

ET

ET

: EXCEPT TURBO
AT MODEL

TB

: TURBO MODEL

9
F2
7

11

7

19

F2

5

10

FAN
MODE
RELAY

B100

B100

8
6
F27

LHD

RHD

NA

TB

NA : NON-TURBO
MODEL

RHD

LHD

E
NA

B25
B24

TB

MAIN FAN MOTOR
(EXCEPT TURBO AT MODEL)

B: B135
ECM
(TURBO MODEL)

A14

2

A: B134

ET
TA

A13

1

SUB FAN MOTOR
(EXCEPT TURBO AT MODEL)
TA

ET
ET

2

TA

F17

ECM
(NON- TURBO MODEL)

MAIN FAN MOTOR
(TURBO AT MODEL)

1

ET
TA

1

F16
SUB FAN MOTOR
(TURBO AT MODEL)

2
F17
1
2
F16
F16

(GRAY) : TA

F17

(GRAY) : TA

1 2

F16

(BLACK) : ET

F17

(BLACK) : ET

F2
1 2 3 4
10 11 12 13 14

(BLUE) : LHD

5 6 7 8 9
15 16 17 18 19 20

F2

(BLUE) : RHD

1 2 3 4 5
6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22

2 1
F27
A: B134

*

2

1 2
3 4
5 6
7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
24 25
26 27 28 29
30 31 32 33
34 35

1

2

3

4

5 6 7 10 15 16 17 20 25 26 27 30
8
11
21
18
31
28
9 12 13 14 19 22 23 24 29 32 33 34
A/C RELAY HOLDER

CO(H4SO)-13

B: B135
1 2
3 4 5 6 7
8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35

B72
35
36

1 2
3 4

CO-02003

Radiator Fan System
COOLING

B: INSPECTION
DETECTING CONDITION:
• Engine coolant temperature is above 95°C (203°F).
• Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOM:
Radiator main fan and sub fan does not rotate under the above conditions.

1

2

3

4

5

Step
CHECK OPERATION OF RADIATOR FAN.
1) Connect the test mode connector.
2) Turn the ignition switch to ON.
3) Using Subaru Select Monitor, check the
compulsory operation of radiator fan relay.
NOTE:
• With Subaru Select Monitor
When checking the compulsory operation of
radiator fan, the radiator main and sub fan
repeat the rotation in order of following: low
speed rotation → high speed rotation → off.
• Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for detail procedures. <Ref. to
EN(H4SO)-45, Compulsory Valve Operation
Check Mode.>
CHECK OPERATION OF RADIATOR FAN.
1) Connect the test mode connector.
2) Turn the ignition switch to ON.
3) Using Subaru Select Monitor, check the
compulsory operation of radiator fan relay.

Check
Do the radiator main and sub
fan rotate at low speed?

Yes
Go to step 2.

Do the radiator main and sub
fan rotate at high speed?

Radiator main fan Go to step 32.
system is okay.

NOTE:
• With Subaru Select Monitor
When checking the compulsory operation of
radiator fan, the radiator main and sub fan
repeat the rotation in order of following: low
speed rotation → high speed rotation → off.
• Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for detail procedures. <Ref. to
EN(H4SO)-45, Compulsory Valve Operation
Check Mode.>
CHECK POWER SUPPLY TO MAIN FAN RE- Is the voltage more than 10 V? Go to step 4.
LAY.
1) Turn the ignition switch to OFF.
2) Remove the fan relay 1 from A/C relay
holder.
3) Measure the voltage between main fan
relay terminal and chassis ground.
Connector & terminal
(F27) No. 31 (+) — Chassis ground (−):
CHECK POWER SUPPLY TO MAIN FAN RE- Is the voltage more than 10 V? Go to step 8.
LAY.
1) Turn the ignition switch to ON.
2) Measure the voltage between main fan
relay terminal and chassis ground.
Connector & terminal
(F27) No. 34 (+) — Chassis ground (−):
CHECK FUSE.
Is the fuse blown out?
Replace the fuse.
1) Remove the fuse from A/C relay holder.
2) Check the condition of fuse.

CO(H4SO)-14

No
Go to step 3.

Go to step 5.

Go to step 7.

Go to step 6.

Radiator Fan System
COOLING

6

7

8

9

10

11

12

13

Step
CHECK HARNESS OF FUSE TERMINAL
AND MAIN FAN RELAY TERMINAL.
1) Turn the ignition switch to OFF.
2) Measure the resistance between 20 A fuse
terminal and main fan relay terminal.
Terminal
No. 2 — No. 31:
CHECK FUSE.
1) Turn the ignition switch to OFF
2) Remove the fuse No. 18.
3) Check the condition of fuse.
CHECK MAIN FAN RELAY.
1) Turn the ignition switch to OFF.
2) Measure the resistance between main fan
relay terminals.
Terminal
No. 30 — No. 31:
CHECK MAIN FAN RELAY.
1) Connect the battery to main fan relay terminals No. 32 and No. 34.
2) Measure the resistance between main fan
relay terminals.
Terminal
No. 30 — No. 31:
CHECK HARNESS BETWEEN MAIN FAN
RELAY TERMINAL AND MAIN FAN MOTOR
CONNECTOR.
1) Disconnect the connector from main fan
motor.
2) Measure the resistance between main fan
relay terminal and main fan motor connector.
Connector & terminal
Turbo AT model
(F17) No. 1 — (F27) No. 30:
Except turbo AT model
(F17) No. 2 — (F27) No. 30:
CHECK HARNESS BETWEEN MAIN FAN
MOTOR CONNECTOR AND FAN MODE RELAY CONNECTOR.
1) Remove the fan mode relay from A/C relay
holder.
2) Measure the resistance between main fan
motor connector and fan mode relay connector.
Connector & terminal
Turbo AT model
(F17) No. 2 — (F27) No. 9:
Except turbo AT model
(F17) No. 1 — (F27) No. 9:
CHECK POOR CONTACT.
Check poor contact in main fan motor connector.
CHECK MAIN FAN MOTOR.
Connect the battery positive (+) terminal to terminal No. 2 (except turbo AT model), No. 1
(turbo AT model), and ground (−) terminal to
terminal No. 1 (except turbo AT model), No. 2
(turbo AT model) of main fan motor.

Check
Is the resistance less than 1
Ω?

Yes
Repair the power
supply line.

No
Repair the open
harness.

Is the fuse blown out?

Replace the fuse.

Repair the power
supply line.

Is the resistance more than 1
MΩ?

Go to step 9.

Replace the main
fan relay.

Is the resistance less than 1
Ω?

Go to step 10.

Replace the main
fan relay.

Is the resistance less than 1
Ω?

Go to step 11.

Repair the open
harness between
main fan relay terminal and main fan
motor connector.

Is the resistance less than 1
Ω?

Go to step 12.

Repair the open
harness between
main fan motor
connector and fan
mode relay connector.

Is there poor contact in main
fan motor connector?

Repair poor contact in main fan
motor connector.
Go to step 14.

Go to step 13.

Does the main fan rotate?

CO(H4SO)-15

Replace the main
fan motor with new
one.

Radiator Fan System
COOLING

14

15

16

17

18

19

20

21

Step
CHECK FAN MODE RELAY.
Measure the resistance of fan mode relay.
Terminal
No. 6 — No. 9:
CHECK RESISTANCE BETWEEN FAN
MODE RELAY TERMINAL AND SUB FAN
MOTOR CONNECTOR.
1) Disconnect the connector from sub fan
motor.
2) Measure the resistance between fan mode
relay terminal and sub fan motor connector.
Connector & terminal
Turbo AT model
(F16) No. 1 — (F27) No. 6:
Except turbo AT model
(F16) No. 2 — (F27) No. 6:
CHECK SUB FAN MOTOR AND GROUND
CIRCUIT.
Measure the resistance between sub fan motor
connector and chassis ground.
Connector & terminal
Turbo AT model
(F16) No. 2 — Chassis ground:
Except turbo AT model
(F16) No. 1 — Chassis ground:
CHECK POOR CONTACT.
Check poor contact in sub fan motor connector.
CHECK SUB FAN MOTOR.
Connect the battery positive (+) terminal to terminal No. 2 (except turbo AT model), No. 1
(turbo AT model), and ground (−) terminal to
terminal No. 1 (except turbo AT model), No. 2
(turbo AT model) of sub fan motor.
CHECK HARNESS BETWEEN MAIN FAN
RELAY AND ECM.
1) Disconnect the connector from ECM.
2) Measure the resistance between fan relay 1
terminal and ECM connector.
Connector & terminal
Turbo model
(B135) No. 25 — (F27) No. 32:
Non-turbo model
(B134) No. 14 — (F27) No. 32:
CHECK POOR CONTACT.
Check poor contact in ECM connector.

Check
Is the resistance less than 1
Ω?

Yes
Go to step 15.

No
Replace the fan
mode relay.

Is the resistance less than 1
Ω?

Go to step 16.

Repair the open
harness between
fan mode relay terminal and sub fan
motor connector.

Is the resistance less than 5
Ω?

Go to step 17.

Repair the open
harness between
sub fan motor connector and chassis
ground.

Is there poor contact in sub fan Repair poor conmotor connector?
tact in sub fan
motor connector.
Does the sub fan rotate?
Go to step 19.

Is the resistance less than 1
Ω?

Is there poor contact in ECM
connector?

Go to step 20.

Repair poor contact in ECM connector.
CHECK POWER SUPPLY TO SUB FAN RE- Is the voltage more than 10 V? Go to step 22.
LAY.
1) Turn the ignition switch to OFF.
2) Remove the sub fan relay from A/C relay
holder.
3) Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
(F27) No. 28 (+) — Chassis ground (−):

CO(H4SO)-16

Go to step 18.

Replace the sub
fan motor with new
one.

Repair the open
harness between
fan relay 1 terminal
and ECM.

Contact with SUBARU dealers.
Go to step 23.

Radiator Fan System
COOLING

22

23

24

25

26

27

28

29

Step
CHECK POWER SUPPLY TO SUB FAN RELAY.
1) Turn the ignition switch to ON.
2) Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
(F27) No. 25 (+) — Chassis ground (−):
CHECK FUSE.
1) Remove the fuse from A/C relay holder.
2) Check the condition of fuse.
CHECK HARNESS BETWEEN FUSE TERMINAL AND SUB FAN RELAY TERMINAL.
1) Turn the ignition switch to OFF.
2) Measure the resistance between fuse terminal and sub fan relay terminal.
Terminal
No. 4 — No. 28:
CHECK FUSE.
1) Turn the ignition switch to OFF.
2) Remove the fuse No. 17.
3) Check the condition of fuse.
CHECK SUB FAN RELAY.
1) Turn the ignition switch to OFF.
2) Remove the sub fan relay from A/C relay
holder.
3) Measure the resistance of sub fan relay.
Terminal
No. 28 — No. 29:
CHECK SUB FAN RELAY.
1) Connect the battery to terminals No. 25 and
No. 27 of sub fan relay.
2) Measure the resistance of sub fan relay.
Terminal
No. 28 — No. 29:
CHECK HARNESS BETWEEN SUB FAN RELAY TERMINAL AND SUB FAN MOTOR
CONNECTOR.
1) Disconnect the connector from sub fan
motor.
2) Measure the resistance between sub fan
relay terminal and sub fan motor connector.
Connector & terminal
Turbo AT model
(F16) No. 1 — (F27) No. 29:
Except turbo AT model
(F16) No. 2 — (F27) No. 29:
CHECK HARNESS BETWEEN SUB FAN RELAY AND ECM.
1) Disconnect the connector from ECM.
2) Measure the resistance between sub fan
relay terminal and ECM connector.
Connector & terminal
Non-turbo model: (B134) No. 13 — (F27)
No. 27:
Turbo model: (B135) No. 24 — (F27) No.
27:

Check
Yes
Is the voltage more than 10 V? Go to step 26.

No
Go to step 25.

Is the fuse blown out?

Replace the fuse.

Go to step 24.

Is the resistance less than 1
Ω?

Repair the power
supply line.

Repair the open
harness.

Is the fuse blown out?

Replace the fuse.

Repair the power
supply line.

Is the resistance more than 1
MΩ?

Go to step 27.

Replace the sub
fan relay.

Is the resistance less than 1
Ω?

Go to step 28.

Replace the sub
fan relay.

Is the resistance less than 1
Ω?

Go to step 30.

Repair the open
harness between
sub fan relay terminal and sub fan
motor connector.

Is the resistance less than 1
Ω?

Go to step 30.

Repair the open
harness between
sub fan relay terminal and ECM.

CO(H4SO)-17

Radiator Fan System
COOLING

30

31

Step
CHECK HARNESS BETWEEN FAN MODE
RELAY AND ECM.
Measure the resistance between fan mode
relay terminal and ECM connector.
Connector & terminal
Non-turbo model
(B134) No. 13 — (F27) No. 7:
Turbo model
(B135) No. 24 — (F27) No. 7:

Check
Is the resistance less than 1
Ω?

Yes
Go to step 31.

No
Repair the open
harness between
fan mode relay terminal and ECM.

CHECK POOR CONTACT.
Check poor contact in ECM connector.

Is there poor contact in ECM
connector?

Repair the poor
contact in ECM
connector.

Contact with SUBARU dealers.

32

CHECK OPERATION OF RADIATOR FAN.

33

CHECK GROUND CIRCUIT OF FAN MODE
RELAY.
1) Remove the fan mode relay from A/C relay
holder.
2) Measure the resistance between fan mode
relay terminal and chassis ground.
Connector & terminal
(F27) No. 8 — Chassis ground:
CHECK POWER SUPPLY TO FAN MODE
RELAY.
1) Turn the ignition switch to ON.
2) Measure the voltage between fan mode
relay terminal and chassis ground.
Connector & terminal
(F27) No. 5 (+) — Chassis ground (−):
CHECK FAN MODE RELAY.
1) Turn the ignition switch to OFF.
2) Remove the fan mode relay.
3) Measure the resistance of fan mode relay.
Terminal
(F27) No. 8 — (F27) No. 9:
CHECK FAN MODE RELAY.
1) Connect the battery to terminals No. 5 and
No. 7 of fan mode relay.
2) Measure the resistance of fan mode relay.
Terminal
(F27) No. 8 — (F27) No. 9:

34

35

36

Does the radiator main fan
rotate when the radiator main
and sub fan do not rotate at
high speed?
Is the resistance less than 1
Ω?

Go to step 21.

NOTE:
Probable cause is
deterioration
of
multiple parts.
Go to step 33.

Go to step 34.

Repair the open
harness between
fan mode relay
and chassis
ground.

Is the voltage more than 10 V? Go to step 35.

Repair the power
supply line.

Is the resistance more than 1
MΩ?

Go to step 36.

Replace the fan
mode relay.

Is the resistance less than 1
Ω?

Go to step 29.

Replace the fan
mode relay.

CO(H4SO)-18

Engine Coolant
COOLING

3. Engine Coolant

5) If the engine coolant level drops from Full level of
reservoir tank, add engine coolant to Full level.
6) Attach the radiator cap and reservoir tank cap
properly.

A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
1) Lift-up the vehicle.
2) Remove the under cover.
3) Remove the drain cock to drain engine coolant
into container.
NOTE:
Remove the radiator cap so that engine coolant will
drain faster.

CO-00009

4) Install the drain cock.

2. FILLING OF ENGINE COOLANT
1) Fill engine coolant into the radiator up to filler
neck position.
Coolant capacity (fill up to “FULL” level): <Ref.
to CO(H4SO)-2, SPECIFICATION, General Description.>
NOTE:
The SUBARU Genuine Coolant containing antifreeze and anti-rust agents is especially made for
SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Coolant,
since other coolant may cause corrosion.
2) Fill engine coolant into the reservoir tank up to
Full level.

FULL
FULL

LOW
LOW

CO-00010

3) Warm-up the engine completely for more than 5
minutes at 2,000 to 3,000 rpm.
4) If the engine coolant level drops in radiator, add
engine coolant to filler neck position.

CO(H4SO)-19

Engine Coolant
COOLING

B: INSPECTION
1. RELATIONSHIP OF SUBARU COOLANT
CONCENTRATION AND FREEZING TEMPERATURE
The concentration and safe operating temperature
of the SUBARU coolant is shown in the diagram.
Measuring the temperature and specific gravity of
the engine coolant will provide this information.
[Example]
If the engine coolant temperature is 25°C (77°F)
and its specific gravity is 1.054, the concentration is
35% (point A), the safe operating temperature is −
14°C (7°F) (point B), and the freezing temperature
is −20°C (−4°F) (point C).
(1)
(4)

(2)

1.100
1.090
1.080
60%
1.070
C
1.060

B

2. PROCEDURE TO ADJUST THE CONCENTRATION OF THE ENGINE COOLANT
To adjust the concentration of the engine coolant
according to temperature, find the proper fluid concentration in the above diagram and replace the
necessary amount of the engine coolant with an
undiluted solution of SUBARU genuine coolant
(concentration 50%).
The amount of the engine coolant that should be
replaced can be determined using the diagram.
[Example]
Assume that the engine coolant concentration must
be increased from 25% to 40%. Find point A, where
the 25% line of the engine coolant concentration intersects with the 40% curve of the necessary the
engine coolant concentration, and read the scale
on the vertical axis of the graph at height A. The
quantity of coolant to be drained is 2.12 (2.2 US qt,
1.8 Imp qt). Drain 2.12 (2.2 US qt, 1.8 Imp qt) of
the engine coolant from the cooling system and
add 2.12 (2.2 US qt, 1.8 Imp qt) of the undiluted
solution of SUBARU coolant.
If a engine coolant concentration of 50% is needed,
drain all the engine coolant and refill with the undiluted solution only.

50%

(1.054)

A

1.050

40%
(2)

1.040
1.030

(3)

30%

1.020

1.000

(1)
(2)
(3)
(4)
(5)

(1)

20%
25 C
(77 F)

1.010

10%

0
10 20 30 40 50
-40 -30 -20 -10
(-40) (-22) (-4) (14) (32) (50) (68) (86) (104) (122)
(5)
CO-00283

Safe operating temperature
Concentration of coolant
Freezing temperature
Specific gravity of coolant
Coolant temperature °C (°F)

3
(3.2,
2.6)
2
(2.1,
1.8)
1
(1.1,
0.9)
0

45%
A
35%

40%

30%
25%
20%
10% 15%
10

20

30

40

50

(3)
(4)
CO-00284

(1) Necessary concentration of coolant
(2) Quantity of coolant to be drained 2 (US qt, Imp
qt)
(3) Concentration of coolant in the vehicle cooling
system%
(4) Concentration of coolant in vehicle and quantity
to be drained

CO(H4SO)-20

Water Pump
COOLING

4. Water Pump

7) Remove the belt cover No. 2 (LH).

A: REMOVAL
1. NON-TURBO MODEL
1) Remove the radiator. <Ref. to CO(H4SO)-28,
REMOVAL, Radiator.>
2) Remove the V-belts.
<Ref. to ME(H4SO)-43, REMOVAL, V-belt.>
3) Remove the timing belt.
<Ref. to ME(H4SO)-48, TIMING BELT, REMOVAL, Timing Belt.>
4) Remove the automatic belt tension adjuster.

CO-00019

8) Remove the tensioner bracket.

CO-00016

5) Remove the belt idler No. 2.

CO-00020

9) Disconnect the hose from water pump.
10) Remove the water pump.

CO-00017

6) Remove the camshaft sprocket (LH) by using
ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.

ST

CO-00018

CO(H4SO)-21

CO-00021

Water Pump
COOLING

2. TURBO MODEL

9) Remove the belt cover No. 2 (LH).

1) Remove the radiator. <Ref. to CO(H4SO)-28,
REMOVAL, Radiator.>
2) Remove the V-belts. <Ref. to ME(H4DOTC)-52,
REMOVAL, V-belt.>
3) Remove the timing belt. <Ref. to ME(H4DOTC)58, REMOVAL, Timing Belt Assembly.>
4) Remove the automatic belt tension adjuster (A).
5) Remove the belt idler (B).
6) Remove the belt idler No. 2 (C).
CO-00024

10) Remove the tensioner bracket.
(A)
(B)

(C)
CO-00023

7) Remove the camshaft position sensor. (2.0 L model) <Ref. to FU(H4DOTC)-31, REMOVAL, Camshaft Position Sensor.>
8) Remove the cam sprockets (LH) by using ST.
ST 499977500
CAM SPROCKET WRENCH
(Intake)

CO-00025

11) Disconnect the hose from water pump.
12) Remove the water pump.

CO-00021
ME-00710

ST

499207400

CAM SPROCKET WRENCH
(Exhaust)

ME-00709

CO(H4SO)-22

Water Pump
COOLING

B: INSTALLATION

4) Install the belt cover No. 2 (LH).

1. NON-TURBO MODEL

Tightening torque:
5 N⋅m (0.5 kgf-m, 3.6 ft-lb)

1) Install water pump onto cylinder block (LH).
NOTE:
• Replace the gasket with a new one.
• When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Tightening torque:
First:
12 N⋅m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N⋅m (1.2 kgf-m, 8.7 ft-lb)

CO-00019

5) Install the camshaft sprockets (LH) by using ST.
ST 18231AA010 CAM SPROCKET WRENCH

• Model without ATF warmer

NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.

(F)

(E)

(A)
(D)

Tightening torque:
78 N⋅m (8.0 kgf-m, 57.9 ft-lb)
(B)

(C)
ST
CO-00026

• Model with ATF warmer
(F)
(E)
(A)
(D)
CO-00018
(C)

6) Install the belt idler No. 2.

(B)

Tightening torque:
39 N⋅m (4.0 kgf-m, 28.9 ft-lb)
CO-02008

2) Connect the hose to water pump.
3) Install the tensioner bracket.
Tightening torque:
25 N⋅m (2.5 kgf-m, 18.1 ft-lb)

CO-00017

CO-00020

7) Install the automatic belt tension adjuster which
tension rod is holded with pin. <Ref. to ME(H4SO)49, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt.>
8) Install the timing belt. <Ref. to ME(H4SO)-50,
TIMING BELT, INSTALLATION, Timing Belt.>

CO(H4SO)-23

Water Pump
COOLING

9) Install the V-belts. <Ref. to ME(H4SO)-43, INSTALLATION, V-belt.>
10) Install the radiator. <Ref. to CO(H4SO)-30, INSTALLATION, Radiator.>

4) Install the belt cover No. 2 (LH).
Tightening torque:
5 N⋅m (0.5 kgf-m, 3.6 ft-lb)

2. TURBO MODEL
1) Install the water pump onto cylinder block (LH).
NOTE:
• Replace the gasket with a new one.
• When installing the water pump, tighten bolts in
two stages in alphabetical sequence as shown in
the figure.
Tightening torque:
First:
12 N⋅m (1.2 kgf-m, 8.7 ft-lb)
Second:
12 N⋅m (1.2 kgf-m, 8.7 ft-lb)

CO-00024

5) Install the cam sprockets (LH) by using ST.
ST 499977500
CAM SPROCKET WRENCH
(Intake)
Tightening torque:
2.0 L model
98 N⋅m (10.0 kgf-m, 72.4 ft-lb)
2.5 L model
29.5 N⋅m (3.0 kgf-m, 21.8 ft-lb), and then
tighten 45° furthermove

(F)
(E)
(A)
(D)

(C)

(B)

CO-00027

2) Connect the hose to water pump.
3) Install the tensioner bracket.
Tightening torque:
25 N⋅m (2.5 kgf-m, 18.1 ft-lb)
ME-00710

ST

499207400

CAM SPROCKET WRENCH
(Exhaust)

Tightening torque:
98 N⋅m (10.0 kgf-m, 72.4 ft-lb)

CO-00025

ME-00709

6) Install the camshaft position sensor. (2.0 L model) <Ref. to FU(H4DOTC)-31, INSTALLATION,
Camshaft Position Sensor.>
7) Install the belt idler No. 2 (C).
8) Install the belt idler (B).

CO(H4SO)-24

Water Pump
COOLING

9) Install the automatic belt tension adjuster (A)
which has tension rod held by pin. <Ref. to
ME(H4DOTC)-60, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt Assembly.>
Tightening torque:
39 N⋅m (4.0 kgf-m, 28.9 ft-lb)

C: INSPECTION
1) Check the water pump bearing for smooth rotation.
2) Check the water pump pulley for abnormalities.
3) Using a dial gauge, measure the impeller runout
in thrust direction while rotating the pulley.
“Thrust” runout limit:
0.5 mm (0.020 in)

(A)
(B)

(C)
CO-00023

10) Install the timing belt. <Ref. to ME(H4DOTC)61, TIMING BELT, INSTALLATION, Timing Belt
Assembly.>
11) Install the V-belts. <Ref. to ME(H4DOTC)-52,
INSTALLATION, V-belt.>
12) Install the radiator. <Ref. to CO(H4SO)-30, INSTALLATION, Radiator.>

CO-00028

4) Check the clearance between impeller and
pump case.
Clearance between impeller and pump case:
Standard
0.5 — 0.7 mm (0.020 — 0.028 in)
Limit
1.0 mm (0.039 in)

CO-00029

5) After water pump installation, check the pulley
shaft for engine coolant leaks. If leaks are noted,
replace the water pump assembly.

CO(H4SO)-25

Thermostat
COOLING

5. Thermostat

7) Remove the thermostat cover and gasket, and
pull out the thermostat.

A: REMOVAL
1) Set the vehicle on a lift.
2) Lift-up the vehicle.
3) Remove the under cover.
4) Drain the engine coolant completely. <Ref. to
CO(H4SO)-19, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

CO-00031

B: INSTALLATION
1) Install the thermostat in the water pump, and
then install the thermostat cover together with a
gasket.
CO-00009

5) Disconnect the radiator outlet hose from thermostat cover.
• NON-TURBO MODEL

NOTE:
• When reinstalling the thermostat, use a new gasket.
• The thermostat must be installed with the jiggle
pin (A) facing to front side.
Tightening torque:
6.5 N⋅m (0.66 kgf-m, 4.8 ft-lb)

(A)
CO-00076

6) Disconnect the radiator outlet hose.
• TURBO MODEL

CO-00032

2) Fill engine coolant. <Ref. to CO(H4SO)-19,
FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

CO-00030

CO(H4SO)-26

Thermostat
COOLING

C: INSPECTION
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the following test shows unsatisfactory results.
Immerse the thermostat and thermometer in water.
Raise water temperature gradually, and measure
the temperature and valve lift when the valve begins to open and when the valve is fully opened.
During the test, agitate the water for even temperature distribution. The measurement should be to
the specification.
Starts to open:
Non-turbo model
80 — 84°C (176 — 183°F)
Turbo model
76 — 80°C (169 — 176°F)
Fully opens:
Non-turbo model
95°C (203°F)
Turbo model
91°C (196°F)
(A)

(B)

CO-00033

(A) Thermometer
(B) Thermostat

CO(H4SO)-27

Radiator
COOLING

6. Radiator

8) Disconnect the ATF cooler hoses from ATF pipe.
(AT model) Plug the openings in the hose and radiator with caps in order to prevent ATF from leaking.

A: REMOVAL
1. NON-TURBO MODEL
WARNING:
The radiator is pressurized. Wait until the engine cools down before working on the radiator.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.

CO-00034

9) Lower the vehicle.
10) Disconnect the over flow hose.
11) Remove the reservoir tank.

FU-00009

3) Lift-up the vehicle.
4) Remove the under cover.
5) Drain the engine coolant completely. <Ref. to
CO(H4SO)-19, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
6) Disconnect the connectors of radiator main fan
motor (A) and sub fan motor (B).

(A)

CO-00015

12) Disconnect the radiator inlet hose from engine.

(B)

CO-00035

CO-00013

7) Disconnect the radiator outlet hose from water
pump.

13) Remove the radiator upper brackets.

CO-00036
CO-00076

CO(H4SO)-28

Radiator
COOLING

14) Detach the power steering hose from clip on radiator.

7) Disconnect the radiator outlet hose from thermostat cover.

CO-00030

CO-00037

15) Lift the radiator up and away from the vehicle.

2. TURBO MODEL
WARNING:
The radiator is pressurized. Wait until the engine cools down before working on the radiator.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.

8) Disconnect the ATF cooler hose from ATF pipe.
(AT model) Plug the opennings in the hose and radiator with caps in order to prevent ATF from leaking.
9) Disconnect the oil cooler hose from oil cooler
pipe. (MT model with oil cooler)
Install the cap to prevent oil from leaking.

CO-00034

FU-00009

10) Lower the vehicle.
11) Remove the V-belt covers.

3) Lift-up the vehicle.
4) Remove the under cover.
5) Drain the engine coolant completely. <Ref. to
CO(H4SO)-19, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
6) Disconnect the connectors of radiator main fan
motor (A) and sub fan motor (B).

SC-00096

(A)

(B)

12) Disconnect the overflow hose.

CO-00013

CO(H4SO)-29

Radiator
COOLING

18) Remove the radiator under cover (AT model).

13) Remove the reservoir tank.

CO-00070

CO-00015

14) Disconnect the radiator inlet hose (A) and water tank hose (B) from radiator.
(B)

B: INSTALLATION
1. NON-TURBO MODEL
1) Attach the radiator lower cushions to holes on
the vehicle.

(A)

CO-00039

15) Remove the radiator upper brackets.
CO-00041

2) Install the radiator to vehicle.
NOTE:
Fit pins on the lower side of radiator into cushions
on the body side.
3) Install the radiator upper brackets and tighten
bolts.
CO-00040

Tightening torque:
18 N⋅m (1.8 kgf-m, 13.0 ft-lb)

16) Disconnect the power steering hose from clips
on radiator.

CO-00036
CO-00037

17) Lift the radiator up and away from the vehicle.

CO(H4SO)-30

Radiator
COOLING

4) Attach the power steering hose to radiator.

10) Connect the radiator outlet hose.

CO-00037

CO-00076

11) Connect the connectors to radiator main fan
motor (A) and sub fan motor (B).

5) Connect the radiator inlet hose.

(A)

(B)

CO-00035
CO-00013

6) Install the reservoir tank.

12) Install the under cover.
13) Lower the vehicle.
14) Connect the battery ground cable to battery.

Tightening torque:
4.9 N⋅m (0.50 kgf-m, 3.6 ft-lb)

CO-00015

7) Connect the overflow hose.
8) Lift-up the vehicle.
9) Connect the ATF cooler hoses. (AT model)

FU-00009

15) Fill engine coolant. <Ref. to CO(H4SO)-19,
FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
16) Check the ATF level. <Ref. to 4AT-30, INSPECTION, Automatic Transmission Fluid.>

CO-00034

CO(H4SO)-31

Radiator
COOLING

2. TURBO MODEL

5) Connect the power steering hose to radiator.

1) Install the radiator under cover to radiator.

CO-00037
CO-00070

2) Attach the radiator lower cushions to holes on
the vehicle.

6) Connect the radiator inlet hose (A) and water
tank hose (B).
(B)

(A)

CO-00039
CO-00041

3) Install the radiator to vehicle.
NOTE:
Fit pins on the lower side of radiator into cushions
on body side.
4) Install the radiator upper brackets, and then
tighten the bolts.

7) Install the reservoir tank.
Tightening torque:
4.9 N⋅m (0.50 kgf-m, 3.6 ft-lb)

Tightening torque:
18 N⋅m (1.8 kgf-m, 13.0 ft-lb)

CO-00015

8) Connect the over flow hose.
9) Install the V-belt cover.

CO-00040

SC-00096

10) Lift-up the vehicle.
11) Connect the ATF cooler hoses. (AT model).

CO(H4SO)-32

Radiator
COOLING

12) Connect the oil cooler hose. (MT model with oil
cooler)

19) Check the ATF level. <Ref. to 4AT-30, INSPECTION, Automatic Transmission Fluid.>

C: INSPECTION
1) Remove the radiator cap, top off radiator, and
then attach the tester (A) to radiator in place of cap.
• NON-TURBO MODEL

(A)

CO-00034

13) Connect the radiator outlet hose.

CO-00042

• TURBO MODEL
(A)

CO-00030

14) Connect the connectors to radiator main fan
motor (A) and sub fan motor (B).
CO-00043

(A)

(B)

CO-00013

15) Install the under cover.
16) Lower the vehicle.
17) Connect the battery ground cable to battery.

2) Apply a pressure of 157 kPa (1.6 kg/cm2, 23 psi)
to the radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
• Inspection must be carried out at the side of
coolant filler tank, not at the side of radiator.
• Engine should be off.
• Wipe engine coolant from check points in advance.
• Be careful to prevent engine coolant from
spurting out when removing the tester.
• Be careful also not to deform the filler neck of
radiator when installing or removing tester.

FU-00009

18) Fill engine coolant. <Ref. to CO(H4SO)-19,
FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

CO(H4SO)-33

Radiator Cap
COOLING

7. Radiator Cap
A: INSPECTION
1) Attach the radiator cap to tester.

CO-00044

2) Increase the pressure until tester gauge pointer
stops. Radiator cap is functioning properly if it holds
the service limit pressure for 5 to 6 seconds.
Standard pressure:
93 — 123 kPa (0.95 — 1.25 kg/cm2 , 14 — 18
psi)
Service limit pressure:
83 kPa (0.85 kg/cm2, 12 psi)
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance otherwise, results of pressure test will be incorrect.

CO(H4SO)-34

Radiator Main Fan and Fan Motor
COOLING

8. Radiator Main Fan and Fan
Motor

11) Remove the radiator fan motor assembly
mounting bolts.

A: REMOVAL
1. NON-TURBO MODEL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.

CO-00064

12) Disconnect the radiator inlet hose from engine.

FU-00009

3) Lift-up the vehicle.
4) Remove the under cover.
5) Drain the coolant aprrox. 12 (1.06 US qt, 0.88
Imp qt). <Ref. to CO(H4SO)-19, DRAINING OF
ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
6) Disconnect the connector of main fan motor (A)
and sub fan motor (B).

(A)

CO-00035

13) Detach the power steering hose from clip on radiator.

(B)

CO-00037

CO-00013

7) Remove the ATF hose from two clips of radiator
fan motor assembly. (AT model)
8) Lower the vehicle.
9) Disconnect the over flow hose.
10) Remove the reservoir tank.

14) Rise up the radiator fan motor assembly to remove it from vehicle.

CO-00065

CO-00015

CO(H4SO)-35

Radiator Main Fan and Fan Motor
COOLING

2. TURBO MODEL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.

8) Remove the radiator under cover securing bolt.
(AT model)

CO-00070
FU-00009

3) Remove the radiator upper bracket. (AT model)

9) Pull the radiator lower hose upward to space radiator from radiator under cover. Remove the ATF
hose to radiator fan motor assembly two clips. (AT
model)

CO-00036

4) Lift-up the vehicle.
5) Remove the under cover.
6) Drain the engine coolant approx. 12(1.06 US qt,
0.88 Imp qt). <Ref. to CO(H4SO)-19, DRAINING
OF ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
7) Disconnect the radiator main fan motor connector (A) and sub fan motor connector (B).

(A)

CO-00143

10) Lower the vehicle.
11) Remove the V-belt cover.
12) Disconnect the overflow hose.
13) Remove the reservoir tank.

(B)

CO-00015

CO-00013

14) Remove the radiator main fan motor assembly
securing bolt.

CO-00064

CO(H4SO)-36

Radiator Main Fan and Fan Motor
COOLING

3) Connect the radiator inlet hose.

15) Disconnect the radiator inlet hose.

CO-00072

16) Disconnect the power steering hose from radiator clip.

CO-00035

4) Install the radiator main fan motor assembly
mounting bolts.
Tightening torque:
4.9 N⋅m (0.50 kgf-m, 3.6 ft-lb)

CO-00037

17) Remove the radiator main fan motor assembly
from vehicle.

CO-00064

5) Install the reservoir tank.
Tightening torque:
4.9 N⋅m (0.50 kgf-m, 3.6 ft-lb)

CO-00065

B: INSTALLATION
1. NON-TURBO MODEL
1) install the radiator main fan motor assembly to
radiator.
2) Connect the power steering hose to radiator.

CO-00015

6) Install the over-flow hose.
7) Lift-up the vehicle.
8) Install the ATF hose to two clips of radiator main
fan motor assembly. (AT model)

CO-00037

CO(H4SO)-37

Radiator Main Fan and Fan Motor
COOLING

9) Connect the main fan motor (A) and sub fan motor (B).

(A)

4) Tighten the radiator under cover securing bolt.
(AT model)

(B)

CO-00070

CO-00013

10) Install the under cover.
11) Lower the vehicle.
12) Connect the battery ground cable to battery.

5) Connect the radiator main fan motor connector
(A) and sub fan motor connector (B).

(A)

(B)

CO-00013
FU-00009

13) Fill the engine coolant. <Ref. to CO(H4SO)-19,
FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>

6) Install the under cover.
7) Lower the vehicle.
8) Connect the power steering hose to radiator clip.

2. TURBO MODEL
1) Install the radiator main fan motor assembly.
2) Lift-up the vehicle.
3) Pull the radiator lower hose upward to space radiator from radiator under cover. Install the ATF
hose to radiator main fan motor assembly two clips.
(AT model)
NOTE:
Fit securely the pins on lower side of radiator into
body side.

CO-00037

9) Connect the radiator inlet hose to radiator.

CO-00143

CO(H4SO)-38

CO-00072

Radiator Main Fan and Fan Motor
COOLING

10) Install the radiator main fan motor assembly
mounting bolts.
Tightening torque:
4.9 N⋅m (0.5 kgf-m, 3.6 ft-lb)

16) Fill the engine coolant. <Ref. to CO(H4SO)-19,
FILLING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
NOTE:
If it is difficult to install the radiator main fan motor
assembly, first loosen the bolts which hold the radiator sub fan motor assembly.

C: DISASSEMBLY
Remove the clip which holds motor connector onto
shroud.
1) Remove the nut which holds fan itself onto fan
motor and shroud assembly.
CO-00064

11) Install the reservoir tank.

CO-00047

2) Remove the bolts which install fan motor onto
shroud.
CO-00015

12) Connect the overflow hose.
13) Install the V-belt cover.
14) Install the radiator upper bracket. (AT model)

CO-00048

D: ASSEMBLY
Assemble in the reverse order of disassembly.
CO-00036

15) Connect the battery ground cable to battery.

NOTE:
Refer to COMPONENT for tightening torque. <Ref.
to CO(H4SO)-4, COMPONENT, General Description.>

FU-00009

CO(H4SO)-39

Radiator Sub Fan and Fan Motor
COOLING

9. Radiator Sub Fan and Fan
Motor
A: REMOVAL
Refer to Radiator Main Fan and Fan Motor. <Ref. to
CO(H4SO)-35, REMOVAL, Radiator Main Fan and
Fan Motor.>

B: INSTALLATION
Refer to Radiator Main Fan and Fan Motor. <Ref. to
CO(H4SO)-37, INSTALLATION, Radiator Main
Fan and Fan Motor.>

C: DISASSEMBLY
1) Remove the clip which holds motor connector
onto shroud.
2) Remove the nut which holds fan itself onto fan
motor and shroud assembly.

CO-00049

3) Remove the bolts which install fan motor onto
shroud.

CO-00050

D: ASSEMBLY
Assemble in the reverse order of disassembly.
NOTE:
Refer to COMPONENT for tightening torque. <Ref.
to CO(H4SO)-4, COMPONENT, General Description.>

CO(H4SO)-40

Reservoir Tank
COOLING

10.Reservoir Tank
A: REMOVAL
1) Disconnect the over flow hose from radiator filler
neck position.
2) Remove the bolts which install reservoir tank
onto radiator main fan shroud.
3) Remove the reservoir tank.

CO-00015

B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Refer to COMPONENT for tightening torque. <Ref.
to CO(H4SO)-4, COMPONENT, General Description.>

C: INSPECTION
Make sure the engine coolant level is between full
and low.

CO(H4SO)-41

Coolant Filler Tank
COOLING

11.Coolant Filler Tank

B: INSTALLATION

A: REMOVAL

1) Install in the reverse order of removal.

WARNING:
The radiator is pressurized. Wait until the engine cools down before working on the radiator.
1) Drain the coolant about 3.02 (3.2 US qt, 2.6 Imp
qt). <Ref. to CO(H4SO)-19, DRAINING OF ENGINE COOLANT, REPLACEMENT, Engine Coolant.>
2) Remove the air cleaner upper cover and air intake boot. <Ref. to IN(H4DOTC)-7, REMOVAL, Air
Cleaner.>
3) Remove the air cleaner element.
4) Disconnect the engine coolant hoses from coolant filler tank.

Tightening torque:
T1: 19 N⋅m (1.9 kgf-m, 13.7 ft-lb)
T2: 21 N⋅m (2.1 kgf-m, 15.2 ft-lb)

T1

T2
CO-00053

CO-00051

5) Remove the bolts and nut which install coolant
filler tank.
6) Disconnect the engine coolant hose which connects under side of coolant filler tank.
7) Remove the coolant filler tank.

2) Fill engine coolant. <Ref. to CO(H4SO)-19, FILLING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>

CO-00052

CO(H4SO)-42

Engine Cooling System Trouble in General
COOLING

12.Engine Cooling System Trouble in General
A: INSPECTION
Trouble

Over-heating

Over-cooling

Engine coolant
leaks.

Noise

Possible cause

Corrective action
Replenish the engine coolant, inspect for leakage, and
a. Insufficient engine coolant
repair.
b. Loose timing belt
Repair or replace the timing belt tensioner.
c. Oil on drive belt
Replace.
d. Malfunction of thermostat
Replace.
e. Malfunction of water pump
Replace.
f. Clogged engine coolant passage
Clean.
Inspect and repair the ignition control system.
<Ref. to EN(H4SO)-2, Basic Diagnostics Procedure.>
g. Improper ignition timing
<Ref. to EN(H4DOTC)-2, PROCEDURE, Basic Diagnostics Procedure.>
h. Clogged or leaking radiator
Clean or repair, or replace.
i. Improper engine oil in engine coolant
Replace the engine coolant.
Inspect and repair the fuel injection system.
<Ref. to EN(H4SO)-2, Basic Diagnostics Procedure.>
j. Air/fuel mixture ratio too lean
<Ref. to EN(H4DOTC)-2, PROCEDURE, Basic Diagnostics Procedure.>
k. Excessive back pressure in exhaust system
Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch
Repair or replace.
n. Dragging brake
Adjust.
o. Defective thermostat
Replace.
Inspect the radiator fan relay, engine coolant temperap. Malfunction of radiator fan
ture sensor or radiator motor and replace there.
a. Atmospheric temperature extremely low
Partly cover the radiator front area.
b. Defective thermostat
Replace.
a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from water pump
Replace.
c. Leakage from water pipe
Repair or replace.
d. Leakage around cylinder head gasket
Retighten the cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case
Repair or replace.
g. Leakage from radiator
Repair or replace.
a. Defective drive belt
Replace.
b. Defective radiator fan
Replace.
c. Defective water pump bearing
Replace the water pump.
d. Defective water pump mechanical seal
Replace the water pump.

CO(H4SO)-43

Engine Cooling System Trouble in General
COOLING

CO(H4SO)-44