Engine Cooling System (H4DOTC): Diagnosis Subaru Baja I

TROUBLE SYMPTOM

1. Radiator main and sub fan do not rotate under the above conditions.

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1. Lift-up the vehicle.
2. Remove the under cover.
3. Remove the drain cock to drain engine coolant into container. NOTE: Remove the coolant filler tank cap so that engine coolant will drain faster.
4. Install the drain cock.

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1. Fill engine coolant into the coolant filler tank up to filler neck position. Coolant capacity (fill up to "FULL" level):342 AT model Approx. 7.6 l (8.03 US qt, 6.69 Imp qt) MT model Approx. 7.7 l (8.14 US qt, 6.78 Imp qt) CAUTION: Do not mix up the coolant filler tank side cap with radiator side cap. NOTE: Do not remove the radiator side cap when filling engine coolant. The SUBARU Genuine Coolant containing antifreeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crank-case. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion.
2. Fill engine coolant into the reservoir tank up to Full level.
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 coolant filler tank, add engine coolant to filler neck position.
5. If the engine coolant level drops from Full level of reservoir tank, add engine coolant to Full level.
6. Attach the coolant filler tank cap and reservoir tank cap properly.

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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 coolant will provide this information. [Example] If the coolant temperature is 25°C (77°F) and its specific gravity is 1.054, the concentration is 45% (point A), the safe operating temperature is -14°C (7°F) (point B), and the freezing temperature is - 20°C (-4°F) (point C).
2. PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration 50%). The amount of coolant that should be replaced can be determined using the diagram. [Example] Assume that the coolant concentration must be increased from 25% to 40%. Find point A, where the 25% line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 2.1 l (2.2 US qt, 1.8 Imp qt). Drain 2.1 l (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 l (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU coolant. If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only.

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1. Remove the radiator. Refer to «REMOVAL»(ref-208377-S12962400862005120700000) .
2. Remove the V-belts. Refer to «REMOVAL»(ref-208375-S06595322272005120700000) , V-belt.
3. Remove the timing belt. Refer to «REMOVAL»(ref-208375-S32338247512005120700000) , 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).
7. Remove the camshaft position sensor. Refer to «REMOVAL»(ref-208372-S25293014962005120700000) , Camshaft Position Sensor.
8. Remove the camshaft sprockets (LH) by using, Refer to «REMOVAL»(ref-208375-S40888963902005120700000) , Camshaft Sprocket.
9. Remove the belt cover No. 2 (LH).
10. Remove the tensioner bracket.
11. Disconnect the hose from water pump.
12. Remove the water pump.

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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)
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)
4. Install the belt cover No. 2 (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb)
5. Install the camshaft sprockets (LH) by using ST. Refer to «INSTALLATION»(ref-208375-S31527616642005120700000) , Camshaft Sprocket.
6. Install the camshaft position sensor. Refer to «INSTALLATION»(ref-208372-S02252550232005120700000) , Camshaft Position Sensor.
7. Install the belt idler No. 2 (C).
8. Install the belt idler (B).
9. Install the automatic belt tension adjuster (A) which has tension rod held by pin. Refer to «INSTALLATION»(ref-208375-S23626259932005120700000) , Timing Belt Assembly. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
10. Install the timing belt. Refer to «TIMING BELT»(ref-208375-S20292881532005120700000) , INSTALLATION, Timing Belt Assembly.
11. Install the V-belts. Refer to «INSTALLATION»(ref-208375-S41189240582005120700000) , V-belt.
12. Install the radiator. Refer to «INSTALLATION»(ref-208377-S14445070912005120700000) , Radiator.

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1. Check the water pump bearing for smooth rotation.
2. Check the water pump pulley for abnormalities.
3. Check the clearance between impeller and pump case. Clearance between impeller and pump case: Standard 0.5 1.5 mm (0.020 0.059 in)
4. After water pump installation, check the pulley shaft for engine coolant leaks. If leaks are noted, replace the water pump assembly.

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1. Set the vehicle on a lift.
2. Lift-up the vehicle.
3. Remove the under cover.
4. Drain the engine coolant completely. Refer to «ENGINE COOLANT»(ref-208377-S02091020672005120700000) .
5. Disconnect the radiator outlet hose.
6. Remove the thermostat cover and gasket, and then pull out the thermostat.

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1. Install the thermostat in water pump, and then install the thermostat cover together with a gasket. 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: 12 N.m (1.2 kgf-m, 8.7 ft-lb)
2. Fill engine coolant. Refer to «ENGINE COOLANT»(ref-208377-S02091020672005120700000) .

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

76 80 °C (169 176°F)

Fully opens

91°C (196°F)

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