Engine Cooling System (H4DOTC): Removal & Installation Subaru Baja I

REMOVAL

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1. Set the vehicle on a lift.
2. Disconnect the ground cable from battery.
3. Lift-up the vehicle.
4. Remove the under cover.
5. Drain the engine coolant completely. Refer to «ENGINE COOLANT»(ref-208377-S02091020672005120700000) .
6. Disconnect the connectors of radiator main fan rotor (A) and sub fan motor (B).
7. Disconnect the ATF cooler hose from ATF pipe. (AT model) Plug the openings in the hose and radiator with caps in order to prevent ATF from leaking.
8. Disconnect the radiator outlet hose from thermostat cover.
9. Lower the vehicle.
10. Remove the air intake duct.
11. Remove the V-belt covers.
12. Disconnect the overflow hose.
13. Remove the reservoir tank. Refer to «RESERVOIR TANK»(ref-208377-S31743192662005120700000) .
14. Disconnect the radiator inlet hose (A) and water tank hose (B) from radiator.
15. Remove the radiator upper brackets.
16. Lift-up the radiator, and then remove it from vehicle.

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1. Attach the radiator mounting cushions to the holes on vehicle.
2. Install the radiator to vehicle. NOTE: Fit the pins on lower side of radiator into the cushions on body side.
3. Install the radiator brackets, and then tighten the bolts. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
4. Connect the radiator inlet hose (A) and water tank hose (B).
5. Install the reservoir tank. Refer to «RESERVOIR TANK»(ref-208377-S31743192662005120700000) .
6. Connect the overflow hose.
7. Install the V-belt cover.
8. Install the air intake duct. Refer to «INSTALLATION»(ref-208374-S11890443402005120700000) , Air Intake Duct.
9. Lift-up the vehicle.
10. Connect the ATF cooler hoses. (AT model).
11. Connect the radiator outlet hose.
12. Connect the connectors to radiator main fan motor (A) and sub fan motor (B).
13. Install the under cover.
14. Lower the vehicle.
15. Connect the battery ground cable to battery.
16. Fill engine coolant. Refer to «ENGINE COOLANT»(ref-208377-S02091020672005120700000) .
17. Check the ATF level. Refer to «INSPECTION»(ref-208395-S08573280712005120700000) , Automatic Transmission Fluid.

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1. Remove the coolant filler tank cap, top off coolant filler tank, and then attach the tester to coolant filler tank in place of cap.
2. Apply a pressure of 122 kPa (1.2 kg/cm 2 , 18 psi) to the radiator to check if: Engine coolant leaks at/around radiator. Engine coolant leaks at/around hoses or connections.

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1. Attach the radiator cap to tester.
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.

Coolant filler tank side

Standard pressure

93 123 kPa (0.95 1.25 kg/cm 2 , 14 18 psi)

Service limit pressure

83 kPa (0.85 kg/cm 2 , 12 psi)

Radiator side

Standard pressure

122 152 kPa (1.24 1.55 kg/cm 2 , 18 22 psi)

Service limit pressure

112 kPa (1.14 kg/cm 2 , 16 psi)

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1. Disconnect the ground cable from battery.
2. Lift-up the vehicle.
3. Remove the under cover.
4. Disconnect the connector of main fan motor.
5. Lower the vehicle.
6. Remove the air intake duct.
7. Disconnect the overflow hose.
8. Remove the overflow pipe.
9. Remove the reservoir tank. Refer to «RESERVOIR TANK»(ref-208377-S31743192662005120700000) .
10. Remove the radiator main fan motor assembly.

INSTALLATION

Install in the reverse order of removal.

Note. When the main fan motor assembly cannot be installed as is, loosen the sub fan motor assembly securing bolts to install it.

Tightening torque

4.9 N.m (0.50 kgf-m, 3.6 ft-lb)

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1. Remove the nut which holds the fan itself onto fan motor and shroud assembly.
2. Remove the bolts which install the fan motor onto shroud.

Install in the reverse order of removal.

Tightening torque

4.9 N.m (0.50 kgf-m, 3.6 ft-lb)

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1. Remove the clip which holds the motor harness onto shroud.
2. Remove the nut which holds the fan itself onto fan motor and shroud assembly.
3. Remove the bolts which install the fan motor onto shroud.

Install in the reverse order of removal.

Note. Refer to COMPONENT , General Description.

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1. Drain the coolant about 3.0 l (3.2 US qt, 2.6 Imp qt). Refer to «ENGINE COOLANT»(ref-208377-S02091020672005120700000) .
2. Remove the air cleaner upper cover and air intake boot. Refer to «REMOVAL»(ref-208374-S06540615662005120700000) , Air Cleaner.
3. Remove the air cleaner element.
4. Disconnect the engine coolant hoses from coolant filler tank.
5. Remove the bolts and nut which install the coolant filler tank.
6. Disconnect the engine coolant hose which connects the under side of coolant filler tank.
7. Remove the coolant filler tank.

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1. Install in the reverse order of removal. Tightening torque: T1: 16 N.m (1.6 kgf-m, 11.8 ft-lb) T2: 13 N.m (1.3 kgf-m, 9.6 ft-lb)
2. Fill engine coolant. Refer to «ENGINE COOLANT»(ref-208377-S02091020672005120700000) .

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