Engine Cooling System: Removal & Installation Subaru BRZ ZC

Installation

1. Engine water pump Assembly installation Install a new gasket and install the engine water pump Assembly with the five bolts. Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf}
2. Water pump pulley installation Temporarily tighten the three bolts to secure the water pump pulley. Use the SST to secure the water pump pulley. SST 18355AA000, 18334AA030 Tighten the three bolts. Standard value: T=14N.m {143kgf.cm} {10.3ft.lbf}
3. Installation of exhaust manifold (Refer to «REMOVAL»(ref-619189-S14759733182014053000000) )
4. Installation of fan & generator V-belt (Refer to «INSTALLATION»(ref-619184-S20922063212014053000000) )
5. Replenishing of coolant (SUBARU Super Coolant) (Refer to «REPLACEMENT»(ref-619192-S38018017162014053000000) )
6. Leak check of coolant (SUBARU Super Coolant) (Refer to «ON-VEHICLE INSPECTION»(ref-619192-S42694459552014053000000) )
7. Installation of under cover front AL (Refer to «COOLING SYSTEM (FA20)»(ref-619192-S36331344062014053000000) )

On-Vehicle Inspection

1. Engine water pump Assembly check Make sure that there is no bearing noise and drag. NOTE: If noise or drag is noted, replace the engine water pump Assembly. Make sure that the water pump pulley has no fault. Check the impeller for damage or abnormal deformation. NOTE: If the impeller is scratched or abnormally deformed, replace the engine water pump Assembly.

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1. Battery ground terminal disconnection (Refer to «WORKING PRECAUTIONS AND NOTES»(ref-619149-S01292846772014053000000) )
2. Removal of air cleaner case sub-assembly Move the hose clip and disconnect the ventilation hose NO. 2. Disconnect the connector from the intake air flow meter sub-assembly. Release the clamp and disconnect the wiring harness from the air cleaner cap. Loosen the two hose clamps and remove the air cleaner duct and air intake boot. Remove the three bolts and remove the air cleaner case sub-assembly.
3. Front bumper cover removal (Refer to «FRONT BUMPER»(ref-619181-S08279588312014053000000) )
4. Under cover front AL removal (Refer to «REMOVAL»(ref-619189-S01819081472014053000000) )
5. Draining of coolant (SUBARU Super Coolant) (Refer to «REPLACEMENT»(ref-619192-S38018017162014053000000) )
6. Radiator outlet hose disconnection (Refer to «REMOVAL»(ref-619192-S24164508762014053000000) )
7. Radiator reservoir tank Assembly removal Remove the two bolts and remove the radiator reservoir tank Assembly.
8. Air cleaner duct removal Remove the two bolts and remove the air cleaner duct.
9. Radiator cover plate removal Release the six clips and remove the radiator cover plate.
10. Water filler sub-assembly removal Disconnect the radiator cap hose. Move the two hose clamps and disconnect the radiator inlet hose and radiator hose NO. 1. NOTE: Since the hose has its proper installation position, mark the alignment mark before removing it. Remove the four bolts and remove the radiator cap stay.
11. Hood lock assembly disconnection (Refer to «INSTALLATION»(ref-619177-S35789727462014053000000) )
12. Radiator support sub-assembly removal Remove the two lower bolts of radiator support sub-assembly. Remove the four bolts and remove the radiator support sub-assembly.
13. Cooler condenser assembly disconnection Remove the bolt. Remove the bolt. Remove the bolt. Remove the bolt A. Remove the bolt B and disconnect the cooler condenser assembly from the radiator Assembly.
14. Fan shroud removal (Refer to «REMOVAL»(ref-619192-S15296362252014053000000) )
15. Radiator assembly removal Remove the two bolts and remove the radiator support bracket RH. Remove the two bolts and remove the radiator support bracket LH. Disconnect the ambient sensor connector. Remove the radiator assembly while lifting the radiator outlet hose. CAUTION: Insert a cardboard, blanket, etc. between the radiator assembly and cooler condenser assembly to protect the cooler condenser Assembly. Remove the two radiator supports LWR.
16. Radiator hose NO. 1 removal Move the hose clamp and remove the radiator hose NO. 1 from the radiator Assembly. NOTE: Since the hose has its proper installation position, mark the alignment mark before removing it.
17. Radiator outlet hose removal Move the hose clamp and remove the radiator outlet hose. NOTE: Since the hose has its proper installation position, mark the alignment mark before removing it.
18. Radiator inlet hose removal Move the hose clamp and remove the radiator inlet hose from the radiator cap stay. NOTE: Since the hose has its proper installation position, mark the alignment mark before removing it.
19. Radiator gasket removal (for the upper side) Remove the radiator gasket.
20. Radiator gasket NO. 1 removal Remove the radiator gasket NO. 1.
21. Radiator gasket NO. 2 removal Remove the radiator gasket NO. 2.
22. Radiator gasket removal (for the lower side) Remove the radiator gasket.

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1. Radiator gasket installation (for the lower side) Install a new radiator gasket.
2. Radiator gasket NO. 2 installation Install a new radiator gasket NO. 2.
3. Radiator gasket NO. 1 installation Install a new radiator gasket NO. 1.
4. Radiator gasket installation (for the upper side) Install a new radiator gasket. NOTE: Cut the gasket at the location where the old gasket was cut when removing it.
5. Radiator inlet hose installation Align the marks marked when removing the hose and install the radiator inlet hose to the radiator cap stay with the hose clamp.
6. Radiator outlet hose installation Align the marks marked when removing the hose and install the radiator outlet hose to the radiator with the hose clamp.
7. Radiator hose NO. 1 installation Align the marks marked when removing the hose and install the radiator hose NO. 1 to the radiator with the hose clamp.
8. Radiator assembly installation Install the two radiator supports LWR. Install the radiator assembly to the vehicle while lifting the radiator outlet hose. CAUTION: Place a cardboard, blanket, etc. on the cooler condenser assembly to protect the cooler condenser Assembly. Connect the ambient sensor connector. Install the radiator support bracket RH with the two bolts. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf} Install the radiator support bracket LH with the two bolts. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}
9. Fan shroud installation (Refer to «INSTALLATION»(ref-619192-S16407280562014053000000) )
10. Cooler condenser assembly connection Connect the cooler condenser assembly to the radiator assembly with the five bolts. Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}
11. Radiator support sub-assembly installation Install the radiator support sub-assembly with the six bolts. Standard value: T=18N.m {184kgf.cm} {13.3ft.lbf}
12. Hood lock assembly connection (Refer to «INSTALLATION»(ref-619177-S35789727462014053000000) )
13. Water filler sub-assembly installation Install the water filler sub-assembly with the four bolts. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf} Align the marks marked when removing the hoses and install the radiator inlet hose and radiator hose NO. 1 with the two hose clamps. Connect the radiator cap hose.
14. Radiator cover plate installation Install the radiator cover plate with the six clips.
15. Air cleaner duct installation Install the air cleaner duct with the two bolts. Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf}
16. Radiator reservoir tank assembly installation Install the radiator reservoir tank assembly with the two bolts. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}
17. Radiator outlet hose connection (Refer to «INSTALLATION»(ref-619192-S23259079292014053000000) )
18. Replenishing of coolant (SUBARU Super Coolant) (Refer to «REPLACEMENT»(ref-619192-S38018017162014053000000) )
19. Leak check of coolant (SUBARU Super Coolant) (Refer to «ON-VEHICLE INSPECTION»(ref-619192-S42694459552014053000000) )
20. Under cover front AL installation (Refer to «COOLING SYSTEM (FA20)»(ref-619192-S36331344062014053000000) )
21. Front bumper cover installation (Refer to «INSTALLATION»(ref-619181-S05475449692014053000000) )
22. Air cleaner case sub-assembly installation Install the air cleaner case sub-assembly with the three bolts. Standard value: T=6.0N.m {61kgf.cm} {4.4ft.lbf} Install the air cleaner duct and air cleaner intake boot with the two hose clamps. Standard value: T=2.0N.m {20kgf.cm} {1.5ft.lbf} Engage the clamp and install the wiring harness to the air cleaner cap. Connect the connector to the intake air flow meter sub-assembly. Connect the ventilation hose NO. 2 with the hose clip.

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1. Radiator cap sub-assembly check WARNING: To avoid the risk of burn, do not remove the radiator cap sub-assembly when the engine and radiator are hot. The fluid and steam may blow out due to the pressure. Perform the visual check. When water scale or foreign matter is on the gaskets 1, 2 and 3, wash it with water. NOTE: Always perform the work by hands so as not to damage the gaskets 1, 2 and 3. Check the gaskets 1, 2 and 3 for deformation, cracks and expansion. Make sure that the gaskets 3 and 4 are not stuck. Perform the function check. Apply the engine coolant to the gaskets 2 and 3 before using the radiator cap tester. Pump the cap tester several times and check the maximum pressure. Pumping speed: Pump once a second CAUTION: When using the cap tester, perform the check by tilting it 30° or more. NOTE: There is a case that the radiator cap sub-assembly cannot keep the maximum pressure, but it is not abnormal. Standard value: 93 to 123 kPa {0.95 to 1.25 kgf/cm 2 , 14 to 18 psi} Limit: 83 kPa {0.85 kgf/cm 2 , 12 psi} NOTE: The valve opening pressure of a new radiator cap sub-assembly is 93 to 123 kPa {0.95 to 1.25 kgf/cm 2 , 14 to 18 psi}. If the maximum valve opening pressure does not exceed the limit value, replace the radiator cap sub-assembly.

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1. Draining of coolant (SUBARU Super Coolant) (Refer to «REPLACEMENT»(ref-619192-S38018017162014053000000) )
2. Removal of intake manifold (Refer to «DISASSEMBLY»(ref-619189-S01395914062014053000000) )
3. Radiator outlet hose disconnection Move the hose clamp and disconnect the radiator outlet hose.
4. Water inlet housing removal Remove the two bolts and remove the water inlet housing.
5. Thermostat removal Remove the thermostat. Remove the gasket from the thermostat.

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1. Thermostat check Check that the valve is fully closed when the thermostat is at 45°C {113°F} or less. NOTE: Replace the thermostat if the valve is not fully closed. Immerse the thermostat in water and heat it gradually. NOTE: Hold the thermostat with a wire or the like to avoid contacting with container bottom. Check the temperature when the valve starts to open. Standard value: 48 to 52°C {118 to 126°F} NOTE: Replace the thermostat if the temperature when the valve opens is outside the standard range. Check the valve lift. Standard value: Lift 6.0mm {0.236in} or more Full open temperature 63°C {145°F} NOTE: Replace the thermostat if the valve lift is outside the standard range.

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1. Thermostat installation Install a new gasket to the thermostat. Install the thermostat to the thermostat cover with the jiggle valve facing upward as shown in the figure. NOTE: The direction of jiggle valve must be within 10° from the upright.
2. Water inlet housing installation Install the thermostat cover with the two bolts. Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf}
3. Radiator outlet hose connection Connect the water hose to the thermostat cover and secure it with the hose clamp.
4. Replenishing of coolant (SUBARU Super Coolant) (Refer to «REPLACEMENT»(ref-619192-S38018017162014053000000) )
5. Leak check of coolant (SUBARU Super Coolant) (Refer to «ON-VEHICLE INSPECTION»(ref-619192-S42694459552014053000000) )
6. Installation of intake manifold (Refer to «INSTALLATION»(ref-619189-S11634536132014053000000) )

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1. Removal of exhaust manifold (Refer to «REMOVAL»(ref-619189-S14759733182014053000000) )
2. Draining of coolant (SUBARU Super Coolant) (Refer to «REPLACEMENT»(ref-619192-S38018017162014053000000) )
3. Radiator outlet hose disconnection Move the hose clamp and disconnect the radiator outlet hose. NOTE: Since the hose has its proper installation position, mark the alignment mark before removing it.
4. Water outlet removal Remove the two bolts and remove the water outlet.
5. Thermostat removal Remove the thermostat. Remove the gasket from the thermostat.

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1. Thermostat check Check that the valve is fully closed when the thermostat is at 83°C {181°F} or less. NOTE: Replace the thermostat if the valve is not fully closed. Immerse the thermostat in water and heat it gradually. NOTE: Hold the thermostat with a wire or the like to avoid contacting with container bottom. Check the temperature when the valve starts to open. Standard value: 86 to 90°C {187 to 194°F} NOTE: Replace the thermostat if the temperature when the valve opens is outside the standard range. Check the valve lift. Standard value: Lift 8mm {0.315 in} or more Full open temperature 95°C {203°F} NOTE: Replace the thermostat if the valve lift is outside the standard range.

1. Thermostat installation Install a new gasket to the thermostat. Install the thermostat to the water outlet.
2. Water outlet installation Install the water outlet with the two bolts. Standard value: T=6.4N.m {65kgf.cm} {4.7ft.lbf}
3. Radiator outlet hose connection Align the marks marked when removing the hose, install the radiator outlet hose to the water outlet and secure the hose with the hose clamp.
4. Replenishing of coolant (SUBARU Super Coolant) (Refer to «REPLACEMENT»(ref-619192-S38018017162014053000000) )
5. Leak check of coolant (SUBARU Super Coolant) (Refer to «ON-VEHICLE INSPECTION»(ref-619192-S42694459552014053000000) )
6. Exhaust manifold installation (Refer to «REMOVAL»(ref-619189-S14759733182014053000000) )

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1. Air cleaner case sub-assembly removal (Refer to «REMOVAL»(ref-619192-S21416420212014053000000) )
2. Front bumper cover removal (Refer to «FRONT BUMPER»(ref-619181-S08279588312014053000000) )
3. Air cleaner duct removal (Refer to «REMOVAL»(ref-619192-S21416420212014053000000) )
4. Radiator cover plate removal (Refer to «REMOVAL»(ref-619192-S21416420212014053000000) )
5. Radiator reservoir tank assembly removal (Refer to «REMOVAL»(ref-619192-S21416420212014053000000) )
6. Water filler sub-assembly removal Remove the four bolts and disconnect the water filler sub-assembly.
7. Hood lock assembly disconnection (Refer to «INSTALLATION»(ref-619177-S35789727462014053000000) )
8. Radiator support sub-assembly removal (Refer to «REMOVAL»(ref-619192-S21416420212014053000000) )
9. Fan shroud removal Remove the two clamps. Disconnect the connector for cooling fan and connector for cooling fan NO. 2. Put a mark on the sponge at the upper side of fan shroud and cut the sponge using scissors etc. NOTE: Cut on the line from the corner of radiator gasket to the edge of fan shroud. Release the two claws and disconnect the fan shroud from the radiator Assembly. NOTE: Insert a cardboard, blanket, etc. between the radiator assembly and fan shroud to protect the radiator Assembly. Remove the fan shroud. CAUTION: Be careful not to damage the radiator outlet hose, discharge hose and A/C tube & accessory Assembly. Be careful not to damage the radiator inlet hose, radiator hose NO. 1 and water filler sub-assembly.
10. Fan removal Remove the nut and remove the fan.
11. Fan NO. 2 removal Remove the nut and remove the fan NO. 2.
12. Cooling fan motor removal Release the clamp of connector on the cooling fan side and disconnect the wiring harness from the cooling fan motor NO. 2. Remove the three screws and remove the cooling fan motor.
13. Cooling fan motor NO. 2 removal Remove the three screws and remove the cooling fan motor NO. 2.

1. Cooling fan motor NO. 2 installation Remove the three screws and install the cooling fan motor NO. 2. Standard value: T=3.9N.m {40kgf.cm} {2.9ft.lbf}
2. Cooling fan motor installation Install the cooling fan motor with the three screws. Standard value: T=3.9N.m {40kgf.cm} {2.9ft.lbf} Connect the wiring harness to the cooling fan motor. Engage the clamp of connector on the cooling fan motor NO. 2 side to the fan shroud.
3. Fan NO. 2 installation Install the fan NO. 2 with the nut. Standard value: T=6.3N.m {64kgf.cm} {4.6 ft.lbf}
4. Fan installation Install the fan with the nut. Standard value: T=6.3N.m {64kgf.cm} {4.6 ft.lbf}
5. Fan shroud installation NOTE: Insert a cardboard, blanket, etc. between the radiator assembly and fan shroud to protect the radiator Assembly. When installing a new fan shroud, put a new radiator gasket (upper side) and cut the radiator gasket (upper side) at the location where the old gasket was cut when removing it. Insert the fitting area at the lower part of fan shroud to the fitting area at the lower part of radiator Assembly. CAUTION: Be careful not to damage the radiator outlet hose, discharge hose and A/C tube & accessory Assembly. Be careful not to damage the radiator inlet hose, radiator hose NO. 1 and water filler sub-assembly. Engage the two claws and install the fan shroud to the radiator Assembly. Engage the two clamps. Connect the connector for cooling fan and connector for cooling fan NO. 2.
6. Radiator support sub-assembly installation (Refer to «INSTALLATION»(ref-619192-S21154310402014053000000) )
7. Radiator cover plate installation (Refer to «INSTALLATION»(ref-619192-S21154310402014053000000) )
8. Air cleaner duct installation (Refer to «INSTALLATION»(ref-619192-S21154310402014053000000) )
9. Hood lock assembly connection (Refer to «INSTALLATION»(ref-619177-S35789727462014053000000) )
10. Water filler sub-assembly installation Install the radiator cap stay with the four bolts. Standard value: T=7.5N.m {77kgf.cm} {5.5ft.lbf}
11. Radiator reservoir tank assembly installation (Refer to «INSTALLATION»(ref-619192-S21154310402014053000000) )
12. Front bumper cover installation (Refer to «INSTALLATION»(ref-619181-S05475449692014053000000) )
13. Air cleaner case sub-assembly installation (Refer to «INSTALLATION»(ref-619192-S21154310402014053000000) )

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1. Cooling fan motor check Make sure that the motor rotates smoothly when the battery voltage is applied to the connectors. Measure the current when the motor is rotating. CURRENT VALUE Inspection terminals Inspection conditions Standard value 1 - 2 20°C {68°F}, 12 V 7.4 to 11.4 A
2. Cooling fan motor NO. 2 check Make sure that the motor rotates smoothly when the battery voltage is applied to the connectors. Measure the current when the motor is rotating. CURRENT VALUE Inspection terminals Inspection conditions Standard value 1 - 2 20°C {68°F}, 12 V 7.4 to 11.4 A

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1. Cooling fan relay check Check the resistance between connector terminals. RESISTANCE Inspection terminals Inspection conditions Standard value 3 - 5 When the battery voltage is not applied to the terminal 1 and terminal 2: 10 k ohmsor more 3 - 5 When the battery voltage is applied to the terminal 1 and terminal 2: Less than 1 ohms
2. Cooling fan relay NO. 2 check Check the resistance between connector terminals. RESISTANCE Inspection terminals Inspection conditions Standard value 3 - 4 When the battery voltage is not applied to the terminal 1 and terminal 2: Less than 1 ohms 3 - 4 When the battery voltage is applied to the terminal 1 and terminal 2: 10 k ohmsor more 3 - 5 When the battery voltage is not applied to the terminal 1 and terminal 2: 10 k ohmsor more 3 - 5 When the battery voltage is applied to the terminal 1 and terminal 2: Less than 1 ohms
3. Cooling fan relay NO. 3 check Check the resistance between connector terminals. RESISTANCE Inspection terminals Inspection conditions Standard value 3 - 5 When the battery voltage is not applied to the terminal 1 and terminal 2: 10 k ohmsor more 3 - 5 When the battery voltage is applied to the terminal 1 and terminal 2: Less than 1 ohms