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Cooling System (H4SO): Other Subaru Forester SG рестайлинг

Cooling Fan 34 illustrations ~2273 words

CAUTION

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

NON-TURBO MODEL

TOOL NUMBER DESCRIPTION CHART - NON-TURBO MODEL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977100 CRANK PULLEY WRENCH Used for stopping crank pulley when loosening and tightening crank pulley bolts. 18231AA010 CAM SPROCKET WRENCH (For LH) Used for removing and installing cam sprocket (LH). CAM SPROCKET WRENCH (499207100) can also be used. 499207400 CAM SPROCKET WRENCH (For RH) Used for removing and installing cam sprocket (RH)

Scheme 41

Scheme 41: NON-TURBO MODEL
Scheme 41: NON-TURBO MODEL

Scheme 42

Scheme 42
Scheme 42

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Scheme 43
Scheme 43

TURBO MODEL

TOOL NUMBER DESCRIPTION CHART - TURBO MODEL ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS 499977100 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)

Scheme 44

Scheme 44
Scheme 44

Scheme 45

Scheme 45: WIRING DIAGRAM
Scheme 45: WIRING DIAGRAM

RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE

The concentration and safe operating temperature of 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 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).

Scheme 46

Scheme 46: RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE
Scheme 46: RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE
  1. Install the water pump onto cylinder block (LH). NOTE: Always use new gasket. When installing the water pump, tighten the bolts in two stages in alphabetical sequence as shown in figure. Tightening torque: First: 12 N.m (1.2 kgf-m, 8.9 ft-lb) Second: 12 N.m (1.2 kgf-m, 8.9 ft-lb)
  2. Install 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 cam sprocket (LH) using ST. ST 499977500 CAM SPROCKET WRENCH (Intake) Tightening torque: Tighten to 30 N.m (3.0 kgf-m, 21.8 ft-lb), and then tighten further by 45°. ST 499207400 CAM SPROCKET WRENCH (Exhaust) Tightening torque: Tighten to 30 N.m (3.0 kgf-m, 21.8 ft-lb), and then tighten further by 45°.
  6. Install the camshaft position sensor. INSTALLATION . >
  7. Install the belt idler No. 2 (C).
  8. Install the belt idler (B).
  9. Install the automatic belt tension adjuster (A) which has a tension rod held by a pin. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER INSTALLATION, Timing Belt. > Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
  10. Install the timing belt. TIMING BELT INSTALLATION, Timing Belt. >
  11. Install the crank pulley. INSTALLATION Crank Pulley. >
  12. Install the V-belts. INSTALLATION V-belt. >
  13. Install the radiator. INSTALLATION RADIATOR. >

Scheme 47

Scheme 47: INSPECTION
Scheme 47: INSPECTION
  1. Check the water pump bearing for smooth rotation.
  2. Check the water pump pulley for abnormalities.
  3. Make sure the impeller is not deformed or damaged.
  4. Inspect the clearance between impeller and pump case. Clearance between impeller and pump case: Specification 0.5 - 1.5 mm (0.020 - 0.060 in)
  5. After water pump installation, check pulley shaft for engine coolant leaks. If leaks are noted, replace the water pump assembly.

Scheme 48

Scheme 48
Scheme 48
  1. Set the vehicle on a lift.
  2. Lift-up the vehicle.
  3. Remove the under cover.
  4. Drain engine coolant completely. DRAINING OF ENGINE COOLANT REPLACEMENT, ENGINE COOLANT. >
  5. Disconnect the radiator outlet hose from thermostat cover.
  6. Remove the thermostat cover, and then remove the gasket and thermostat.

Scheme 49

Scheme 49
Scheme 49

Scheme 50

Scheme 50: INSTALLATION
Scheme 50: INSTALLATION
  1. Install a gasket to thermostat, and install the thermostat and gasket to water pump as a unit. Then, install the thermostat cover. NOTE: When reinstalling the thermostat, use a new gasket. The thermostat must be installed with the jiggle pin facing upward. Tightening torque: 12 N.m (1.2 kgf-m, 8.9 ft-lb)
  2. Connect the radiator outlet hose to thermostat cover.
  3. Install the under cover.
  4. Lower the vehicle.
  5. Fill engine coolant. FILLING OF ENGINE COOLANT REPLACEMENT, ENGINE COOLANT. >
WARNINGThe radiator is pressurized. Wait until engine cools down before working on the radiator.

Scheme 51

Scheme 51
Scheme 51

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Scheme 52
Scheme 52

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Scheme 53
Scheme 53

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Scheme 54
Scheme 54

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Scheme 55
Scheme 55

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Scheme 56
Scheme 56

Scheme 57

Scheme 57
Scheme 57
  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 engine coolant completely. DRAINING OF ENGINE COOLANT REPLACEMENT, ENGINE COOLANT. >
  6. Disconnect the connectors of radiator main fan (A) and sub fan motor (B).
  7. Disconnect the radiator outlet hose from thermostat cover.
  8. Disconnect the ATF cooler hoses from ATF pipes. (AT model) Apply the cap to prevent ATF leaks.
  9. Lower the vehicle.
  10. Disconnect the W.
  11. Remove the reservoir tank.
  12. Disconnect the radiator inlet hose from radiator.
  13. Remove the radiator upper brackets.
  14. Detach the power steering hose from the clip on the radiator.
  15. Lift the radiator up and away from vehicle.
  16. Remove the radiator under cover. (AT model)

Scheme 58

Scheme 58
Scheme 58
WARNINGThe radiator is pressurized. Wait until engine cools down before working on the radiator.

Scheme 59

Scheme 59
Scheme 59

Scheme 60

Scheme 60
Scheme 60
  1. Set the vehicle on a lift.
  2. Remove the collector cover.
  3. Disconnect the ground cable from battery.
  4. Lift-up the vehicle.
  5. Remove the under cover.
  6. Drain engine coolant completely. DRAINING OF ENGINE COOLANT REPLACEMENT, ENGINE COOLANT. >
  7. Disconnect the connectors of radiator main fan (A) and sub fan motor (B).
  8. Disconnect the radiator outlet hose from thermostat cover.
  9. Disconnect the ATF cooler hoses from ATF pipes. (AT model) Apply the cap to prevent ATF leaks.
  10. Lower the vehicle.
  11. Remove the reservoir tank.
  12. Disconnect the radiator inlet hose, air breather hose and the overflow hose from radiator.
  13. Remove the radiator upper brackets.
  14. Disconnect the power steering hose from the clip on the radiator.
  15. Lift the radiator up and away from vehicle.
  16. Remove the radiator under cover. (AT model)

Scheme 61

Scheme 61
Scheme 61
  1. Attach the radiator under cover to the radiator.
  2. Attach the radiator lower cushions to holes on the vehicle.
  3. Install the radiator to vehicle. NOTE: Make pins on the lower side of radiator be fitted into the radiator lower cushions on body side.
  4. Install the radiator upper brackets and tighten the bolts. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
  5. Attach the power steering hose to the radiator.
  6. Connect the radiator inlet hose.
  7. Install the reservoir tank. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
  8. Connect the over flow hose.
  9. Lift-up the vehicle.
  10. Connect the ATF cooler hoses. (AT model)
  11. Connect the radiator outlet hose.
  12. Connect the connectors to the radiator main fan motor (A) and sub fan motor (B).
  13. Install the under cover.
  14. Lower the vehicle.
  15. Connect the ground cable to battery.
  16. Fill engine coolant. FILLING OF ENGINE COOLANT REPLACEMENT, ENGINE COOLANT. >
  17. Check the ATF level. INSPECTION Automatic Transmission Fluid. >

Scheme 62

Scheme 62
Scheme 62
  1. Attach the radiator under cover to the radiator.
  2. Attach the radiator lower cushions to holes on the vehicle.
  3. Install the radiator to vehicle. NOTE: Make pins on the lower side of radiator be fitted into the radiator lower cushions on body side.
  4. Install the radiator upper brackets and tighten the bolts. Tightening torque: 18 N.m (1.8 kgf-m, 13.0 ft-lb)
  5. Attach the power steering hose to the radiator.
  6. Connect the radiator inlet hose, air breather hose and the overflow hose (B).
  7. Install the reservoir tank. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
  8. Lift-up the vehicle.
  9. Connect the ATF cooler hoses. (AT model)
  10. Connect the radiator outlet hose.
  11. Connect the connectors to the radiator main fan motor (A) and sub fan motor (B).
  12. Install the under cover.
  13. Lower the vehicle.
  14. Connect the ground cable to battery.
  15. Fill engine coolant. FILLING OF ENGINE COOLANT REPLACEMENT, ENGINE COOLANT. >
  16. Check the ATF level. INSPECTION Automatic Transmission Fluid. >
  17. Install the collector cover.

Scheme 63

Scheme 63: INSPECTION
Scheme 63: INSPECTION

Scheme 64

Scheme 64
Scheme 64
  1. Remove the radiator cap (for Non-turbo models) or the coolant filler tank cap (fro turbo models), and fill the engine coolant, and then install the tester (A) to the installation position of cap. Non-turbo model Turbo model
  2. When engine coolant leaks at/around radiator, apply the following pressure. Non-turbo model 157 kpa (1.6 kg/cm 2 , 23 psi) Turbo model 122 kpa (1.2 kg/cm 2 , 18 psi) CAUTION: Inspection must be carried out at the side of coolant filler tank, not at the side of radiator. (Turbo model) Engine should be turned off. Wipe engine coolant from check points in advance. Be careful to prevent engine coolant from spurting out when removing tester. Be careful not to deform the filler neck of radiator when installing and removing the tester.

Scheme 65

Scheme 65: INSPECTION
Scheme 65: INSPECTION
  1. Attach the radiator cap to tester.
  2. Increase pressure until the tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 - 6 seconds. Non-turbo model radiator side and turbo model coolant filler tank side Specified pressure: 93 - 123 kPa (0.95 - 1.25 kgf/cm 2 , 14 - 18 psi) Service limit pressure: 83 kPa (0.85 kgf/cm 2 , 12 psi) Radiator side on turbo models Specified pressure: 122 - 152 kPa (1.24 - 1.55 kgf/cm 2 , 18 - 22 psi) Service limit pressure: 112 kPa (1.14 kgf/cm 2 , 16 psi) CAUTION: Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect. Do not confuse the cap of coolant filler tank and cap of radiator.

Scheme 66

Scheme 66
Scheme 66

Scheme 67

Scheme 67
Scheme 67
  1. Set the vehicle on a lift.
  2. Disconnect the ground cable from battery.
  3. Remove the radiator upper brackets. (AT model)
  4. Lift-up the vehicle.
  5. Remove the under cover.
  6. Drain the coolant about 1 l (1.06 US qt, 0.88 Imp qt). DRAINING OF ENGINE COOLANT REPLACEMENT, ENGINE COOLANT. >
  7. Disconnect the connectors of main fan motor (A) and sub fan motor (B).
  8. Remove the radiator under cover attaching bolts. (AT model)
  9. Lift the radiator lower hose and float the radiator from the radiator under cover. Remove the ATF hose from 2 places on the clip of radiator fan motor assembly. (AT model)
  10. Lower the vehicle.
  11. Remove the V-belt covers.
  12. Disconnect the over flow hose.
  13. Remove the reservoir tank.
  14. Remove the mounting bolts from the radiator fan motor assembly.
  15. Disconnect the radiator inlet hose from radiator.
  16. Detach the power steering hose from the clip on the radiator.
  17. Lift the radiator fan motor assembly up and away from vehicle.

Scheme 68

Scheme 68
Scheme 68

Scheme 69

Scheme 69
Scheme 69

Scheme 70

Scheme 70
Scheme 70
  1. Set the vehicle on a lift.
  2. Remove the collector cover.
  3. Disconnect the ground cable from battery.
  4. Remove the radiator upper brackets. (AT model)
  5. Lift-up the vehicle.
  6. Remove the under cover.
  7. Drain the coolant about 1 l (1.06 US qt, 0.88 Imp qt). DRAINING OF ENGINE COOLANT REPLACEMENT, ENGINE COOLANT. >
  8. Disconnect the connectors of radiator main fan motor connector (A) and sub fan motor connector (B).
  9. Remove the radiator under cover attaching bolts. (AT model)
  10. Lift the radiator lower hose and float the radiator from the radiator under cover. Remove the ATF hose from 2 places on the clip of radiator fan motor assembly. (AT model)
  11. Lower the vehicle.
  12. Remove the reservoir tank.
  13. Remove the mounting bolts from radiator main fan motor assembly.
  14. Disconnect the radiator inlet hose and the over flow hose.
  15. Disconnect the power steering hose from the clip on the radiator.
  16. Remove the radiator main fan motor assembly from vehicle.
  1. Install the radiator main fan motor assembly to the radiator.
  2. Lift-up the vehicle.
  3. Lift the radiator lower hose and float the radiator from the radiator under cover. Connect the ATF hose to 2 locations on the clip of radiator main fan motor assembly. (AT model) NOTE: Make pins on the lower side of radiator be fitted into the vehicle side.
  4. Tighten the attachment bolts of the radiator under cover. (AT model)
  5. Connect the radiator main fan motor connector (A) and sub fan motor connector (B).
  6. Install the under cover.
  7. Lower the vehicle.
  8. Attach the power steering hose to the radiator.
  9. Connect the radiator inlet hose.
  10. Install the mounting bolts to radiator main fan motor assembly. Tightening torque: 4.9 N.m (0.50 kgf-m, 3.6 ft-lb)
  11. Install the reservoir tank. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
  12. Install the over flow hose.
  13. Install the radiator upper brackets. (AT model)
  14. Connect the ground cable to battery.
  15. Fill engine coolant. FILLING OF ENGINE COOLANT REPLACEMENT, ENGINE COOLANT. >

Scheme 71

Scheme 71
Scheme 71

Scheme 72

Scheme 72
Scheme 72
  1. Install the radiator main fan motor assembly to the radiator.
  2. Lift-up the vehicle.
  3. Lift the radiator lower hose and float the radiator from the radiator under cover. Connect the ATF hose to 2 locations on the clip of radiator main fan motor assembly. (AT model) NOTE: Make pins on the lower side of radiator be fitted into the vehicle side.
  4. Tighten the attachment bolts of the radiator under cover. (AT model)
  5. Connect the radiator main fan motor connector (A) and sub fan motor connector (B).
  6. Install the under cover.
  7. Lower the vehicle.
  8. Connect the power steering hose to the clip on the radiator.
  9. Connect the radiator inlet hose and the overflow hose to radiator.
  10. Install the mounting bolts to radiator main fan motor assembly. Tightening torque: 4.9 N.m (0.5 kgf-m, 3.6 ft-lb)
  11. Install the reservoir tank. Tightening torque: 7.5 N.m (0.76 kgf-m, 5.5 ft-lb)
  12. Install the radiator upper brackets. (AT model)
  13. Connect the ground cable to battery.
  14. Fill engine coolant. FILLING OF ENGINE COOLANT REPLACEMENT, ENGINE COOLANT. >
  15. Install the collector cover.

Scheme 73

Scheme 73: DISASSEMBLY
Scheme 73: DISASSEMBLY
  1. Remove the clip which holds motor connector onto the shroud.
  2. Remove the nut which holds fan to fan motor and shroud assembly.
  3. Remove the bolts which hold fan motor onto shroud.

Scheme 74

Scheme 74
Scheme 74

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