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 and sub fans do not rotate under the above conditions.
| Step | Check | Yes | No |
|---|---|---|---|
| 1 CHECK OPERATION OF RADIATOR FAN. Connect the test mode connector. Turn the ignition switch to ON. Using Subaru Select Monitor, check the compulsory operation of radiator fan. NOTE: When performing the compulsory operation check for the radiator fan using Subaru Select Monitor, the radiator main fan and sub fan will repeat such a operation as low speed revolution --> high speed revolution --> OFF in this order. Subaru Select Monitor Refer to Compulsory Valve Operation Check Mode for detail procedures. COMPULSORY VALVE OPERATION CHECK MODE . > | Do the radiator main and sub fans rotate at low speed? | Go to step 2. | Go to step 3. |
| 2 CHECK OPERATION OF RADIATOR FAN. Connect the test mode connector. Turn the ignition switch to ON. Using Subaru Select Monitor, check the compulsory operation of radiator fan. NOTE: When performing the compulsory operation check for the radiator fan using Subaru Select Monitor, the radiator main fan and sub fan will repeat such a operation as low speed revolution --> high speed revolution --> OFF in this order. Subaru Select Monitor Refer to Compulsory Valve Operation Check Mode for detail procedures. COMPULSORY VALVE OPERATION CHECK MODE . > | Do the radiator main and sub fans rotate at high speed? | Radiator main fan system is normal. | Go to step 32. |
| 3 CHECK POWER SUPPLY TO FAN RELAY 1. Turn the ignition switch to OFF. Remove the fan relay 1 from A/C relay holder. Measure the voltage between fan relay 1 terminal and chassis ground. Connector & terminal (F27) No. 31 (+) - Chassis ground (-) | Is the voltage more than 10 V? | Go to step 4. | Go to step 5. |
| 4 CHECK POWER SUPPLY TO FAN RELAY 1. Turn the ignition switch to ON. Measure the voltage between fan relay 1 terminal and chassis ground. Connector & terminal (F27) No. 34 (+) - Chassis ground (-) | Is the voltage more than 10 V? | Go to step 8. | Go to step 7. |
| 5 CHECK FUSE. Remove the 30 A fuse from A/C relay holder. Check the condition of fuse. | Is the fuse blown out? | Replace the fuse. | Go to step 6. |
| 6 CHECK HARNESS OF 30 A FUSE TERMINAL AND FAN RELAY 1 TERMINAL. Turn the ignition switch to OFF. Measure the resistance between 30 A fuse terminal and fan relay 1 terminal. Terminal No. 2 - No. 31 | Is the resistance less than 1 ohms? | Repair the power supply line. | Repair the open harness. |
| 7 CHECK FUSE. Turn the ignition switch to OFF. Remove the fuse No. 18. Check the condition of fuse. | Is the fuse blown out? | Replace the fuse. | Repair the power supply line. |
| 8 CHECK FAN RELAY 1. Turn the ignition switch to OFF. Measure the resistance between fan relay 1 terminals. Terminal No. 30 - No. 31 | Is the resistance more than 1 Mohms? | Go to step 9. | Replace the fan relay 1. |
| 9 CHECK FAN RELAY 1. Connect the battery to fan relay 1 terminals No. 32 and No. 34. Measure the resistance between fan relay 1 terminals. Terminal No. 30 - No. 31 | Is the resistance less than 1 ohms? | Go to step 10. | Replace the fan relay 1. |
| 10 CHECK HARNESS BETWEEN FAN RELAY 1 TERMINAL AND MAIN FAN MOTOR CONNECTOR. Disconnect the connectors from main fan motor. Measure the resistance of the harness between fan relay 1 terminal and main fan motor connector. Connector & terminal (F17) No. 1 - (F27) No. 30 | Is the resistance less than 1 ohms? | Go to step 11. | Repair the open harness between fan relay 1 terminal and main fan motor connector. |
| 11 CHECK THE HARNESS BETWEEN MAIN FAN MOTOR CONNECTOR AND FAN MODE RELAY CONNECTOR. Remove the fan mode relay from A/C relay holder. Measure the resistance of harness between main fan motor connector and fan mode relay connector. Connector & terminal (F17) No. 2 - (F27) No. 9 | Is the resistance less than 1 ohms? | Go to step 12. | Repair the open circuit of the harness between the main fan motor connector and fan mode relay connector. |
| 12 CHECK POOR CONTACT. Check poor contact of main fan motor connector. | Is there poor contact in main fan motor connector? | Repair the poor contact of main fan motor connector. | Go to step 13. |
| 13 CHECK MAIN FAN MOTOR. Connect the battery positive (+) terminal to terminal No. 1, and the ground (-) terminal to terminal No. 2 of main fan motor. | Does the main fan rotate? | Go to step 14. | Replace the main fan motor with new one. |
| 14 CHECK FAN MODE RELAY. Measure the resistance of fan mode relay. Terminal No. 6 - No. 9 | Is the resistance less than 1 ohms? | Go to step 15. | Replace the fan mode relay. |
| 15 CHECK HARNESS BETWEEN FAN MODE RELAY TERMINAL AND SUB FAN MOTOR CONNECTOR. Disconnect the connector from sub fan motor. Measure the resistance of harness between fan mode relay terminal and sub fan motor connector. Connector & terminal (F16) No. 1 - (F27) No. 6 | Is the resistance less than 1 ohms? | Go to step 16. | Repair the open harness between fan mode relay terminal and sub fan motor connector. |
| 16 CHECK SUB FAN MOTOR AND GROUND CIRCUIT. Measure the resistance between sub fan motor connector and chassis ground. Connector & terminal (F16) No. 2 - Chassis ground | Is the resistance less than 5 ohms? | Go to step 17. | Repair the open circuit of harness between sub fan motor connector and chassis ground. |
| 17 CHECK POOR CONTACT. Check the poor contact of sub fan motor connector. | Is there poor contact in sub fan motor connector? | Repair the poor contact of sub fan motor connector. | Go to step 18. |
| 18 CHECK SUB FAN MOTOR. Connect the battery positive (+) terminal to terminal No. 1, and the ground (-) terminal to terminal No. 2 of sub fan motor. | Does the sub fan rotate? | Go to step 19. | Replace the sub fan motor with new one. |
| 19 CHECK HARNESS BETWEEN FAN RELAY 1 AND ECM. Disconnect the connectors from ECM. Measure the resistance between fan relay 1 terminal and ECM connector. Connector & terminal (B136) No. 18 - (F27) No. 32 | Is the resistance less than 1 ohms? | Go to step 20. | Repair the open harness between fan relay 1 terminal and ECM. |
| 20 CHECK POOR CONTACT. Check the poor contact of ECM connector. | Is there poor contact in ECM connector? | Repair the poor contact of ECM connector. | Contact with your SOA Service Center. NOTE: Multiple parts may be deteriorated. |
| 21 CHECK POWER SUPPLY TO FAN RELAY 2. Turn the ignition switch to OFF. Remove the fan relay 2 from A/C relay holder. Measure the voltage between fan relay 2 terminal and chassis ground. Connector & terminal (F27) No. 28 (+) - Chassis ground (-) | Is the voltage more than 10 V? | Go to step 22. | Go to step 23. |
| 22 CHECK POWER SUPPLY TO FAN RELAY 2. Turn the ignition switch to ON. Measure the voltage between fan relay 2 terminal and chassis ground. Connector & terminal (F27) No. 25 (+) - Chassis ground (-) | Is the voltage more than 10 V? | Go to step 26. | Go to step 25. |
| 23 CHECK FUSE. Remove the 30 A fuse from A/C relay holder. Check the condition of fuse. | Is the fuse blown out? | Replace the fuse. | Go to step 24. |
| 24 CHECK HARNESS OF 30 A FUSE TERMINAL AND FAN RELAY 2 TERMINAL. Turn the ignition switch to OFF. Measure the resistance between 30 A fuse terminal and fan relay 2 terminal. Terminal No. 4 - No. 28 | Is the resistance less than 1 ohms? | Repair the power supply line. | Repair the open harness. |
| 25 CHECK FUSE. Turn the ignition switch to OFF. Remove the fuse No. 17. Check the condition of fuse. | Is the fuse blown out? | Replace the fuse. | Repair the power supply line. |
| 26 CHECK FAN RELAY 2. Turn the ignition switch to OFF. Remove the fan relay 2 from A/C relay holder. Measure the resistance of fan relay 2. Terminal No. 28 - No. 29 | Is the resistance more than 1 Mohms? | Go to step 27. | Replace the fan relay 2. |
| 27 CHECK FAN RELAY 2. Connect the battery to fan relay 2 terminals No. 25 and No. 27. Measure the resistance between fan relay 2 terminals. Terminal No. 28 - No. 29 | Is the resistance less than 1 ohms? | Go to step 28. | Replace the fan relay 2. |
| 28 CHECK HARNESS BETWEEN FAN RELAY 2 TERMINAL AND SUB FAN MOTOR CONNECTOR. Disconnect the connector from sub fan motor. Measure the resistance of harness between fan relay 2 terminal and sub fan motor connector. Connector & terminal (F16) No. 1 - (F27) No. 29 | Is the resistance less than 1 ohms? | Go to step 29. | Repair the open harness between fan relay 2 terminal and sub fan motor connector. |
| 29 CHECK HARNESS BETWEEN FAN RELAY 2 AND ECM. Disconnect the connectors from ECM. Measure the resistance between fan relay 2 terminal and ECM connector. Connector & terminal (B136) No. 29 - (F27) No. 27 | Is the resistance less than 1 ohms? | Go to step 30. | Repair the open harness between fan relay 2 terminal and ECM. |
| 30 CHECK HARNESS BETWEEN FAN MODE RELAY AND ECM. Measure the resistance between fan mode relay terminal and ECM connector. Connector & terminal (B136) No. 29 - (F27) No. 7 | Is the resistance less than 1 ohms? | Go to step 31. | Repair the open harness between fan mode relay terminal and ECM. |
| 31 CHECK POOR CONTACT. Check the poor contact of ECM connector. | Is there poor contact in ECM connector? | Repair the poor contact of ECM connector. | Contact with your SOA Service Center. NOTE: Multiple parts may be deteriorated. |
| 32 CHECK OPERATION OF RADIATOR FAN. | Does the radiator main fan rotate when the radiator main and sub fans do not rotate at high speed? | Go to step 21. | Go to step 33. |
| 33 CHECK GROUND CIRCUIT OF FAN MODE RELAY. Remove the fan mode relay from A/C relay holder. Measure the resistance between fan mode relay terminal and chassis ground. Connector & terminal (F27) No. 8 - Chassis ground | Is the resistance less than 1 ohms? | Go to step 34. | Repair the open circuit of harness between fan mode relay and chassis ground. |
| 34 CHECK POWER SUPPLY TO FAN MODE RELAY. Turn the ignition switch to ON. Measure the voltage between fan mode relay terminal and chassis ground. Connector & terminal (F27) No. 5 (+) - Chassis ground (-) | Is the voltage more than 10 V? | Go to step 35. | Repair the power supply line. |
| 35 CHECK FAN MODE RELAY. Turn the ignition switch to OFF. Remove the fan mode relay. Measure the resistance of fan mode relay. Terminal (F27) No. 8 - (F27) No. 9 | Is the resistance more than 1 Mohms? | Go to step 36. | Replace the fan mode relay. |
| 36 CHECK FAN MODE RELAY. Connect the battery to terminals No. 5 and No. 7 of fan mode relay. Measure the resistance of fan mode relay. Terminal (F27) No. 8 - (F27) No. 9 | Is the resistance less than 1 ohms? | Go to step 29. | Replace the fan mode relay. |
| NOTE |
|---|
| When performing the compulsory operation check for the radiator fan using Subaru Select Monitor, the radiator main fan and sub fan will repeat such a operation as low speed revolution --> high speed revolution --> OFF in this order. Subaru Select Monitor |
| NOTE |
|---|
| When performing the compulsory operation check for the radiator fan using Subaru Select Monitor, the radiator main fan and sub fan will repeat such a operation as low speed revolution --> high speed revolution --> OFF in this order. Subaru Select Monitor |
| NOTE |
|---|
| Multiple parts may be deteriorated. |
| NOTE |
|---|
| Multiple parts may be deteriorated. |
SYMPTOM CHART
Scheme 33
- Lift-up the vehicle.
- Remove the under cover.
- Remove the drain cock to drain engine coolant into container. NOTE: Remove the radiator cap so that engine coolant will drain faster.
- Install the drain cock.
Scheme 34
- Fill cooling system conditioner into the filler neck of the radiator (the filler neck of the coolant filler tank on turbo models). COOLING SYSTEM PROTECTING AGENT: Cooling system conditioner (part number SOA345001)
- Fill engine coolant into the filler neck of the radiator (the filler neck of the coolant filler tank on turbo models) up to the filler neck position. Coolant capacity (fill up to "FULL" level): SPECIFICATION GENERAL DESCRIPTION. > NOTE: 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.
- Fill engine coolant into the reservoir tank up to "FULL" level.
- Close the radiator cap (on Non-turbo models) or the coolant filler tank cap (on turbo models), start the engine and race 5 to 6 times at less than 3,000 rpm, then stop the engine. (Complete this operation within 40 seconds.)
- Wait for one minute after the engine stops, then open the radiator cap (on Non-turbo models) or the coolant filler tank cap (on turbo models). If the engine coolant level drops, add engine coolant into the radiator filler neck (on Non-turbo models) or the coolant filler tank filler neck (on turbo models) up to the filler neck position.
- Perform the procedures 4) and 5) again.
- Close the radiator cap (on Non-turbo models) or the coolant filler tank cap (on turbo models), and the reservoir tank cap.
- Start the engine and operate the heater at maximum hot position and the blower speed setting to "LO"
- Run the engine at 2,000 rpm or less until radiator fan starts and stops. NOTE: Be careful with the engine coolant temperature gauge to prevent overheating.
- Stop the engine and wait until the engine coolant temperature lowers to 30°C (86°F).
- Open the radiator cap (on Non-turbo models) or the coolant filler tank cap (on turbo models). If the engine coolant level drops, add engine coolant into the radiator filler neck (on Non-turbo models) or the coolant filler tank filler neck (on turbo models) up to the filler neck position. Then, pour the coolant into reservoir tank up to "FULL" level.
- Close the radiator cap (on Non-turbo models) or the coolant filler tank cap (on turbo models), and the reservoir tank cap.
- Set the heater setting to maximum hot position and the blower speed setting to "LO" and start the engine. Perform racing at less than 3,000 rpm. If the flowing sound is heard, repeat the procedures from 9) again.
Replace the thermostat if the valve does not close completely at an ambient temperature or if the following test shows unsatisfactory results.
- Inspection method Immerse the thermostat and a 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 measured value should meet the specification.
Note. Leave the thermostat in the boiling water for more than five minutes before measuring valve lift. Hold the thermostat with a wire or the like to avoid contacting with container bottom.
Starting temperature 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)
Valve lift: 9.0 mm (0.354 in) or more
Scheme 35
Make sure the engine coolant level is between "FULL" and "LOW".
| Trouble | Possible cause | Corrective action |
|---|---|---|
| Overheating | A. Insufficient engine coolant | Replenish engine coolant, inspect for leakage, and repair it if necessary. |
| B. Loose timing belt | Repair or replace timing belt tensioner. | |
| C. Oil on timing belt | Replace. | |
| D. Malfunction of thermostat | Replace. | |
| E. Malfunction of water pump | Replace. | |
| F. Clogged engine coolant passage | Clean. | |
| G. Improper ignition timing | Inspect and repair ignition control system. PROCEDURE Basic Diagnostic Procedure. > PROCEDURE Basic Diagnostic Procedure. > | |
| H. Clogged or leaking radiator | Clean, repair or replace. | |
| I. Engine oil mixed in engine coolant | Replace engine coolant. | |
| J. Air/fuel mixture ratio too lean | Inspect and repair the fuel injection system. PROCEDURE Basic Diagnostic Procedure. > PROCEDURE Basic Diagnostic Procedure. > | |
| K. Excessive back pressure in exhaust system | Clean or replace. | |
| L. Insufficient clearance between piston and cylinder | Adjust or replace. | |
| M. Slipping clutch | Correct or replace. | |
| N. Dragging brake | Adjust. | |
| O. Defective radiator fan | Inspect the radiator fan relay, engine coolant temperature sensor or fan motor and replace them. | |
| Over-cooling | A. Ambient temperature extremely low | Partly cover radiator front area. |
| B. Defective thermostat | Replace. | |
| Engine coolant leaks | A. Loosened or damaged connecting units on hoses | Correct or replace. |
| B. Leakage from water pump | Replace. | |
| C. Leakage from water pipe | Correct or replace. | |
| D. Leakage around cylinder head gasket | Retighten cylinder head bolts or replace gasket. | |
| E. Damaged or cracked cylinder head and crankcase | Correct or replace. | |
| F. Damaged or cracked thermostat case | Correct or replace. | |
| G. Leakage from radiator | Correct or replace. | |
| Strange noise | A. Defective drive belt | Replace. |
| B. Defective radiator fan | Replace. | |
| C. Defective water pump bearing | Replace water pump. | |
| D. Defective water pump mechanical seal | Replace water pump. |
POSSIBLE CAUSE