Engine Cooling System - Cooling (H4DOTC): Removal & Installation Subaru Forester SH

REMOVAL

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

1. Set the vehicle on a lift.
2. Remove the collector cover.
3. Disconnect the ground cable from the battery.
4. Lift up the vehicle.
5. Remove the under cover.
6. Remove the heat shield cover from radiator.
7. Drain engine coolant completely. Refer to «DRAINING OF ENGINE COOLANT»(ref-325304-S01033522502009071800000) , REPLACEMENT, Engine Coolant .
8. Disconnect the connectors of main fan motor (A) and sub fan motor (B).
9. Disconnect the radiator outlet hose from thermostat cover.
10. Disconnect the ATF cooler hoses from ATF pipes. NOTE: Plug the ATF pipe to prevent ATF from leaking.
11. Lower the vehicle.
12. Remove the air intake duct. Refer to «REMOVAL»(ref-325300-S04200539772009071800000) , Air Intake Duct .
13. Remove the reservoir tank. Refer to «REMOVAL»(ref-325304-S20417842822009071800000) , Reservoir Tank .
14. Disconnect the radiator inlet hose from the radiator.
15. Disconnect the two coolant filler tank hoses from the radiator.
16. Remove the radiator upper brackets.
17. Move the radiator to the left while lifting it upward.
18. Lift the radiator up and away from vehicle.

Scheme 65

1. Attach the radiator lower cushion to the hole on the radiator lower bracket.
2. Install the radiator to vehicle. NOTE: Make pins on the lower side of radiator be fitted into the radiator lower cushions on body side.
3. Install the radiator upper brackets and tighten the bolts. Tightening torque: 12 N.m (1.2 kgf-m, 8.9 ft-lb)
4. Connect the two coolant filler tank hoses to the radiator.
5. Connect the radiator inlet hose.
6. Install the reservoir tank. Refer to «INSTALLATION»(ref-325304-S01271956452009071800000) , Reservoir Tank .
7. Install the air intake duct. Refer to «INSTALLATION»(ref-325300-S02354694642009071800000) , Air Intake Duct .
8. Lift up the vehicle.
9. Connect the ATF cooler hoses.
10. Connect the radiator outlet hose.
11. Connect the connectors to the main fan motor (A) and sub fan motor (B).
12. Install the heat shield cover to the radiator. Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
13. Install the under cover.
14. Lower the vehicle.
15. Connect the battery ground cable to battery.
16. Fill engine coolant. Refer to «FILLING OF ENGINE COOLANT»(ref-325304-S22895877052009071800000) , REPLACEMENT, Engine Coolant .
17. Check the ATF level. Refer to «INSPECTION»(ref-325309-S11821766972009071800000) , Automatic Transmission Fluid .
18. Install the collector cover.

Scheme 66

1. Remove the coolant filler tank cap, fill the coolant filler tank with engine coolant, then install the tester to the installation position of the cap.
2. Apply a pressure of 122 kPa (1.2 kg/cm 2 , 18 psi) to the radiator and check the following points

1. Leakage from the radiator or its vicinity
2. Leakage from the hose or its connections

Scheme 67

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 five to six seconds. Remove the cap if it is opened under a pressure less than the service limit value

Coolant filler tank side

Specification

93 - 123 kPa

(0.95 - 1.25 kg/cm 2 , 14 - 18 psi)

Service limit

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

Radiator side

Specification

122 - 152 kPa

(1.24 - 1.55 kg/cm 2 , 18 - 22 psi)

Service limit

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

Scheme 68

Scheme 69

1. Set the vehicle on a lift.
2. Remove the collector cover.
3. Disconnect the ground cable from the battery.
4. Lift up the vehicle.
5. Remove the under cover.
6. Disconnect the main fan motor connector (A).
7. Remove the heat shield cover from radiator.
8. Remove the ATF hose from the hose clip of the radiator main fan motor assembly.
9. Lower the vehicle.
10. Remove the air intake duct (rear). Refer to «REMOVAL»(ref-325300-S04200539772009071800000) , Air Intake Duct .
11. Remove the reservoir tank. Refer to «REMOVAL»(ref-325304-S20417842822009071800000) , Reservoir Tank .
12. Remove the bolts that hold the radiator main fan motor assembly and the over flow pipe.
13. Remove the radiator main fan motor assembly from the upper side of the vehicle.

INSTALLATION

Install in the reverse order of removal.

Tightening torque

7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

Tightening torque

3 N.m (0.3 kgf-m, 2.2 ft-lb)

Scheme 70

1. Remove the clip which holds the main fan motor connector onto the radiator main fan shroud.
2. Remove the nut which holds the radiator main fan to the main fan motor.
3. Remove the bolts which hold the main fan motor onto radiator main fan shroud.

Scheme 71

Install in the reverse order of removal.

Tightening torque

7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

Tightening torque

3 N.m (0.3 kgf-m, 2.2 ft-lb)

Scheme 72

1. Remove the clip which holds the sub fan motor connector onto the radiator sub fan shroud.
2. Remove the nut which holds the radiator sub fan to the sub fan motor.
3. Remove the bolts which hold the sub fan motor onto the radiator sub fan shroud.

1. Pull out the overflow hose (A).
2. Pull out the reservoir tank to the arrow direction while pushing the claw (B).

Scheme 73

Install in the reverse order of removal.

Scheme 74

1. Remove the collector cover.
2. Drain approximately 3.0 l (3.2 US qt, 2.6 Imp qt) of coolant. Refer to «DRAINING OF ENGINE COOLANT»(ref-325304-S01033522502009071800000) , REPLACEMENT, Engine Coolant .
3. Disconnect the engine coolant hoses from coolant filler tank.
4. Remove the bolts which install the coolant filler tank.
5. Disconnect the engine coolant hose which connects the under side of coolant filler tank.
6. Remove the coolant filler tank.

Install in the reverse order of removal.

Tightening torque

16 N.m (1.6 kgf-m, 11.8 ft-lb)

Scheme 75