Cooling System (h4dotc) Subaru Impreza WRX GD/GG рестайлинг 2

SPECIFICATION

GENERAL SPECIFICATION

Identifying Water Pump Component Location. Scheme 55

Identifying Radiator And Radiator Fan Components Location. Scheme 56

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 yourself, because each part in 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 electrical connectors of sensors or units, be sure to disconnect the ground cable from battery.

PREPARATION TOOL

PREPARATION TOOL 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 intake cam sprocket. 499207400 CAM SPROCKET WRENCH Used for removing and installing exhaust cam sprocket

Scheme 57

Scheme 58

Scheme 59

Scheme 60

INSPECTION

DETECTING CONDITION

1. Engine coolant temperature is above 96°C (205°F).
2. A/C compressor is rotated.
3. Vehicle speed is below 19 km/h (12 MPH).

TROUBLE SYMPTOM

1. Radiator main fan does not rotate under the above conditions.
2. Radiator main fan does not rotate at high speed when the following conditions are both met: Engine coolant temperature is above 90°C (194°F). A/C is ON.

SYMPTOM CHART

DETECTING CONDITION

1. Engine coolant temperature is above 96°C (205°F).
2. A/C compressor is rotated.
3. Vehicle speed is below 19 km/h (12 MPH).

TROUBLE SYMPTOM

1. Radiator sub fan does not rotate under the above conditions.
2. Radiator sub fan does not rotate at high speed when the following conditions are both met

1. Engine coolant temperature is above 90°C (194°F).
2. A/C is ON.

SYMPTOM CHART

Scheme 61

1. Lift-up the vehicle.
2. Remove the under cover.
3. Remove the drain cock to drain engine coolant into container. NOTE: Remove the coolant filler tank cap so that engine coolant will drain faster. If engine coolant adheres to the exhaust pipe, wipe it off completely. (Scheme 59): Locating Coolant Filler Tank Cap
4. Install the drain cock.

Scheme 62

1. Pour cooling system conditioner through the filter neck. Cooling system protective agent: COOLING SYSTEM CONDITIONER (Part No. SOA635071)
2. Fill engine coolant into the coolant filler tank up to filler neck position. Coolant capacity (fill up to "FULL" level): AT model Approx. 7.6 l (8.0 US qt, 6.7 Imp qt) MT model Approx. 7.7 l (8.1 US qt, 6.8 Imp qt) CAUTION: Do not mix up the coolant filler tank side cap with radiator side cap. NOTE: Do not remove the radiator side cap when filling engine coolant. The SUBARU Genuine Coolant containing anti-freeze 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.
3. Fill engine coolant into the reservoir tank up to "FULL" level. (Scheme 60): Identifying Engine Coolant Into Reservoir Tank Up To "FULL" Level
4. Close the coolant filler tank cap, 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.)
5. Wait for one minute after the engine stops, open the coolant filler tank cap. If the engine coolant level drops, add engine coolant to the filler neck position of radiator.
6. Perform the procedures 4) and 5) again.
7. Attach the coolant filler tank cap and reservoir tank cap properly.
8. Start the engine and operate the heater at maximum hot position and the blower speed setting to "LO".
9. 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. If the radiator hose becomes to harden by the pressure of engine coolant, air bleeding operation seems to be almost completed.
10. Stop the engine and wait until engine coolant temperature lowers to 30°C (86°F) or less.
11. Open the coolant filler tank cap. If the engine coolant level drops, add engine coolant into the coolant filler tank up to the filler neck position and the reservoir tank to "FULL" level.
12. Attach the coolant filler tank cap and reservoir tank cap properly.
13. Operate the heater at maximum hot position and the blower speed setting to "LO" and start the engine. Race at less than 3,000 rpm. If the flowing sound is heard from heater core, repeat the procedures from step 9 ).
14. Install the collector cover.

RELATIONSHIP OF SUBARU COOLANT CONCENTRATION AND FREEZING TEMPERATURE

The concentration and safe operating temperature of the 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 and 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).

Coolant Temperature Diagram. Scheme 63

PROCEDURE TO ADJUST THE CONCENTRATION OF THE COOLANT

To adjust the concentration of the coolant according to temperature, find the proper fluid concentration in the above diagram and replace the necessary amount of coolant with an undiluted solution of SUBARU genuine coolant (concentration 50%).

The amount of coolant that should be replaced can be determined using the diagram.

[Example]

Assume that the coolant concentration must be increased from 25% to 40%. Find point A, where the 25% line of coolant concentration intersects with the 40% curve of the necessary coolant concentration, and read the scale on the vertical axis of the graph at height A. The quantity of coolant to be drained is 2.1 l (2.2 US qt, 1.8 Imp qt). Drain 2.1 l (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 l (2.2 US qt, 1.8 Imp qt) of the undiluted solution of SUBARU coolant.

If a coolant concentration of 50% is needed, drain all the coolant and refill with the undiluted solution only.

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

1. Remove the radiator. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), Radiator. >
2. Remove the V-belts. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-h4dotc), V-belt. >
3. Remove the timing belt. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-h4dotc), Timing Belt. >
4. Remove the automatic belt tension adjuster (A).
5. Remove the belt idler (B).
6. Remove the belt idler No. 2 (C). (Scheme 62): Identifying Automatic Belt Tension Adjuster And Belt Idler
7. Remove the camshaft position sensor. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/fuel-system/#fuel-injection-fuel-systems-h4dotc), Camshaft Position Sensor. >
8. Remove the cam sprockets (LH) by using ST. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-h4dotc), Cam Sprocket. >
9. Remove the belt cover No. 2 (LH). see scheme 10: Identifying Belt Cover
10. Remove the tensioner bracket. (Scheme 64): Identifying Tensioner Bracket
11. Disconnect the hose from water pump.
12. Remove the water pump. (Scheme 65): Identifying Water Pump

Scheme 69

1. Install the water pump onto cylinder block (LH). NOTE: Replace the gasket with a new one. When installing the water pump, tighten bolts in two stages in alphabetical sequence as shown in the figure. Tightening torque: First: 12 N.m (1.2 kgf-m, 8.7 ft-lb) Second: 12 N.m (1.2 kgf-m, 8.7 ft-lb) (Scheme 66): Identifying Water Pump Bolts
2. Connect the hose to water pump.
3. Install the tensioner bracket. Tightening torque: 24.5 N.m (2.5 kgf-m, 18.1 ft-lb) (Scheme 67): Identifying Tensioner Bracket
4. Install the belt cover No. 2 (LH). Tightening torque: 5 N.m (0.5 kgf-m, 3.6 ft-lb) (Scheme 68): Identifying Belt Cover
5. Install the cam sprockets (LH) by using ST. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-h4dotc), Cam Sprocket. >
6. Install the camshaft position sensor. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/fuel-system/#fuel-injection-fuel-systems-h4dotc), Camshaft Position Sensor. >
7. Install the belt idler No. 2 (C).
8. Install the belt idler (B).
9. Install the automatic belt tension adjuster (A) which has tension rod held by pin. < Ref. to «AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-h4dotc), INSTALLATION, Timing Belt. > Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb) (Scheme 69): Identifying Automatic Belt Tension Adjuster And Belt Idler
10. Install the timing belt. < Ref. to «TIMING BELT»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-h4dotc), INSTALLATION, Timing Belt. >
11. Install the V-belts. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#engine-mechanical-h4dotc), V-belt. >
12. Install the radiator. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), Radiator. >

Scheme 70

1. Check the water pump bearing for smooth rotation.
2. Check the water pump pulley for abnormalities.
3. Make sure the impller is not deformed or damaged.
4. Check the clearance between impeller and pump case. Clearance between impeller and pump case: Standard 0.5 - 1.5 mm (0.020 - 0.059 in) see scheme 17: Checking Clearance Between Impeller And Pump Case
5. After water pump installation, check the pulley shaft for engine coolant leaks. If leaks are noted, replace the water pump assembly.

Scheme 71

Scheme 72

1. Set the vehicle on a lift.
2. Lift-up the vehicle.
3. Remove the under cover.
4. Drain the engine coolant completely. < Ref. to «DRAINING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), REPLACEMENT, Engine Coolant. > see scheme 18: Locating Coolant Filler Tank Cap
5. Disconnect the radiator outlet hose. see scheme 19: Identifying Radiator Outlet Hose
6. Remove the thermostat cover, and then remove the gasket and thermostat. (Scheme 70): Identifying Thermostat Cover, Gasket And Thermostat

Scheme 73

1. Install the gasket to thermostat, and install the thermostat and gasket to water pump as a unit. NOTE: When reinstalling the thermostat, use a new gasket. The thermostat must be installed with the jiggle pin (D) facing upward. Tightening torque: 12 N.m (1.2 kgf-m, 8.7 ft-lb) see scheme 21: Identifying Thermostat Cover, Gasket And Thermostat
2. Fill engine coolant. < Ref. to «FILLING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), REPLACEMENT, Engine Coolant. >

Replace the thermostat if the valve does not close completely at an ambient temperature or if the following test shows unsatisfactory results.

Immerse the thermostat and 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 measurement should be to the specification.

Note. Leave the thermostat in a boiled water for more than five minutes before measuring the valve lift. Hold the thermostat with a wire or the like to avoid contacting with the bottom of container.

Starts to open: 76 - 80°C (169 - 176°F)

Fully opens: 91°C (196°F)

Valve lift: 9.0 mm (0.35 in) or more

Scheme 74

REMOVAL

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

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. < Ref. to «DRAINING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), REPLACEMENT, Engine Coolant. >
6. Disconnect the connectors of radiator main fan motor (A) and sub fan motor (B). (Scheme 72): Identifying Radiator Main Fan Motor Connector (Scheme 73): Identifying Sub Fan Motor Connector
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. (Scheme 74): Locating ATF Cooler Hose Clamp
8. Disconnect the radiator outlet hose from thermostat cover. (Scheme 75): Identifying Radiator Outlet Hose From Thermostat Cover
9. Lower the vehicle.
10. Remove the air intake duct. (Scheme 76): Identifying Air Intake Duct
11. Remove the V-belt covers. (Scheme 77): Locating V-Belt Covers
12. Disconnect the overflow hose.
13. Remove the reservoir tank. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), Reservoir Tank. >
14. Disconnect the radiator inlet hose (A) and water tank hose (B) from radiator. see scheme 29: Identifying Radiator Inlet Hose (Scheme 78): Identifying Water Tank Hose
15. Remove the radiator upper brackets. (Scheme 79): Locating Radiator Upper Brackets
16. While lifting the radiator up, slide it to the left.
17. Lift-up the radiator, and then remove it from vehicle.

Scheme 83

1. Attach the radiator mounting cushions to the holes on vehicle. (Scheme 80): Identifying Radiator Mounting Cushions To 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) (Scheme 81): Locating Radiator Brackets
4. Connect the radiator inlet hose (A) and water tank hose (B). (Scheme 82): Identifying Radiator Inlet Hose (Scheme 83): Identifying Water Tank Hose
5. Install the reservoir tank. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), Reservoir Tank. >
6. Connect the overflow hose.
7. Install the V-belt cover. see scheme 36: Locating V-Belt Cover
8. Install the air intake duct. < Ref. to «INSTALLATION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#intake-induction-h4dotc-engine), Air Intake Duct. >
9. Lift-up the vehicle.
10. Connect the ATF cooler hoses. (AT model). see scheme 37: Locating ATF Cooler Hoses Clamp
11. Connect the radiator outlet hose. see scheme 38: Identifying Radiator Outlet Hose
12. Connect the connectors to radiator main fan motor (A) and sub fan motor (B). see scheme 39: Identifying Radiator Main Fan Motor Connector see scheme 40: Identifying Sub Fan Motor Connector
13. Install the under cover.
14. Lower the vehicle.
15. Connect the battery ground cable to battery.
16. Fill engine coolant. < Ref. to «FILLING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), REPLACEMENT, Engine Coolant. >
17. Check the ATF level. < Ref. to «INSPECTION»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/automatic-trans/#automatic-transmission__inspection), Automatic Transmission Fluid. >

Scheme 84

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. see scheme 41: Attaching Tester To Coolant Filler Tank In Place Of Cap
2. Apply a pressure of 122 kPa (1.2 kgf/cm 2, 18 psi) to the coolant filler tank to check if: Engine coolant leaks at/around radiator. Engine coolant leaks at/around hoses or connections. CAUTION: Inspection must be carried out at the side of coolant filler tank, not at the side of radiator. Engine should be turned off. Wipe engine coolant from check points in advance. If engine coolant adheres to the exhaust pipe, wipe it off completely. Be careful to prevent engine coolant from spurting out when removing the tester. Be careful also not to deform the filler neck of coolant filler tank when installing or removing tester.

Scheme 85

1. Attach the radiator cap to tester. see scheme 42: Attaching 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 kgf/cm 2, 14 - 18 psi) Service limit pressure: 83 kPa (0.85 kgf/cm 2, 12 psi) Radiator side Standard 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 mix up the coolant filler tank side cap with radiator side cap.

Scheme 86

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 (A). see scheme 43: Identifying Main Fan Motor Connector
5. Lower the vehicle.
6. Remove the air intake duct. (Scheme 84): Identifying Air Intake Duct
7. Disconnect the overflow hose.
8. Remove the overflow pipe.
9. Remove the reservoir tank. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), Reservoir Tank. >
10. Remove the radiator main fan motor assembly. (Scheme 85): Locating Radiator Main Fan Motor Bolts

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)

Scheme 87

Scheme 88

1. Remove the nut which holds the fan onto fan motor and shroud assembly. see scheme 47: Locating Fan Motor Bolt
2. Remove the bolts which install the fan motor onto shroud. (Scheme 86): Locating Fan Motor Shroud Bolt

ASSEMBLY

Assemble in the reverse order of disassembly.

Tightening torque: 4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

Tightening torque: 3.4 N.m (0.35 kgf-m, 2.5 ft-lb)

Scheme 89

1. Disconnect the ground cable from battery.
2. Lift-up the vehicle.
3. Remove the under cover.
4. Disconnect the connector of sub fan motor (B). (Scheme 88): Identifying Sub Fan Motor Connector
5. Lower the vehicle.
6. Remove the air intake duct. see scheme 52: Identifying Air Intake Duct
7. Remove the bolts which hold the sub fan shroud to radiator.
8. Remove the overflow pipe.
9. Remove the radiator sub fan shroud through the under side of vehicle. see scheme 53: Locating Radiator Bolt

Install in the reverse order of removal.

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

Scheme 90

Scheme 91

1. Remove the clip which holds the motor harness onto shroud. see scheme 55: Removing Clip
2. Remove the nut which holds the fan onto fan motor and shroud assembly. (Scheme 89): Locating Fan Motor Bolt
3. Remove the bolts which install the fan motor onto shroud. see scheme 57: Locating Fan Motor Shroud Bolt

Assemble in the reverse order of disassembly.

Tightening torque: 4.4 N.m (0.45 kgf-m, 3.3 ft-lb)

Tightening torque: 3.4 N.m (0.35 kgf-m, 2.5 ft-lb)

Scheme 92

1. Disconnect the overflow hose from the radiator filler neck position.
2. Pull out the reservoir tank to the direction of arrow while pushing the pawl (A). see scheme 60: Identifying Reservoir Tank

Install in the reverse order of removal.

Note. Refer to COMPONENT for tightening torque. < Ref. to COMPONENT , General Description. >

Make sure the engine coolant level is between "FULL" and "LOW".

Scheme 93

Scheme 94

1. Drain the coolant about 3.0 l (3.2 US qt, 2.6 Imp qt). < Ref. to «DRAINING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), REPLACEMENT, Engine Coolant. >
2. Remove the air cleaner upper cover and air intake boot. < Ref. to «REMOVAL»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/mechanical/#intake-induction-h4dotc-engine), Air Cleaner Case. >
3. Remove the air cleaner element.
4. Disconnect the engine coolant hoses from coolant filler tank. see scheme 61: Locating Engine Coolant Hoses
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. see scheme 62: Locating Coolant Filler Tank Bolt

Scheme 95

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) (Scheme 92): Identifying Coolant Filler Tank Bolt
2. Fill engine coolant. < Ref. to «FILLING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2-2005-2007/remont/cooling-fan/#cooling-system-h4dotc), REPLACEMENT, Engine Coolant. >

ENGINE COOLING SYSTEM - SYMPTOM CHART

See also:
• READ DIAGNOSTIC TROUBLE CODE (DTC)
• REMOVAL
• REMOVAL
• INSTALLATION
• INSPECTION
• REMOVAL