Engine Cooling System Subaru Impreza WRX GD/GG рестайлинг

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CAUTION

1. Wear working 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 or 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 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 safety stands at the specified points.
8. Before disconnecting electrical connectors of sensors or units, be sure to disconnect negative terminal from battery.

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Condition

1. Engine coolant temperature is above 95°C (203°F).
2. Vehicle speed is below 19 km/h (12 MPH).

TROUBLE SYMPTOM

1. Radiator main fan does not rotate under the above conditions.

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Note. Inspection by SOA (distributor) service is required, because probable cause is deterioration of multiple parts.

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).

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

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

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Note. Inspection by SOA (distributor) service is required, because probable cause is deterioration of multiple parts.

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NON-TURBO MODEL

Note. System for A/C equipped vehicles only.

Condition (1)

1. Engine coolant temperature is below 95°C (203°F).
2. A/C switch is turned ON.
3. Vehicle speed is below 19 km/h (12 MPH).

Condition (2)

1. Engine coolant temperature is above 100°C (212°F).
2. A/C switch is turned OFF.
3. Vehicle speed is below 19 km/h (12 MPH).

1. Radiator sub fan does not rotate under conditions (1) and (2) above.

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Note. Inspection by SOA (distributor) service is required, because probable cause is deterioration of multiple parts.

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).

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: Engine coolant temperature is above 90°C (194°F) A/C is ON

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Note. Inspection by SOA (distributor) service is required, because probable cause is deterioration of multiple parts.

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1. Lift-up the vehicle.
2. Remove the under cover.
3. Remove the drain cock to drain engine coolant into container. NOTE: Remove the radiator cap so that engine coolant will drain faster.

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1. Fill engine coolant into radiator up to the filler neck position. Coolant capacity (fill up to "FULL" level): Non-turbo AT model: Approximately, 6.9 l (7.29 US qt, 6.07 Imp qt) Non-turbo MT model: Approximately, 7 l (7.4 US qt, 6.2 Imp qt) Turbo AT model: Approximately, 7.6 l (8.03 US qt, 6.69 Imp qt) Turbo MT model: Approximately, 7.7 l (8.14 US qt, 6.78 Imp qt) CAUTION: The SUBARU Genuine Coolant containing antifreeze and anti-rust agents is especially made for SUBARU engine, which has an aluminum crankcase. Always use SUBARU Genuine Coolant, since other coolant may cause corrosion.
2. Fill engine coolant into reservoir tank up to the upper level.
3. Warm-up engine completely for more than five minutes at 2,000 to 3,000 rpm.
4. If the engine coolant level drops in radiator, add the engine coolant to filler neck position.
5. If the engine coolant level drops from upper level of reservoir tank, add the engine coolant to the upper level.
6. Attach the radiator cap and reservoir tank cap properly.

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, the concentration is 45% (point A), the safe operating temperature is -14°C (7°F) (point B), and the freezing temperature is - 20°C (-4°F) (point C).

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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 liters (2.2 US qt, 1.8 Imp qt). Drain 2.1 liters (2.2 US qt, 1.8 Imp qt) of coolant from the cooling system and add 2.1 liters (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.

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1. Remove the radiator, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , Radiator.
2. Remove V-belts, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mecahnical-25l-sohc) , V-belt.
3. Remove the timing belt, see «TIMING BELT»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mecahnical-25l-sohc) , REMOVAL, Timing Belt.
4. Remove the automatic belt tension adjuster.
5. Remove the belt idler No. 2.
6. Remove the left-hand camshaft sprocket by using ST. ST 18231AA010 CAMSHAFT SPROCKET WRENCH NOTE: Also the CAMSHAFT SPROCKET WRENCH (499207100) can be used.
7. Remove the left-hand belt cover No. 2.
8. Remove the tensioner bracket.
9. Disconnect the heater hose from the water pump.
10. Remove the water pump.

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1. Remove the radiator, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , Radiator.
2. Remove the V-belts, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mechanical-20l-dohctc) , V-belt.
3. Remove the timing belt, see «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mechanical-20l-dohctc) , Timing Belt Assembly.
4. Remove the automatic belt tension adjuster (A).
5. Remove the belt idler (B).
6. Remove the belt idler No. 2 (C).
7. Remove the camshaft position sensor, see «REMOVAL & INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/removal-installation/#engine-controls-removal-installation-impreza-outback-sport) , Camshaft Position Sensor.
8. Remove the left-hand camshaft sprockets by using ST. ST 18231AA010 CAMSHAFT SPROCKET WRENCH (Intake) ST 499207400 CAMSHAFT SPROCKET WRENCH (Exhaust)
9. Remove the left-hand belt cover No. 2.
10. Remove the tensioner bracket.
11. Disconnect the heater hose from the water pump.
12. Remove the water pump.

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1. Install the water pump onto the left-hand cylinder block. NOTE: Replace gasket with a new one. When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in 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)
2. Install the hose to the water pump.
3. Install the tensioner bracket. Tightening torque: 25 N.m (2.5 kgf.m, 18.1 ft.lb)
4. Install the left-hand belt cover No. 2. Tightening torque: 5 N.m (0.5 kgf.m, 3.6 ft.lb)
5. Install the left-hand camshaft sprockets by using ST. ST 18231AA010 CAMSHAFT SPROCKET WRENCH NOTE: Also the CAMSHAFT SPROCKET WRENCH (499207100) can be used. Tightening torque: 78 N.m (8.0 kgf.m, 57.9 ft.lb)
6. Install the belt idler No. 2. Tightening torque: 39 N.m (4.0 kgf.m, 28.9 ft.lb)
7. Install the automatic belt tension adjuster which tension rod is held with pin. See «AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mecahnical-25l-sohc) , Installation, Timing Belt.
8. Install the timing belt, see «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mecahnical-25l-sohc) , Timing Belt.
9. Install V-belts, see «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mecahnical-25l-sohc) , V-belt.
10. Install the radiator, see «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , Radiator.

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1. Install the water pump onto the left-hand cylinder block. NOTE: Replace gasket with a new one. When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in 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)
2. Install the hose to the water pump.
3. Install the tensioner bracket. Tightening torque: 25 N.m (2.5 kgf.m, 18.1 ft.lb)
4. Install the left-hand belt cover No. 2. Tightening torque: 5 N.m (0.5 kgf.m, 3.6 ft.lb)
5. Install the left-hand camshaft sprockets by using ST. ST 18231AA010 CAMSHAFT SPROCKET WRENCH (Intake) ST 499207400 CAMSHAFT SPROCKET WRENCH (Exhaust) Tightening torque: 98 N.m (10.0 kgf.m, 72.4 ft.lb)
6. Install the camshaft position sensor, see «REMOVAL & INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/removal-installation/#engine-controls-removal-installation-impreza-outback-sport) , 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 a tension rod held by a pin. See «AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mechanical-20l-dohctc) , Installation, Timing Belt Assembly Tightening torque: 39 N.m (4.0 kgf.m, 28.9 ft.lb)
10. Install the timing belt, see «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mechanical-20l-dohctc) , Timing Belt Assembly.
11. Install the V-belts, see «INSTALLATION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#engine-mechanical-20l-dohctc) , V-belt.
12. Install the radiator, see «TURBO MODEL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , Installation, Radiator.

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1. Check the water pump bearing for smooth rotation.
2. Check the water pump pulley for abnormalities.
3. Using a dial gauge, measure impeller runout in thrust direction while rotating the pulley. "Thrust" runout limit: 0.5 mm (0.020 in)
4. Check the clearance between impeller and pump case. Clearance between impeller and pump case: Standard; 0.5-0.7 mm (0.020-0.028 in) Limit; 1.0 mm (0.039 in)
5. After water pump installation, check pulley shaft for engine coolant leaks. If leaks are noted, replace the water pump assembly.

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1. Lift-up the vehicle.
2. Remove the under cover.
3. Drain engine coolant completely. See «DRAINING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , Replacement, Engine Coolant.
4. Disconnect the radiator outlet hose from the thermostat cover. NON-TURBO MODEL
5. Disconnect the radiator outlet hose. TURBO MODEL
6. Remove the thermostat cover and gasket, and pull out the thermostat.

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1. Install the thermostat in the water pump, and install the thermostat cover together with a gasket. NOTE: When reinstalling the thermostat, use a new gasket. The thermostat must be installed with the jiggle pin (A) facing to front side. At this time, set the jiggle pin of thermostat for front side. Tightening torque: 6.5 N.m (0.66 kgf.m, 4.8 ft.lb)
2. Fill engine coolant, see «FILLING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , REPLACEMENT, Engine Coolant.

INSPECTION

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 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 measurement should be to the specification.

1. Starts to open: 76-80°C (169-176°F)
2. Fully opens: 91°C (196°F)

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1. Disconnect the battery ground cable.
2. Lift-up the vehicle.
3. Drain engine coolant completely. See «DRAINING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , Replacement, Engine Coolant.
4. Disconnect the connectors of radiator main fan (A) and sub fan (B) motor.
5. Disconnect the radiator outlet hose (A) from thermostat cover.
6. Disconnect the ATF cooler hoses (B) from the radiator. (AT vehicles only)
7. Lower the vehicle.
8. Disconnect the over flow hose.
9. Remove the reservoir tank.
10. Disconnect the radiator inlet hose from the engine.
11. Remove the radiator upper brackets.
12. Detach the power steering hose from the clip on the radiator.
13. While slightly lifting radiator, slide it to left.
14. Lift the radiator up and away from the vehicle.

TURBO MODEL

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1. Set the vehicle on the lift.
2. Disconnect the battery ground cable.
3. Lift-up the vehicle.
4. Remove the under cover.
5. Drain the engine coolant completely. See «DRAINING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , Replacement, Engine Coolant.
6. Remove the radiator under cover. (AT vehicles only)
7. Disconnect the connectors of radiator main fan (A) and sub fan motor (B).
8. Disconnect the ATF cooler hoses from the radiator. (AT vehicles only)
9. Disconnect the radiator outlet hose from the thermostat cover.
10. Lower the vehicle.
11. Remove the air intake duct.
12. Disconnect the over flow hose.
13. Remove the reservoir tank.
14. Remove the V-belt covers.
15. Disconnect the radiator inlet hose (A) and coolant filler tank hose (B) from the radiator.
16. Remove the radiator upper brackets.
17. While slightly lifting radiator, slide it to left.
18. Lift the radiator up and away from the vehicle.

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1. Attach the radiator mounting cushions to holes on the vehicle.
2. Install the radiator while fitting radiator pins to cushions. NOTE: Fit pins on lower side of radiator into cushions on body side.
3. Install the radiator brackets and tighten the bolts. Tightening torque: 18 N.m (1.8 kgf.m, 13.0 ft.lb)
4. Attach the power steering hose to the radiator.
5. Connect the radiator inlet hose.
6. Install the reservoir tank. Tightening torque: 4.9 N.m (0.50 kgf.m, 3.6 ft.lb)
7. Lift-up the vehicle.
8. Connect the radiator outlet hose (A).
9. Connect the ATF cooler hoses (B). (AT vehicles only)
10. Connect the connectors to the radiator main fan motor (A) and sub fan motor (B).
11. Install the under cover.
12. Lower the vehicle.
13. Connect the battery ground cable.
14. Fill engine coolant, see «FILLING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , REPLACEMENT, Engine Coolant.
15. Check ATF level, see «INSPECTION»(/subaru/impreza-wrx/gdgg-2002-2005/remont/automatic-trans/#overhaul__inspection) , ATF.

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1. Attach the radiator mounting cushions to holes on the vehicle.
2. Install the radiator brackets and tighten bolts. Tightening torque: 18 N.m (1.8 kgf.m, 13.0 ft.lb)
3. Connect the radiator inlet hose (A) and coolant filler tank hose (B).
4. Install the reservoir tank. Tightening torque: 4.9 N.m (0.50 kgf.m, 3.6 ft.lb)
5. Connect the over flow hose.
6. Lift-up the vehicle.
7. Connect the connectors to the radiator main fan motor (A) and sub fan motor (B).
8. Connect the ATF cooler hoses. (AT vehicles only)
9. Connect the radiator outlet hose.
10. Install the radiator under cover. (AT vehicle only)
11. Install the under cover.
12. Lower the vehicle.
13. Install the V-belt covers.
14. Install the air intake duct.
15. Connect the battery ground cable.
16. Fill engine coolant, see «FILLING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , REPLACEMENT, Engine Coolant.

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1. Remove the radiator cap, top off radiator, and attach tester to the radiator in place of cap. NON-TURBO MODEL TURBO MODEL
2. Apply a pressure of 157 kPa (1.6 kg/cm 2 , 23 psi) to the radiator to check if: Engine coolant leaks at/around radiator. Engine coolant leaks at/around hoses or connections. CAUTION: Engine should be off. Wipe engine coolant from check points in advance. Be careful to prevent engine coolant from spurting out when removing tester. Be careful also not to deform filler neck of radiator when installing or removing tester.

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1. Attach the radiator cap to the 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. Standard pressure: 93-123 kPa (0.95-1.25 kg/cm 2 , 14-18 psi) Service limit pressure: 83 kPa (0.85 kg/cm 2 NOTE: Be sure to remove foreign matter and rust from the cap in advance otherwise, results of pressure test will be incorrect.

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1. Disconnect the battery ground cable.
2. Lift-up the vehicle.
3. Remove the under cover.
4. Remove the radiator under cover. (AT vehicle only)
5. Disconnect the connector of main fan motor (A).
6. Lower the vehicle.
7. Remove the air intake duct. (Turbo model)
8. Disconnect the over flow hose.
9. Remove the over flow pipe. (Turbo model)
10. Remove the reservoir tank.
11. Remove the radiator main fan motor assembly.

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.

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

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1. Remove the clip which holds motor connector onto the shroud.
2. Remove the nut which holds fan itself onto the fan motor and shroud assembly.
3. Remove the bolts which install fan motor onto the shroud.

ASSEMBLY

Assemble in the reverse order of disassembly.

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

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

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1. Disconnect the battery ground cable.
2. Lift-up the vehicle.
3. Remove the under cover.
4. Remove the radiator under cover.
5. Disconnect the connector of sub fan motor.
6. Lower the vehicle.
7. Remove the air intake duct. (Turbo model)
8. Remove the bolts which hold sub fan shroud to the radiator.
9. Remove the over flow pipe. (Turbo model)
10. Remove the radiator sub fan shroud through the under side of vehicle.

Install in the reverse order of removal.

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

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1. Remove the clip which holds motor harness onto the shroud.
2. Remove the nut which holds fan itself onto the fan motor and shroud assembly.
3. Remove the bolts which install fan motor onto the shroud.

Assemble in the reverse order of disassembly.

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

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

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1. Disconnect the over flow hose from the radiator filler neck position.
2. Remove the bolts which install reservoir tank onto the radiator main fan shroud.
3. Remove the reservoir tank.

Install in the reverse order of removal.

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

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Make sure the engine coolant level is between full and low.

REMOVAL

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1. Drain the coolant about 3.0 (3.2 US qt, 2.6 Imp qt). See «DRAINING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , Replacement, Engine Coolant.
2. Remove the air cleaner upper cover and air intake boot. See «REMOVAL»(/subaru/impreza-wrx/gdgg-2002-2005/remont/mechanical/#air-intake-system-h4dotc) , Air Cleaner.
3. Remove the air cleaner element.
4. Disconnect the engine coolant hoses from the coolant filler tank.
5. Remove the bolts and nut which install coolant filler tank.
6. Disconnect the engine coolant hose which connects the under side of coolant filler tank.
7. Remove the coolant filler tank.

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1. Install in the reverse order of removal. Tightening torque: T1: 19 N.m (1.9 kgf.m, 13.7 ft.lb) T2: 21 N.m (2.1 kgf.m, 15.2 ft.lb)
2. Fill engine coolant, see «FILLING OF ENGINE COOLANT»(/subaru/impreza-wrx/gdgg-2002-2005/remont/cooling-fan/#engine-cooling-system) , REPLACEMENT, Engine Coolant.

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See also:
• REMOVAL
• REMOVAL
• REMOVAL & INSTALLATION
• INSPECTION
• REMOVAL
• REMOVAL