Engine Cooling System (H4DOTC) (Except Sti): Removal & Installation Subaru Impreza GH

REMOVAL

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

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. Remove the heat shield cover from radiator. (AT model)
6. Drain the engine coolant. Ref. to «DRAINING OF ENGINE COOLANT»(ref-357239-S42364927112010031100000) , REPLACEMENT, Engine Coolant.
7. Disconnect the connectors of main fan motor connector (A) and sub fan motor connector (B).
8. Disconnect the radiator outlet hose from thermostat cover.
9. Disconnect the ATF cooler hoses from ATF pipes. (AT model) NOTE: Plug the ATF pipe to prevent ATF from leaking.
10. Lower the vehicle.
11. Remove the air intake duct. Ref. to «REMOVAL»(ref-357235-S10313590332010031100000) , Air Intake Duct.
12. Remove the reservoir tank. Ref. to «REMOVAL»(ref-357239-S11074877122010031100000) , Reservoir Tank.
13. Disconnect the radiator inlet hose (A) from the radiator.
14. Disconnect the two coolant filler tank hoses from the radiator.
15. Remove the radiator upper brackets.
16. Move the radiator to the left while lifting it upward.
17. Lift the radiator up and remove the radiator from vehicle.

Scheme 93

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.
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 (A).
6. Install the reservoir tank. Ref. to «INSTALLATION»(ref-357239-S22910798512010031100000) , Reservoir Tank.
7. Install the air intake duct. Ref. to «INSTALLATION»(ref-357235-S12040137862010031100000) , Air Intake Duct.
8. Lift up the vehicle.
9. Connect the ATF cooler hoses. (AT model)
10. Connect the radiator outlet hose.
11. Connect the connectors of main fan motor connector (A) and sub fan motor connector (B).
12. Install the heat shield cover to the radiator. (AT model) Tightening torque: 3 N.m (0.3 kgf-m, 2.2 ft-lb)
13. Install the undercover.
14. Lower the vehicle.
15. Connect the ground cable to battery.
16. Fill engine coolant. Ref. to «FILLING OF ENGINE COOLANT»(ref-357239-S07197404722010031100000) , REPLACEMENT, Engine Coolant.
17. Check the ATF level. (AT model) Ref. to «INSPECTION»(ref-357244-S25560399872010031100000) , Automatic Transmission Fluid.

Scheme 94

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 95

1. Attach the radiator cap tester to radiator cap.
2. Increase pressure until the radiator cap tester gauge pointer stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 - 6 seconds. Replace 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 96

Scheme 97

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. Disconnect the main fan motor connector (A).
6. Remove the heat shield cover from radiator. (AT model)
7. Remove the ATF hose from the hose clip of the radiator main fan motor assembly. (AT model)
8. Lower the vehicle.
9. Remove the air intake duct. Ref. to «REMOVAL»(ref-357235-S10313590332010031100000) , Air Intake Duct.
10. Remove the reservoir tank. Ref. to «REMOVAL»(ref-357239-S11074877122010031100000) , Reservoir Tank.
11. Remove the bolts which secure the radiator main fan motor assembly and the over flow pipe.
12. 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 98

Scheme 99

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 the radiator main fan shroud.

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 100

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.

Scheme 101

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

Scheme 102

Install in the reverse order of removal.

Scheme 103

1. Drain approximately 3.0 l (3.2 US qt, 2.6 lmp qt) of coolant. Ref. to «DRAINING OF ENGINE COOLANT»(ref-357239-S42364927112010031100000) , REPLACEMENT, Engine Coolant.
2. Disconnect the engine coolant hoses from coolant filler tank.
3. Remove the bolts which secure the coolant filler tank.
4. Disconnect the engine coolant hose which connects the under side of coolant filler tank.
5. 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 104