cooling SUBARU FORESTER 2004 Service Owner's Guide

CO(H4SO)-2
COOLING
General Description
1. General Description
A: SPECIFICATION
ModelNon-turbo Turbo
Cooling system Electric fan+Forced engine coolant circulation system
Total engine coolant capacity2(US qt, Imp qt)2.0L with ATF warmer:
Approx. 6.9 (7.29, 6.07)
2.0L AT:
Approx. 6.5 (6.87, 5.72)
2.0L MT:
Approx. 6.6 (6.98, 5.81)
2.5L AT:
Approx. 6.8 (7.19, 5.98)
2.5L MT:
Approx. 6.9 (7.29, 6.07)AT :
Approx. 7.3 (7.71, 6.42)
MT with oil cooler:
Approx. 7.3 (7.71, 6.42)
MT without oil cooler:
Approx. 7.4 (7.82, 6.51)
Water pumpType Centrifugal impeller type
Discharge perfor-
mance IDischarge 202 (5.3 US gal, 4.4 Imp gal)/min.
Pump speed — Discharge
pressure760 rpm — 2.9 kPa (0.3 mAq)
Engine coolant temperature 85°C (185°F)
Discharge perfor-
mance IIDischarge 1002 (26.4 US gal, 22.0 Imp gal)/min.
Pump speed — Discharge
pressure3,000 rpm — 49.0 kPa (5.0 mAq)
Engine coolant temperature 85°C (185°F)
Discharge perfor-
mance IIIDischarge 2002 (52.8 US gal, 44.0 Imp gal)/min.
Pump speed — Discharge
pressure6,000 rpm — 225.4 kPa (23.0 mAq)
Engine coolant temperature 85°C (185°F)
Impeller diameter 76 mm (2.99 in)
Number of impeller vanes 8
Pump pulley diameter 60 mm (2.36 in)
Clearance between
impeller and caseStandard 0.5 — 0.7 mm (0.020 — 0.028 in)
Limit 1.0 mm (0.039 in)
“Thrust” runout of impeller end 0.5 mm (0.020 in)
ThermostatType Wax pellet type
Starts to open 80 — 84°C (176 — 183°F) 76 — 80°C (169 — 176°F)
Fully opened 95°C (203°F) 91°C (196°F)
Valve lift 9.0 mm (0.354 in) or more
Valve bore 35 mm (1.38 in)
Radiator fanMotorMain fan 70 W2.0L AT (K4
★1) : 70 W
2.0L AT (EC, EK★1) :
120 W
2.0 L MT: 70 W
2.5 L: 120 W
Sub fan 70 W2.0L AT (K4
★1) : 70 W
2.0L AT (EC, EK★1) :
120 W
2.0 L MT: 70 W
2.5 L: 120 W
Fan diameter×Blade320 mm (11.81 in)×5 (main fan)
320 mm (11.81 in)×7 (sub fan)

CO(H4SO)-3
COOLING
General Description
★1: For option code, refer to ID section. RadiatorType Down flow, pressure type
Core dimensions Width×Height×Thickness691.5×360×16 mm
(27.22×14.17×0.63 in)
Pressure range in which cap valve is openAbove: 108±15 kPa
(1.1±0.15 kg/cm
2, 16±2 psi)
Below: −1.0 to −4.9 kPa
(−0.01 to −0.05 kg/cm
2, −0.1 to −0.7 psi)
Fins Corrugated fin type
Reservoir
tankCapacity 0.52 (0.5 US qt, 0.4 Imp qt)

CO(H4SO)-4
COOLING
General Description
B: COMPONENT
1. WATER PUMP
 NON-TURBO MODEL
(1) Water pump ASSY (5) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Gasket (6) Thermostat coverT1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(3) Heater by-pass hose
(4) ThermostatT2: 6.5 (0.66, 4.8)
CO-00001
T2(2) (1)
(4)
T1
(3)
(5)
(6)
T1

CO(H4SO)-5
COOLING
General Description
 TURBO MODEL
(1) Thermostat cover (5) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Gasket (6) Heater by-pass hoseT1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(3) Thermostat (7) Coolant filler tank by-pass hose
(4) Water pump ASSY (8) Water by-pass pipeT2: 6.5 (0.66, 4.8)
CO-00002
T2
(1)(3)
(6)(7)(8)
(4)
(2)
(5)
T2
T2
T1
T1

CO(H4SO)-6
COOLING
General Description
 MODEL WITH ATF WARMER
(1) Thermostat cover (5) GasketTightening torque: N⋅m (kgf-m, ft-lb)
(2) Gasket (6) Heater by-pass hoseT1: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
(3) Thermostat (7) Coolant filler tank by-pass hose
(4) Water pump ASSY (8) Water by-pass pipeT2: 6.5 (0.66, 4.8)
CO-02006
(1)(3)
(6)(7)(8)
(4)
(2)
(5)
T2
T2
T1
T1

CO(H4SO)-7
COOLING
General Description
2. RADIATOR AND RADIATOR FAN
 NON-TURBO MODEL
(1) Radiator lower cushion (11) Radiator sub fan (21) Radiator outlet hose
(2) Radiator (12) Radiator sub fan motor (22) Radiator drain plug
(3) Radiator upper cushion (13) Radiator main fan (23) Radiator cap
(4) Radiator upper bracket (14) Radiator main fan motor
(5) Clamp (15) ATF hose clamp (AT model)Tightening torque: N
⋅m (kgf-m, ft-lb)
(6) Radiator inlet hose (16) ATF inlet hose A (AT model)T1: 4.4 (0.45, 3.3)
(7) Engine coolant reservoir tank cap (17) ATF outlet hose A (AT model)T2: 7.5 (0.76, 5.5)
(8) Overflow hose (18) ATF pipe (AT model)T3: 18 (1.8, 13.0)
(9) Engine coolant reservoir tank (19) ATF inlet hose B (AT model)T4: 3.4 (0.35, 2.5)
(10) Radiator sub fan shroud (20) ATF outlet hose B (AT model)T5: 4.9 (0.50, 3.6)
CO-00003
(9)
(1)(10)(8)
(2)
T3
T2
T2
T4
T4(14)
(20) (22)(3) (4)
(19)(16)
(18)(7)
(17)
(15) (15)
(15)
(15) (15) (15)(12)
(11)
(13)
T5
T1
T1
(5) (5)
(5)(6)
(21)
A
A
C
T3
B
B
C
(23)

CO(H4SO)-8
COOLING
General Description
 TURBO MODEL
CO-00140 (9)
(1)(10)(8)
(2)
T3
T2
T4(14)
(20) (22)(3) (4)
(19)(7)
(12)
(11)
(13)
T5
T5
T1
T1
(5) (5)(5)(5)
(5)(6)
(21) (27)
(25)(24)
(23)
(26)
(5)
B
C
B
C
T2(16) (18)(17)
(15) (15)
(15)
(15)
T3
T2
T3
(32) (31)
B
C
(15)
(33)
(28)(29)
(33)
(34)
(34)
(35)(35)
(30) (15)(15)
T4

CO(H4SO)-9
COOLING
General Description
(1) Radiator lower cushion (18) ATF pipe (AT model) (31) Oil cooler inlet hose B (MT model
with oil cooler)
(2) Radiator (19) ATF inlet hose B (AT model)
(3) Radiator upper cushion (20) ATF outlet hose B (AT model) (32) Oil cooler outlet hose B (MT
model with oil cooler)
(4) Radiator upper bracket (21) Radiator outlet hose
(5) Clamp (22) Radiator drain plug (33) Spacer (MT model with oil cooler)
(6) Radiator inlet hose (23) Engine coolant filler tank (34) Cushion (MT model with oil
cooler)
(7) Engine coolant reservoir tank cap (24) Engine coolant filler tank cap
(8) Over flow hose (25) Engine overflow hose (35) Setting washer (MT model with oil
cooler)
(9) Engine coolant reservoir tank (26) Radiator under cover (AT model)
(10) Radiator fan shroud (27) Engine air breather hose
(11) Radiator sub fan (28) Oil cooler inlet hose A (MT model
with oil cooler)Tightening torque: N
⋅m (kgf-m, ft-lb)
(12) Radiator sub fan motorT1: 4.4 (0.45, 3.3)
(13) Radiator main fan (29) Oil cooler outlet hose A (MT
model with oil cooler)T2: 7.5 (0.76, 5.5)
(14) Radiator main fan motorT3: 18 (1.8, 13.0)
(15) ATF hose clamp (AT model) (30) Oil cooler pipe (MT model with oil
cooler)T4: 3.4 (0.35, 2.5)
(16) ATF inlet hose A (AT model)T5: 4.9 (0.50, 3.6)
(17) ATF outlet hose A (AT model)

CO(H4SO)-10
COOLING
General Description
C: CAUTION
 Wear working clothing, including a cap, protec-
tive goggles, and protective shoes during opera-
tion.
 Remove contamination including dirt and corro-
sion before removal, installation or disassembly.
 Keep the disassembled parts in order and pro-
tect them from dust or dirt.
 Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary re-
moval, installation, disassembly, and replacement.
 Be careful not to burn your hands, because each
part in the vehicle is hot after running.
 Be sure to tighten fasteners including bolts and
nuts to the specified torque.
 Place shop jacks or rigid racks at the specified
points.
 Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.

CO(H4SO)-11
COOLING
General Description
D: PREPARATION TOOL
1. NON-TURBO MODEL
ILLUSTRATION TOOL NUMBER DESCRIPTION REMARKS
499977400
(2.0 L model)CRANK PULLEY
WRENCHUsed for stopping crank pulley when loosening
and tightening crank pulley bolts.
499977100
(2.5 L model)CRANK PULLEY
WRENCHUsed for stopping crank pulley when loosening
and tightening crank pulley bolts.
18231AA010 CAM SPROCKET
WRENCH (For left
side) Used for removing and installing cam sprocket
(LH).
 Also the CAM SPROCKET WRENCH
(499207100) can be used.
499207400 CAM SPROCKET
WRENCH (For right
side)Used for removing and installing cam sprocket
(RH).
ST-499977400
ST-499977100
ST18231AA010
ST-499207400