cooling SUBARU FORESTER 2004 Service Service Manual

CO(H4SO)-12
COOLING
General Description
2. 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.
499977500 CAM SPROCKET
WRENCHUsed for removing and installing cam sprocket.
(Intake)
499207400 CAM SPROCKET
WRENCHUsed for removing and installing cam sprocket.
(Exhaust)
ST-499977400
ST-499977100
ST-499977500
ST-499207400

CO(H4SO)-13
COOLING
Radiator Fan System
2. Radiator Fan System
A: WIRING DIAGRAM
CO-02003
B72 SBF-1
SBF-4
NO.17
NO.18
MAIN FAN MOTOR
(EXCEPT TURBO AT MODEL)
F17
2
1
ET
MAIN
FA N
RELAY-1
FA N
MODE
RELAY31
34
32
30
5
9
7
8
6 SUB
FA N
RELAY A/C RELAY HOLDER
28
25
3
4
27
29
RHD
RHD
RHD
RHDLHD
LHD
LHD
F2
B1001110F2
B100197
2
1
F27
B25
B24
A14
ECM
(NON- TURBO MODEL)B134 A:
A13
NA
F17
F16
21
LHD
RHD
F2(BLACK)
(BLACK) (GRAY)
(GRAY)F2
A/C RELAY HOLDER
F27
12
34
567891110
1312142120
2322243130
333234
1615171819
26252728293536
B:B135
A:
B134
1234567891011121314151617181920212223242526272829303132333435
: : ::
ET
TA
1234 5678910 11 12 13 14 15 16 17 18 19 2012345
678910
11 12 19 20 2113 14 15 16 17 18 22
B135 B:
ECM
(TURBO MODEL)
(BLUE)
(BLUE)
567 2 134
2910
1112131415252416
30
98171819202821222332312627333435
: TURBO MODELTB
: NON-TURBO
MODEL
NA: TURBO AT MODEL
TA
: EXCEPT TURBO
AT MODEL
ET
: KA TURBO MODEL AND
EC,EK TURBO AT MODEL : 30A 1*
1*
1*
: LHD MODEL : (GRAY) 2*
2*
SUB FAN MOTOR
(TURBO AT MODEL)
F16
1
2
MAIN FAN MOTOR
(TURBO AT MODEL)
F17
1
2
SUB FAN MOTOR
(EXCEPT TURBO AT MODEL)
F16
2
1
TA
ET
TA
TA
LHD
TA
ET
ET
TBNA
TB
12
F17
F16TA
:
TA
ET
:
ET
E
EXCEPT KA TURBO MODEL AND
EC,EK TURBO AT MODEL: 20A
IGNITION SWITCH
BATTERY
3412
B72

CO(H4SO)-14
COOLING
Radiator Fan System
B: INSPECTION
DETECTING CONDITION:
 Engine coolant temperature is above 95°C (203°F).
 Vehicle speed is below 19 km/h (12 MPH).
TROUBLE SYMPTOM:
Radiator main fan and sub fan does not rotate under the above conditions.
Step Check Yes No
1 CHECK OPERATION OF RADIATOR FAN.
1) Connect the test mode connector.
2) Turn the ignition switch to ON.
3) Using Subaru Select Monitor, check the
compulsory operation of radiator fan relay.
N
OTE:
 With Subaru Select Monitor
When checking the compulsory operation of
radiator fan, the radiator main and sub fan
repeat the rotation in order of following: low
speed rotation → high speed rotation → off.
 Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for detail procedures. EN(H4SO)-45, Compulsory Valve Operation
Check Mode.>Do the radiator main and sub
fan rotate at low speed?Go to step 2.Go to step 3.
2 CHECK OPERATION OF RADIATOR FAN.
1) Connect the test mode connector.
2) Turn the ignition switch to ON.
3) Using Subaru Select Monitor, check the
compulsory operation of radiator fan relay.
N
OTE:
 With Subaru Select Monitor
When checking the compulsory operation of
radiator fan, the radiator main and sub fan
repeat the rotation in order of following: low
speed rotation → high speed rotation → off.
 Subaru Select Monitor
Refer to Compulsory Valve Operation Check
Mode for detail procedures. EN(H4SO)-45, Compulsory Valve Operation
Check Mode.>Do the radiator main and sub
fan rotate at high speed?Radiator main fan
system is okay.Go to step 32.
3 CHECK POWER SUPPLY TO MAIN FAN RE-
LAY.
1) Turn the ignition switch to OFF.
2) Remove the fan relay 1 from A/C relay
holder.
3) Measure the voltage between main fan
relay terminal and chassis ground.
Connector & terminal
(F27) No. 31 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 4.Go to step 5.
4 CHECK POWER SUPPLY TO MAIN FAN RE-
LAY.
1) Turn the ignition switch to ON.
2) Measure the voltage between main fan
relay terminal and chassis ground.
Connector & terminal
(F27) No. 34 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 8.Go to step 7.
5 CHECK FUSE.
1) Remove the fuse from A/C relay holder.
2) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Go to step 6.

CO(H4SO)-15
COOLING
Radiator Fan System
6 CHECK HARNESS OF FUSE TERMINAL
AND MAIN FAN RELAY TERMINAL.
1) Turn the ignition switch to OFF.
2) Measure the resistance between 20 A fuse
terminal and main fan relay terminal.
Te r m i n a l
No. 2 — No. 31:Is the resistance less than 1
Ω?Repair the power
supply line.Repair the open
harness.
7 CHECK FUSE.
1) Turn the ignition switch to OFF
2) Remove the fuse No. 18.
3) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Repair the power
supply line.
8 CHECK MAIN FAN RELAY.
1) Turn the ignition switch to OFF.
2) Measure the resistance between main fan
relay terminals.
Te r m i n a l
No. 30 — No. 31:Is the resistance more than 1
MΩ?Go to step 9.Replace the main
fan relay.
9 CHECK MAIN FAN RELAY.
1) Connect the battery to main fan relay termi-
nals No. 32 and No. 34.
2) Measure the resistance between main fan
relay terminals.
Te r m i n a l
No. 30 — No. 31:Is the resistance less than 1
Ω?Go to step 10.Replace the main
fan relay.
10 CHECK HARNESS BETWEEN MAIN FAN
RELAY TERMINAL AND MAIN FAN MOTOR
CONNECTOR.
1) Disconnect the connector from main fan
motor.
2) Measure the resistance between main fan
relay terminal and main fan motor connector.
Connector & terminal
Turbo AT model
(F17) No. 1 — (F27) No. 30:
Except turbo AT model
(F17) No. 2 — (F27) No. 30:Is the resistance less than 1
Ω?Go to step 11.Repair the open
harness between
main fan relay ter-
minal and main fan
motor connector.
11 CHECK HARNESS BETWEEN MAIN FAN
MOTOR CONNECTOR AND FAN MODE RE-
LAY CONNECTOR.
1) Remove the fan mode relay from A/C relay
holder.
2) Measure the resistance between main fan
motor connector and fan mode relay connec-
tor.
Connector & terminal
Turbo AT model
(F17) No. 2 — (F27) No. 9:
Except turbo AT model
(F17) No. 1 — (F27) No. 9:Is the resistance less than 1
Ω?Go to step 12.Repair the open
harness between
main fan motor
connector and fan
mode relay con-
nector.
12 CHECK POOR CONTACT.
Check poor contact in main fan motor connec-
tor.Is there poor contact in main
fan motor connector?Repair poor con-
tact in main fan
motor connector.Go to step 13.
13 CHECK MAIN FAN MOTOR.
Connect the battery positive (+) terminal to ter-
minal No. 2 (except turbo AT model), No. 1
(turbo AT model), and ground (−) terminal to
terminal No. 1 (except turbo AT model), No. 2
(turbo AT model) of main fan motor.Does the main fan rotate? Go to step 14.Replace the main
fan motor with new
one. Step Check Yes No

CO(H4SO)-16
COOLING
Radiator Fan System
14 CHECK FAN MODE RELAY.
Measure the resistance of fan mode relay.
Te r m i n a l
No. 6 — No. 9:Is the resistance less than 1
Ω?Go to step 15.Replace the fan
mode relay.
15 CHECK RESISTANCE BETWEEN FAN
MODE RELAY TERMINAL AND SUB FAN
MOTOR CONNECTOR.
1) Disconnect the connector from sub fan
motor.
2) Measure the resistance between fan mode
relay terminal and sub fan motor connector.
Connector & terminal
Turbo AT model
(F16) No. 1 — (F27) No. 6:
Except turbo AT model
(F16) No. 2 — (F27) No. 6:Is the resistance less than 1
Ω?Go to step 16.Repair the open
harness between
fan mode relay ter-
minal and sub fan
motor connector.
16 CHECK SUB FAN MOTOR AND GROUND
CIRCUIT.
Measure the resistance between sub fan motor
connector and chassis ground.
Connector & terminal
Turbo AT model
(F16) No. 2 — Chassis ground:
Except turbo AT model
(F16) No. 1 — Chassis ground:Is the resistance less than 5
Ω?Go to step 17.Repair the open
harness between
sub fan motor con-
nector and chassis
ground.
17 CHECK POOR CONTACT.
Check poor contact in sub fan motor connec-
tor.Is there poor contact in sub fan
motor connector?Repair poor con-
tact in sub fan
motor connector.Go to step 18.
18 CHECK SUB FAN MOTOR.
Connect the battery positive (+) terminal to ter-
minal No. 2 (except turbo AT model), No. 1
(turbo AT model), and ground (−) terminal to
terminal No. 1 (except turbo AT model), No. 2
(turbo AT model) of sub fan motor.Does the sub fan rotate? Go to step 19.Replace the sub
fan motor with new
one.
19 CHECK HARNESS BETWEEN MAIN FAN
RELAY AND ECM.
1) Disconnect the connector from ECM.
2) Measure the resistance between fan relay 1
terminal and ECM connector.
Connector & terminal
Turbo model
(B135) No. 25 — (F27) No. 32:
Non-turbo model
(B134) No. 14 — (F27) No. 32:Is the resistance less than 1
Ω?Go to step 20.Repair the open
harness between
fan relay 1 terminal
and ECM.
20 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair poor con-
tact in ECM con-
nector.Contact with SUB-
ARU dealers.
21 CHECK POWER SUPPLY TO SUB FAN RE-
LAY.
1) Turn the ignition switch to OFF.
2) Remove the sub fan relay from A/C relay
holder.
3) Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
(F27) No. 28 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 22.Go to step 23. Step Check Yes No

CO(H4SO)-17
COOLING
Radiator Fan System
22 CHECK POWER SUPPLY TO SUB FAN RE-
LAY.
1) Turn the ignition switch to ON.
2) Measure the voltage between sub fan relay
terminal and chassis ground.
Connector & terminal
(F27) No. 25 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 26.Go to step 25.
23 CHECK FUSE.
1) Remove the fuse from A/C relay holder.
2) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Go to step 24.
24 CHECK HARNESS BETWEEN FUSE TERMI-
NAL AND SUB FAN RELAY TERMINAL.
1) Turn the ignition switch to OFF.
2) Measure the resistance between fuse ter-
minal and sub fan relay terminal.
Te r m i n a l
No. 4 — No. 28:Is the resistance less than 1
Ω?Repair the power
supply line.Repair the open
harness.
25 CHECK FUSE.
1) Turn the ignition switch to OFF.
2) Remove the fuse No. 17.
3) Check the condition of fuse.Is the fuse blown out? Replace the fuse. Repair the power
supply line.
26 CHECK SUB FAN RELAY.
1) Turn the ignition switch to OFF.
2) Remove the sub fan relay from A/C relay
holder.
3) Measure the resistance of sub fan relay.
Te r m i n a l
No. 28 — No. 29:Is the resistance more than 1
MΩ?Go to step 27.Replace the sub
fan relay.
27 CHECK SUB FAN RELAY.
1) Connect the battery to terminals No. 25 and
No. 27 of sub fan relay.
2) Measure the resistance of sub fan relay.
Te r m i n a l
No. 28 — No. 29:Is the resistance less than 1
Ω?Go to step 28.Replace the sub
fan relay.
28 CHECK HARNESS BETWEEN SUB FAN RE-
LAY TERMINAL AND SUB FAN MOTOR
CONNECTOR.
1) Disconnect the connector from sub fan
motor.
2) Measure the resistance between sub fan
relay terminal and sub fan motor connector.
Connector & terminal
Turbo AT model
(F16) No. 1 — (F27) No. 29:
Except turbo AT model
(F16) No. 2 — (F27) No. 29:Is the resistance less than 1
Ω?Go to step 30.Repair the open
harness between
sub fan relay ter-
minal and sub fan
motor connector.
29 CHECK HARNESS BETWEEN SUB FAN RE-
LAY AND ECM.
1) Disconnect the connector from ECM.
2) Measure the resistance between sub fan
relay terminal and ECM connector.
Connector & terminal
Non-turbo model: (B134) No. 13 — (F27)
No. 27:
Turbo model: (B135) No. 24 — (F27) No.
27:Is the resistance less than 1
Ω?Go to step 30.Repair the open
harness between
sub fan relay ter-
minal and ECM. Step Check Yes No

CO(H4SO)-18
COOLING
Radiator Fan System
30 CHECK HARNESS BETWEEN FAN MODE
RELAY AND ECM.
Measure the resistance between fan mode
relay terminal and ECM connector.
Connector & terminal
Non-turbo model
(B134) No. 13 — (F27) No. 7:
Turbo model
(B135) No. 24 — (F27) No. 7:Is the resistance less than 1
Ω?Go to step 31.Repair the open
harness between
fan mode relay ter-
minal and ECM.
31 CHECK POOR CONTACT.
Check poor contact in ECM connector.Is there poor contact in ECM
connector?Repair the poor
contact in ECM
connector.Contact with SUB-
ARU dealers.
N
OTE:
Probable cause is
deterioration of
multiple parts.
32 CHECK OPERATION OF RADIATOR FAN.Does the radiator main fan
rotate when the radiator main
and sub fan do not rotate at
high speed?Go to step 21.Go to step 33.
33 CHECK GROUND CIRCUIT OF FAN MODE
RELAY.
1) Remove the fan mode relay from A/C relay
holder.
2) Measure the resistance between fan mode
relay terminal and chassis ground.
Connector & terminal
(F27) No. 8 — Chassis ground:Is the resistance less than 1
Ω?Go to step 34.Repair the open
harness between
fan mode relay
and chassis
ground.
34 CHECK POWER SUPPLY TO FAN MODE
RELAY.
1) Turn the ignition switch to ON.
2) Measure the voltage between fan mode
relay terminal and chassis ground.
Connector & terminal
(F27) No. 5 (+) — Chassis ground (
−):Is the voltage more than 10 V? Go to step 35.Repair the power
supply line.
35 CHECK FAN MODE RELAY.
1) Turn the ignition switch to OFF.
2) Remove the fan mode relay.
3) Measure the resistance of fan mode relay.
Te r m i n a l
(F27) No. 8 — (F27) No. 9:Is the resistance more than 1
MΩ?Go to step 36.Replace the fan
mode relay.
36 CHECK FAN MODE RELAY.
1) Connect the battery to terminals No. 5 and
No. 7 of fan mode relay.
2) Measure the resistance of fan mode relay.
Te r m i n a l
(F27) No. 8 — (F27) No. 9:Is the resistance less than 1
Ω?Go to step 29.Replace the fan
mode relay. Step Check Yes No

CO(H4SO)-19
COOLING
Engine Coolant
3. Engine Coolant
A: REPLACEMENT
1. DRAINING OF ENGINE COOLANT
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.
4) Install the drain cock.
2. FILLING OF ENGINE COOLANT
1) Fill engine coolant into the radiator up to filler
neck position.
Coolant capacity (fill up to “FULL” level): to CO(H4SO)-2, SPECIFICATION, General De-
scription.>
NOTE:
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.
2) Fill engine coolant into the reservoir tank up to
Full level.
3) Warm-up the engine completely for more than 5
minutes at 2,000 to 3,000 rpm.
4) If the engine coolant level drops in radiator, add
engine coolant to filler neck position.5) If the engine coolant level drops from Full level of
reservoir tank, add engine coolant to Full level.
6) Attach the radiator cap and reservoir tank cap
properly.
CO-00009
CO-00010
FULLFULLLOWLOW

CO(H4SO)-20
COOLING
Engine Coolant
B: INSPECTION
1. RELATIONSHIP OF SUBARU COOLANT
CONCENTRATION AND FREEZING TEM-
PERATURE
The concentration and safe operating temperature
of the SUBARU coolant is shown in the diagram.
Measuring the temperature and specific gravity of
the engine coolant will provide this information.
[Example]
If the engine coolant temperature is 25°C (77°F)
and its specific gravity is 1.054, 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).
2. PROCEDURE TO ADJUST THE CON-
CENTRATION OF THE ENGINE COOLANT
To adjust the concentration of the engine coolant
according to temperature, find the proper fluid con-
centration in the above diagram and replace the
necessary amount of the engine coolant with an
undiluted solution of SUBARU genuine coolant
(concentration 50%).
The amount of the engine coolant that should be
replaced can be determined using the diagram.
[Example]
Assume that the engine coolant concentration must
be increased from 25% to 40%. Find point A, where
the 25% line of the engine coolant concentration in-
tersects with the 40% curve of the necessary the
engine coolant concentration, and read the scale
on the vertical axis of the graph at height A. The
quantity of coolant to be drained is 2.12 (2.2 US qt,
1.8 Imp qt). Drain 2.12 (2.2 US qt, 1.8 Imp qt) of
the engine coolant from the cooling system and
add 2.12 (2.2 US qt, 1.8 Imp qt) of the undiluted
solution of SUBARU coolant.
If a engine coolant concentration of 50% is needed,
drain all the engine coolant and refill with the undi-
luted solution only.
(1) Safe operating temperature
(2) Concentration of coolant
(3) Freezing temperature
(4) Specific gravity of coolant
(5) Coolant temperature °C (°F)
CO-00283
60%
(1.054)
1.000 1.010 1.020
1.030
1.040
1.050
1.060
1.070 1.080 1.090
1.100(1)
(2)
(3)
(5) (4)B
A C
-40
(-40) (-22)(-4)
(14)(32)(50) (68) (86) (104) (122) -30-20 -1001020304050
(77 F)
50%
40%
30%
20%
25 C10%
(1) Necessary concentration of coolant
(2) Quantity of coolant to be drained 2 (US qt, Imp
qt)
(3) Concentration of coolant in the vehicle cooling
system%
(4) Concentration of coolant in vehicle and quantity
to be drained
CO-00284
10 0 12 3
(1.1,
0.9)(2.1,
1.8) (3.2,
2.6)
10%15%25%
20%30%35%40%45%
A
20 30 40 50
(1) (2)
(3)
(4)

CO(H4SO)-21
COOLING
Water Pump
4. Water Pump
A: REMOVAL
1. NON-TURBO MODEL
1) Remove the radiator. REMOVAL, Radiator.>
2) Remove the V-belts.

3) Remove the timing belt.
AL, Timing Belt.>
4) Remove the automatic belt tension adjuster.
5) Remove the belt idler No. 2.
6) Remove the camshaft sprocket (LH) by using
ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM SPROCKET WRENCH (499207100)
can be used.7) Remove the belt cover No. 2 (LH).
8) Remove the tensioner bracket.
9) Disconnect the hose from water pump.
10) Remove the water pump.
CO-00016
CO-00017
CO-00018
ST
CO-00019
CO-00020
CO-00021