cooling SUBARU FORESTER 2004 Service Workshop Manual

CO(H4SO)-22
COOLING
Water Pump
2. TURBO MODEL
1) Remove the radiator. REMOVAL, Radiator.>
2) Remove the V-belts. REMOVAL, V-belt.>
3) Remove the timing belt. 58, REMOVAL, 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. (2.0 L mod-
el) shaft Position Sensor.>
8) Remove the cam sprockets (LH) by using ST.
ST 499977500 CAM SPROCKET WRENCH
(Intake)
ST 499207400 CAM SPROCKET WRENCH
(Exhaust)9) Remove the belt cover No. 2 (LH).
10) Remove the tensioner bracket.
11) Disconnect the hose from water pump.
12) Remove the water pump.
CO-00023
(A)
(B)
(C)
ME-00710
ME-00709
CO-00024
CO-00025
CO-00021

CO(H4SO)-23
COOLING
Water Pump
B: INSTALLATION
1. NON-TURBO MODEL
1) Install 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)
 Model without ATF warmer
 Model with ATF warmer
2) Connect the hose to water pump.
3) Install the tensioner bracket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)4) Install the belt cover No. 2 (LH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
5) Install the camshaft sprockets (LH) by using ST.
ST 18231AA010 CAM SPROCKET WRENCH
NOTE:
Also the CAM 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 holded with pin. 49, AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt.>
8) Install the timing belt. TIMING BELT, INSTALLATION, Timing Belt.>
CO-00026
(E)
(D)
(B)
(C)(A) (F)
CO-02008
(B) (C) (D)(E)(F)
(A)
CO-00020
CO-00019
CO-00018
ST
CO-00017

CO(H4SO)-24
COOLING
Water Pump
9) Install the V-belts. STALLATION, V-belt.>
10) Install the radiator. STALLATION, Radiator.>
2. TURBO MODEL
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)
2) Connect the hose to water pump.
3) Install the tensioner bracket.
Tightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)4) Install the belt cover No. 2 (LH).
Tightening torque:
5 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
5) Install the cam sprockets (LH) by using ST.
ST 499977500 CAM SPROCKET WRENCH
(Intake)
Tightening torque:
2.0 L model
98 N
⋅m (10.0 kgf-m, 72.4 ft-lb)
2.5 L model
29.5 N
⋅m (3.0 kgf-m, 21.8 ft-lb), and then
tighten 45
° furthermove
ST 499207400 CAM SPROCKET WRENCH
(Exhaust)
Tightening torque:
98 N
⋅m (10.0 kgf-m, 72.4 ft-lb)
6) Install the camshaft position sensor. (2.0 L mod-
el) Camshaft Position Sensor.>
7) Install the belt idler No. 2 (C).
8) Install the belt idler (B).
CO-00027
(B) (C) (D)(E)(F)
(A)
CO-00025
CO-00024
ME-00710
ME-00709

CO(H4SO)-25
COOLING
Water Pump
9) Install the automatic belt tension adjuster (A)
which has tension rod held by pin. ME(H4DOTC)-60, AUTOMATIC BELT TENSION
ADJUSTER ASSEMBLY AND BELT IDLER, IN-
STALLATION, Timing Belt Assembly.>
Tightening torque:
39 N
⋅m (4.0 kgf-m, 28.9 ft-lb)
10) Install the timing belt. 61, TIMING BELT, INSTALLATION, Timing Belt
Assembly.>
11) Install the V-belts. INSTALLATION, V-belt.>
12) Install the radiator. STALLATION, Radiator.>
C: INSPECTION
1) Check the water pump bearing for smooth rota-
tion.
2) Check the water pump pulley for abnormalities.
3) Using a dial gauge, measure the 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 the pulley
shaft for engine coolant leaks. If leaks are noted,
replace the water pump assembly.
CO-00023
(A)
(B)
(C)
CO-00028
CO-00029

CO(H4SO)-26
COOLING
Thermostat
5. Thermostat
A: REMOVAL
1) Set the vehicle on a lift.
2) Lift-up the vehicle.
3) Remove the under cover.
4) Drain the engine coolant completely. CO(H4SO)-19, DRAINING OF ENGINE COOL-
ANT, REPLACEMENT, Engine Coolant.>
5) Disconnect the radiator outlet hose from thermo-
stat cover.
 NON-TURBO MODEL
6) Disconnect the radiator outlet hose.
 TURBO MODEL7) Remove the thermostat cover and gasket, and
pull out the thermostat.
B: INSTALLATION
1) Install the thermostat in the water pump, and
then install the thermostat cover together with a
gasket.
NOTE:
 When reinstalling the thermostat, use a new gas-
ket.
 The thermostat must be installed with the jiggle
pin (A) facing to front side.
Tightening torque:
6.5 N
⋅m (0.66 kgf-m, 4.8 ft-lb)
2) Fill engine coolant. FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
CO-00009
CO-00076
CO-00030
CO-00031
CO-00032
(A)

CO(H4SO)-27
COOLING
Thermostat
C: INSPECTION
Replace the thermostat if the valve does not close
completely at an ambient temperature or if the fol-
lowing 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 be-
gins to open and when the valve is fully opened.
During the test, agitate the water for even temper-
ature distribution. The measurement should be to
the specification.
Starts to open:
Non-turbo model
80 — 84
°C (176 — 183°F)
Turbo model
76 — 80
°C (169 — 176°F)
Fully opens:
Non-turbo model
95
°C (203°F)
Turbo model
91
°C (196°F)
(A) Thermometer
(B) Thermostat
CO-00033
(A)
(B)

CO(H4SO)-28
COOLING
Radiator
6. Radiator
A: REMOVAL
1. NON-TURBO MODEL
WARNING:
The radiator is pressurized. Wait until the en-
gine cools down before working on the radia-
tor.
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. CO(H4SO)-19, DRAINING OF ENGINE COOL-
ANT, REPLACEMENT, Engine Coolant.>
6) Disconnect the connectors of radiator main fan
motor (A) and sub fan motor (B).
7) Disconnect the radiator outlet hose from water
pump.8) Disconnect the ATF cooler hoses from ATF pipe.
(AT model) Plug the openings in the hose and radi-
ator with caps in order to prevent ATF from leaking.
9) Lower the vehicle.
10) Disconnect the over flow hose.
11) Remove the reservoir tank.
12) Disconnect the radiator inlet hose from engine.
13) Remove the radiator upper brackets.
FU-00009
CO-00013
(A)(B)
CO-00076
CO-00034
CO-00015
CO-00035
CO-00036

CO(H4SO)-29
COOLING
Radiator
14) Detach the power steering hose from clip on ra-
diator.
15) Lift the radiator up and away from the vehicle.
2. TURBO MODEL
WARNING:
The radiator is pressurized. Wait until the en-
gine cools down before working on the radia-
tor.
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. CO(H4SO)-19, DRAINING OF ENGINE COOL-
ANT, REPLACEMENT, Engine Coolant.>
6) Disconnect the connectors of radiator main fan
motor (A) and sub fan motor (B).7) Disconnect the radiator outlet hose from thermo-
stat cover.
8) Disconnect the ATF cooler hose from ATF pipe.
(AT model) Plug the opennings in the hose and ra-
diator with caps in order to prevent ATF from leak-
ing.
9) Disconnect the oil cooler hose from oil cooler
pipe. (MT model with oil cooler)
Install the cap to prevent oil from leaking.
10) Lower the vehicle.
11) Remove the V-belt covers.
12) Disconnect the overflow hose.
CO-00037
FU-00009
CO-00013
(A)(B)
CO-00030
CO-00034
SC-00096

CO(H4SO)-30
COOLING
Radiator
13) Remove the reservoir tank.
14) Disconnect the radiator inlet hose (A) and wa-
ter tank hose (B) from radiator.
15) Remove the radiator upper brackets.
16) Disconnect the power steering hose from clips
on radiator.
17) Lift the radiator up and away from the vehicle.18) Remove the radiator under cover (AT model).
B: INSTALLATION
1. NON-TURBO MODEL
1) Attach the radiator lower cushions to holes on
the vehicle.
2) Install the radiator to vehicle.
NOTE:
Fit pins on the lower side of radiator into cushions
on the body side.
3) Install the radiator upper brackets and tighten
bolts.
Tightening torque:
18 N
⋅m (1.8 kgf-m, 13.0 ft-lb)
CO-00015
CO-00039
(A) (B)
CO-00040
CO-00037
CO-00070
CO-00041
CO-00036

CO(H4SO)-31
COOLING
Radiator
4) Attach the power steering hose to 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) Connect the overflow hose.
8) Lift-up the vehicle.
9) Connect the ATF cooler hoses. (AT model)10) Connect the radiator outlet hose.
11) Connect the connectors to radiator main fan
motor (A) and sub fan motor (B).
12) Install the under cover.
13) Lower the vehicle.
14) Connect the battery ground cable to battery.
15) Fill engine coolant. FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
16) Check the ATF level. SPECTION, Automatic Transmission Fluid.>
CO-00037
CO-00035
CO-00015
CO-00034
CO-00076
CO-00013
(A)(B)
FU-00009