1996 SUBARU LEGACY radiator

G2M0213
C: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in fig-
ure.
Tightening torque:
10
+4
0N⋅m (1.0+0.4
0kg-m, 7.2+2.9
0ft-lb)
G2M0214
3. Thermostat
A: REMOVAL AND INSTALLATION
1) Drain engine coolant.
Set container under the vehicle, and remove drain cock
from radiator.
2) Disconnect radiator outlet hose from thermostat cover.
3) Remove thermostat cover and gasket, and pull out the
thermostat.
G2M0227
4) Install the thermostat in the intake manifold, and install
the thermostat cover together with a gasket.
CAUTION:
When reinstalling the thermostat, use a new gasket.
The thermostat must be installed with the jiggle pin
upward.
In this time, set the jiggle pin of thermostat for front
side.
G2M0215
B: INSPECTION
Replace the thermostat if the valve does not close com-
pletely 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.
Starts to open:
76.0—80.0°C (169—176°F)
Fully opens:
91°C (196°F)
12
2-5SERVICE PROCEDURE
2. Engine Coolant Pump - 3. Thermostat

B2M0015A
4. Radiator
A: REMOVAL
1) Disconnect battery cables and remove battery from
body.
2) Drain engine coolant.
Set container under the vehicle, and remove drain cock
from radiator.
B2M0304
3) Disconnect radiator outlet hose from thermostat cover.
4) Disconnect ATF cooler hoses from radiator. (AT model)
B2M0017
5) Remove V-belt cover.
B2M0305
6) Disconnect inlet hose from radiator.
G2M0263
7) Disconnect connectors of radiator main fan and sub fan
motor.
13
2-5SERVICE PROCEDURE
4. Radiator

B2M0320
8) Remove radiator upper brackets.
NOTE:
Place left upper radiator bracket between grille and body.
9) While slightly lifting radiator, slide it to left.
G2M0220
10) Lift radiator up and away from vehicle.
B2M0307A
B: INSTALLATION
1) Attach radiator mounting cushions to body.
G2M0220
2) Install radiator while fitting radiator pins to cushions.
14
2-5SERVICE PROCEDURE
4. Radiator

B2M0320
3) Install radiator brackets and tighten bolts.
4) Connect radiator main fan motor and sub fan motor
connectors.
B2M0137
5) Connect radiator inlet and outlet hoses.
6) Connect ATF cooler hoses. (AT model)
B2M0017
7) Install V-belt cover.
G6M0095
8) Connect ground cable to battery terminal.
15
2-5SERVICE PROCEDURE
4. Radiator

G2M0223
5. Radiator Cap
A: INSPECTION
1) Attach radiator cap to tester.
2) Increase pressure until tester gauge pointer stops.
Radiator cap is functioning properly if it holds the service
limit pressure for five to six seconds.
Standard pressure:
78—98 kPa (0.8—1.0 kg/cm
2,11—14 psi)
Service limit pressure:
69 kPa (0.7 kg/cm
2, 10 psi)
CAUTION:
Be sure to remove foreign matter and rust from the cap
in advance; otherwise, results of pressure test will be
incorrect.
G2M0263
6. Radiator Fan and Fan Motor
A: REMOVAL
1) Disconnect ground cable from battery terminal.
2) Disconnect connector of fan motor.
G2M0224
3) Remove reservoir tank.
B2M0308
4) Remove four bolts holding shroud to radiator.
16
2-5SERVICE PROCEDURE
5. Radiator Cap - 6. Radiator Fan and Fan Motor

B2M0323
5) Remove radiator fan motor assembly.
6) Remove fan motor from shroud.
B: INSTALLATION
Installation is in the reverse order of removal procedures.
Do the following:
1) Before installing radiator fan motor, apply a coat of seal-
ant to threads and tighten nuts.
2) Make sure radiator fan does not come into contact with
shroud when installed.
3) After installation, make sure there is no unusual noise
or vibration when fan is rotated.
G6M0095
7. Engine Coolant Pipe
A: REMOVAL
1) Release fuel pressure.

2) Disconnect ground cable from the battery.
B2M0015A
3) Drain engine coolant completely.

B2M0160
4) Remove intake manifold.

17
2-5SERVICE PROCEDURE
6. Radiator Fan and Fan Motor - 7. Engine Coolant Pipe

B2M0138
5) Disconnect heater inlet hose.
B2M0139
6) Disconnect radiator inlet hose from engine coolant pipe.
B2M0141
7) Remove bolts which install engine coolant pipe on cyl-
inder block.
B2M0141
B: INSTALLATION
1) Install engine coolant pipe on cylinder block.
Tightening torque:
6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
CAUTION:
Use a new O-ring.
B2M0139
2) Connect radiator inlet hose.
18
2-5SERVICE PROCEDURE
7. Engine Coolant Pipe

1. Engine Cooling System
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of engine coolant pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair ignition control system.

h. Clogged or leaking radiator Clean or repair, or replace.
i. Improper engine oil in engine coolant Replace engine coolant.
j. Air/fuel mixture ratio too leanInspect and repair fuel injection system.

k. Excessive back pressure in exhaust system Clean or replace.
l. Insufficient clearance between piston and cylinder Adjust or replace.
m. Slipping clutch Repair or replace.
n. Dragging brake Adjust.
o. Improper transmission oil Replace.
p. Defective thermostat Replace.
q. Malfunction of electric fanInspect radiator fan relay, engine coolant temperature
sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from engine coolant pump Replace.
c. Leakage from engine coolant pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten cylinder head bolts or replace gasket.
e. Damaged or cracked cylinder head and crankcase Repair or replace.
f. Damaged or cracked thermostat case Repair or replace.
g. Leakage from radiator Repair or replace.
Noisea. Defective drive belt Replace.
b. Defective radiator fan Replace.
c. Defective engine coolant pump bearing Replace engine coolant pump.
d. Defective engine coolant pump mechanical seal Replace engine coolant pump.
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2-5DIAGNOSTICS
1. Engine Cooling System