1999 SUBARU LEGACY radiator

2. Radiator and Radiator Fan
B2M2034A
(1) Radiator lower cushion
(2) Radiator
(3) O-ring
(4) Air vent plug
(5) Radiator upper cushion
(6) Radiator upper bracket
(7) Clamp
(8) Radiator inlet hose
(9) Support
(10) Radiator sub fan ASSY
(11) Sub fan shroud
(12) Radiator main fan ASSY
(13) Main fan shroud(14) Engine coolant reservoir tank
cap
(15) Over flow hose
(16) Engine coolant reservoir tank
(17) ATF hose clamp (AT vehicles
only)
(18) ATF inlet hose A (AT vehicles
only)
(19) ATF outlet hose A (AT vehicles
only)
(20) ATF pipe (AT vehicles only)
(21) ATF inlet hose B (AT vehicles
only)(22) ATF outlet hose B (AT vehicles
only)
(23) Radiator outlet hose
(24) Radiator drain pipe
(25) Gasket
(26) Radiator drain plug
Tightening torque: N´m (kg-m, ft-lb)
T1:
7.4±2.0 (0.75±0.20, 5.4±1.4)
T2:12±3 (1.2±0.3, 8.7±2.2)
T3:18±5 (1.8±0.5, 13.0±3.6)
5
[C200]2-5COMPONENT PARTS
2. Radiator and Radiator Fan

1. On-car Service
A: DRAINING OF ENGINE
COOLANT
1) Lift-up the vehicle.
2) Fit vinyl tube to drain pipe.
B2M0133A
3) Loosen drain cock to drain engine coolant into
container.
NOTE:
Remove radiator cap so that engine coolant will
drain faster.
B2M0015A
B: FILLING OF ENGINE COOLANT
1) Remove air vent plug from radiator.
B2M0301
2) Fill engine coolant into radiator up to filler neck
position.
B2M0135
3) Fill engine coolant into reservoir tank up to
upper level.
B2M0140
4) Attach radiator cap and reservoir tank cap prop-
erly.
5) Install air vent plug.
6) Warm-up engine completely for more than five
minutes at 2,000 to 3,000 rpm.
7) Stop engine and wait until temperature drops to
a safe level.
8) If engine coolant level drops in radiator, add
engine coolant to filler neck position.
9) If engine coolant level drops from upper level of
reservoir tank, add engine coolant to upper level.
10) Attach radiator cap and reservoir tank cap
properly.
7
[W1B0]2-5SERVICE PROCEDURE
1. On-car Service

C: CHECKING OF COOLING
SYSTEM
1) Remove radiator cap, top off radiator, and
attach tester to radiator in place of cap.
B2M0136
2) Apply a pressure of 157 kPa (1.6 kg/cm2,23
psi) to radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
IEngine should be off.
IWipe engine coolant from check points in
advance.
IBe careful to prevent engine coolant from
spurting out when removing tester.
IBe careful also not to deform filler neck of
radiator when installing or removing tester.
2. Water Pump
A: REMOVAL AND INSTALLATION
1. 2200 cc MODEL
1) Disconnect ground cable from battery.
B2M1723
2) Lift-up the vehicle.
3) Remove under cover.
B2M0014
4) Drain engine coolant completely. [W1A0].>
B2M0015A
8
2-5[W1C0]SERVICE PROCEDURE
2. Water Pump

C: CHECKING OF COOLING
SYSTEM
1) Remove radiator cap, top off radiator, and
attach tester to radiator in place of cap.
B2M0136
2) Apply a pressure of 157 kPa (1.6 kg/cm2,23
psi) to radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
IEngine should be off.
IWipe engine coolant from check points in
advance.
IBe careful to prevent engine coolant from
spurting out when removing tester.
IBe careful also not to deform filler neck of
radiator when installing or removing tester.
2. Water Pump
A: REMOVAL AND INSTALLATION
1. 2200 cc MODEL
1) Disconnect ground cable from battery.
B2M1723
2) Lift-up the vehicle.
3) Remove under cover.
B2M0014
4) Drain engine coolant completely. [W1A0].>
B2M0015A
8
2-5[W1C0]SERVICE PROCEDURE
2. Water Pump

5) Disconnect radiator outlet hose (A) and heater
by-pass hose (B) from water pump.
H2M2515A
6) Disconnect connectors from radiator main fan
(A) and sub fan (B) motors.
B2M2035A
7) Lower the vehicles.
8) Remove radiator main fan [W6A0].> and sub fan motor assembly [W7A0].>.
B2M2036
9) Remove V-belts.

B2M2308
10) Remove timing belt.

B2M2037
11) Remove automatic belt tension adjuster.
H2M2375
12) Remove belt idler No. 2.
H2M2518
13) Remove camshaft position sensor.

B2M2038
9
[W2A1]2-5SERVICE PROCEDURE
2. Water Pump

4) Drain engine coolant completely.

B2M0015A
5) Disconnect connectors from radiator main fan
(A) and sub fan (B) motors.
B2M2035A
6) Loosen bolts which hold lower side of radiator
main fan and sub fan shrouds.
B2M2041
7) Disconnect radiator outlet hose (A) and heater
by-pass hose (B) from water pump.
H2M2515A
8) Lower the vehicle.
9) Remove radiator main fan [W6A0].> and sub fan assemblies [W7A0].>.
B2M2036
10) Remove V-belts.

B2M2308
11) Remove timing belt.

S2M0017
12) Remove automatic belt tension adjuster.
H2M2403
11
[W2A2]2-5SERVICE PROCEDURE
2. Water Pump

3) Using a dial gauge, measure impeller runout in
thrust direction while rotating the pulley.
ªThrustº runout limit:
0.5 mm (0.020 in)
G2M0211
4) Check clearance between impeller and pump
case.
Clearance between impeller and pump case:
Standard
0.5 Ð 0.7 mm (0.020 Ð 0.028 in)
Limit
1.0 mm (0.039 in)
G2M0212
5) After water pump installation, check pulley shaft
for engine coolant leaks. If leaks are noted, replace
water pump assembly.
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.
G2M0214
4) Install the thermostat in the intake manifold,
and install the thermostat cover together with a
gasket.
CAUTION:
IWhen reinstalling the thermostat, use a new
gasket.
IThe thermostat must be installed with the
jiggle pin upward.
IIn this time, set the jiggle pin of thermostat
for front side.
G2M0227
13
[W3A0]2-5SERVICE PROCEDURE
3. Thermostat

3) Using a dial gauge, measure impeller runout in
thrust direction while rotating the pulley.
ªThrustº runout limit:
0.5 mm (0.020 in)
G2M0211
4) Check clearance between impeller and pump
case.
Clearance between impeller and pump case:
Standard
0.5 Ð 0.7 mm (0.020 Ð 0.028 in)
Limit
1.0 mm (0.039 in)
G2M0212
5) After water pump installation, check pulley shaft
for engine coolant leaks. If leaks are noted, replace
water pump assembly.
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.
G2M0214
4) Install the thermostat in the intake manifold,
and install the thermostat cover together with a
gasket.
CAUTION:
IWhen reinstalling the thermostat, use a new
gasket.
IThe thermostat must be installed with the
jiggle pin upward.
IIn this time, set the jiggle pin of thermostat
for front side.
G2M0227
13
[W3A0]2-5SERVICE PROCEDURE
3. Thermostat