2004 SUBARU FORESTER radiator cap

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)-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)-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.
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CO-00010
FULLFULLLOWLOW

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.
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(A)(B)
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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.
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FU-00009
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(A)(B)
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CO(H4SO)-33
COOLING
Radiator
12) Connect the oil cooler hose. (MT model with oil
cooler)
13) Connect the radiator outlet hose.
14) Connect the connectors to radiator main fan
motor (A) and sub fan motor (B).
15) Install the under cover.
16) Lower the vehicle.
17) Connect the battery ground cable to battery.
18) Fill engine coolant. FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>19) Check the ATF level. SPECTION, Automatic Transmission Fluid.>
C: INSPECTION
1) Remove the radiator cap, top off radiator, and
then attach the tester (A) to radiator in place of cap.
 NON-TURBO MODEL
 TURBO MODEL
2) Apply a pressure of 157 kPa (1.6 kg/cm
2, 23 psi)
to the radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or
connections.
CAUTION:
 Inspection must be carried out at the side of
coolant filler tank, not at the side of radiator.
 Engine should be off.
 Wipe engine coolant from check points in ad-
vance.
 Be careful to prevent engine coolant from
spurting out when removing the tester.
 Be careful also not to deform the filler neck of
radiator when installing or removing tester.
CO-00034
CO-00030
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(A)(B)
FU-00009
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(A)
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(A)

CO(H4SO)-34
COOLING
Radiator Cap
7. Radiator Cap
A: INSPECTION
1) Attach the radiator cap to tester.
2) Increase the pressure until tester gauge pointer
stops. Radiator cap is functioning properly if it holds
the service limit pressure for 5 to 6 seconds.
Standard pressure:
93 — 123 kPa (0.95 — 1.25 kg/cm
2 , 14 — 18
psi)
Service limit pressure:
83 kPa (0.85 kg/cm
2, 12 psi)
CAUTION:
Be sure to remove foreign matter and rust from
the cap in advance otherwise, results of pres-
sure test will be incorrect.
CO-00044

ME(H4DOTC)-41
MECHANICAL
Engine Assembly
9. Engine Assembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Open the front hood fully, and then support with
the hood stay.
3) Collect the refrigerant from A/C system.

4) Release the fuel pressure.
(1) Disconnect the fuel pump relay connector.
(2) Start the engine, and run until stalls.
(3) After the engine stalls, crank it for 5 seconds
more.
(4) Turn the ignition switch to OFF.
5) Remove the filler cap.
6) Disconnect the ground cable from battery.
7) Remove the radiator from vehicle. CO(H4SO)-28, REMOVAL, Radiator.>
8) Remove the coolant filler tank. CO(H4SO)-42, REMOVAL, Coolant Filler Tank.>
9) Disconnect the A/C pressure hoses from A/C
compressor.10) Remove the intercooler. 10, REMOVAL, Intercooler.>
11) Disconnect the following connectors and cable.
(1) Engine harness connector
(2) Engine ground terminal
(3) Disconnect the right and left side engine
ground cables.
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