2004 SUBARU FORESTER engine

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)-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)-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)-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

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
CO-00013
(A)(B)
FU-00009
CO-00042
(A)
CO-00043
(A)