2004 SUBARU FORESTER engine coolant

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)

CO(H4SO)-35
COOLING
Radiator Main Fan and Fan Motor
8. Radiator Main Fan and Fan
Motor
A: REMOVAL
1. NON-TURBO MODEL
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 coolant aprrox. 12 (1.06 US qt, 0.88
Imp qt). ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
6) Disconnect the connector of main fan motor (A)
and sub fan motor (B).
7) Remove the ATF hose from two clips of radiator
fan motor assembly. (AT model)
8) Lower the vehicle.
9) Disconnect the over flow hose.
10) Remove the reservoir tank.11) Remove the radiator fan motor assembly
mounting bolts.
12) Disconnect the radiator inlet hose from engine.
13) Detach the power steering hose from clip on ra-
diator.
14) Rise up the radiator fan motor assembly to re-
move it from vehicle.
FU-00009
CO-00013
(A)(B)
CO-00015
CO-00064
CO-00035
CO-00037
CO-00065

CO(H4SO)-36
COOLING
Radiator Main Fan and Fan Motor
2. TURBO MODEL
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
3) Remove the radiator upper bracket. (AT model)
4) Lift-up the vehicle.
5) Remove the under cover.
6) Drain the engine coolant approx. 12(1.06 US qt,
0.88 Imp qt). OF ENGINE COOLANT, REPLACEMENT, Engine
Coolant.>
7) Disconnect the radiator main fan motor connec-
tor (A) and sub fan motor connector (B).8) Remove the radiator under cover securing bolt.
(AT model)
9) Pull the radiator lower hose upward to space ra-
diator from radiator under cover. Remove the ATF
hose to radiator fan motor assembly two clips. (AT
model)
10) Lower the vehicle.
11) Remove the V-belt cover.
12) Disconnect the overflow hose.
13) Remove the reservoir tank.
14) Remove the radiator main fan motor assembly
securing bolt.
FU-00009
CO-00036
CO-00013
(A)(B)
CO-00070
CO-00143
CO-00015
CO-00064