2004 SUBARU FORESTER cooling

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)
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CO-00143
CO-00015
CO-00064

CO(H4SO)-37
COOLING
Radiator Main Fan and Fan Motor
15) Disconnect the radiator inlet hose.
16) Disconnect the power steering hose from radi-
ator clip.
17) Remove the radiator main fan motor assembly
from vehicle.
B: INSTALLATION
1. NON-TURBO MODEL
1) install the radiator main fan motor assembly to
radiator.
2) Connect the power steering hose to radiator.3) Connect the radiator inlet hose.
4) Install the radiator main fan motor assembly
mounting bolts.
Tightening torque:
4.9 N
⋅m (0.50 kgf-m, 3.6 ft-lb)
5) Install the reservoir tank.
Tightening torque:
4.9 N
⋅m (0.50 kgf-m, 3.6 ft-lb)
6) Install the over-flow hose.
7) Lift-up the vehicle.
8) Install the ATF hose to two clips of radiator main
fan motor assembly. (AT model)
CO-00072
CO-00037
CO-00065
CO-00037
CO-00035
CO-00064
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CO(H4SO)-38
COOLING
Radiator Main Fan and Fan Motor
9) Connect the main fan motor (A) and sub fan mo-
tor (B).
10) Install the under cover.
11) Lower the vehicle.
12) Connect the battery ground cable to battery.
13) Fill the engine coolant. FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
2. TURBO MODEL
1) Install the radiator main fan motor assembly.
2) Lift-up the vehicle.
3) Pull the radiator lower hose upward to space ra-
diator from radiator under cover. Install the ATF
hose to radiator main fan motor assembly two clips.
(AT model)
NOTE:
Fit securely the pins on lower side of radiator into
body side.4) Tighten the radiator under cover securing bolt.
(AT model)
5) Connect the radiator main fan motor connector
(A) and sub fan motor connector (B).
6) Install the under cover.
7) Lower the vehicle.
8) Connect the power steering hose to radiator clip.
9) Connect the radiator inlet hose to radiator.
CO-00013
(A)(B)
FU-00009
CO-00143
CO-00070
CO-00013
(A)(B)
CO-00037
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CO(H4SO)-39
COOLING
Radiator Main Fan and Fan Motor
10) Install the radiator main fan motor assembly
mounting bolts.
Tightening torque:
4.9 N
⋅m (0.5 kgf-m, 3.6 ft-lb)
11) Install the reservoir tank.
12) Connect the overflow hose.
13) Install the V-belt cover.
14) Install the radiator upper bracket. (AT model)
15) Connect the battery ground cable to battery.16) Fill the engine coolant. FILLING OF ENGINE COOLANT, REPLACE-
MENT, Engine Coolant.>
NOTE:
If it is difficult to install the radiator main fan motor
assembly, first loosen the bolts which hold the radi-
ator sub fan motor assembly.
C: DISASSEMBLY
Remove the clip which holds motor connector onto
shroud.
1) Remove the nut which holds fan itself onto fan
motor and shroud assembly.
2) Remove the bolts which install fan motor onto
shroud.
D: ASSEMBLY
Assemble in the reverse order of disassembly.
NOTE:
Refer to COMPONENT for tightening torque. to CO(H4SO)-4, COMPONENT, General Descrip-
tion.>
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CO-00015
CO-00036
FU-00009
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CO(H4SO)-40
COOLING
Radiator Sub Fan and Fan Motor
9. Radiator Sub Fan and Fan
Motor
A: REMOVAL
Refer to Radiator Main Fan and Fan Motor. CO(H4SO)-35, REMOVAL, Radiator Main Fan and
Fan Motor.>
B: INSTALLATION
Refer to Radiator Main Fan and Fan Motor. CO(H4SO)-37, INSTALLATION, Radiator Main
Fan and Fan Motor.>
C: DISASSEMBLY
1) Remove the clip which holds motor connector
onto shroud.
2) Remove the nut which holds fan itself onto fan
motor and shroud assembly.
3) Remove the bolts which install fan motor onto
shroud.
D: ASSEMBLY
Assemble in the reverse order of disassembly.
NOTE:
Refer to COMPONENT for tightening torque. to CO(H4SO)-4, COMPONENT, General Descrip-
tion.>
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CO-00050

CO(H4SO)-41
COOLING
Reservoir Tank
10.Reservoir Tank
A: REMOVAL
1) Disconnect the over flow hose from radiator filler
neck position.
2) Remove the bolts which install reservoir tank
onto radiator main fan shroud.
3) Remove the reservoir tank.
B: INSTALLATION
Install in the reverse order of removal.
NOTE:
Refer to COMPONENT for tightening torque. to CO(H4SO)-4, COMPONENT, General Descrip-
tion.>
C: INSPECTION
Make sure the engine coolant level is between full
and low.
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CO(H4SO)-42
COOLING
Coolant Filler Tank
11.Coolant Filler Tank
A: REMOVAL
WARNING:
The radiator is pressurized. Wait until the en-
gine cools down before working on the radia-
tor.
1) Drain the coolant about 3.02 (3.2 US qt, 2.6 Imp
qt). GINE COOLANT, REPLACEMENT, Engine Cool-
ant.>
2) Remove the air cleaner upper cover and air in-
take boot. Cleaner.>
3) Remove the air cleaner element.
4) Disconnect the engine coolant hoses from cool-
ant filler tank.
5) Remove the bolts and nut which install coolant
filler tank.
6) Disconnect the engine coolant hose which con-
nects under side of coolant filler tank.
7) Remove the coolant filler tank.
B: INSTALLATION
1) Install in the reverse order of removal.
Tightening torque:
T1: 19 N
⋅m (1.9 kgf-m, 13.7 ft-lb)
T2: 21 N
⋅m (2.1 kgf-m, 15.2 ft-lb)
2) Fill engine coolant. ING OF ENGINE COOLANT, REPLACEMENT,
Engine Coolant.>
CO-00051
CO-00052
T2
T1
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CO(H4SO)-43
COOLING
Engine Cooling System Trouble in General
12.Engine Cooling System Trouble in General
A: INSPECTION
Trouble Possible cause Corrective action
Over-heatinga. Insufficient engine coolantReplenish the engine coolant, inspect for leakage, and
repair.
b. Loose timing belt Repair or replace the timing belt tensioner.
c. Oil on drive belt Replace.
d. Malfunction of thermostat Replace.
e. Malfunction of water pump Replace.
f. Clogged engine coolant passage Clean.
g. Improper ignition timingInspect and repair the ignition control system.

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

nostics Procedure.>
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. Defective thermostat Replace.
p. Malfunction of radiator fanInspect the radiator fan relay, engine coolant tempera-
ture sensor or radiator motor and replace there.
Over-coolinga. Atmospheric temperature extremely low Partly cover the radiator front area.
b. Defective thermostat Replace.
Engine coolant
leaks.a. Loosened or damaged connecting units on hoses Repair or replace.
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
d. Leakage around cylinder head gasket Retighten the 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 water pump bearing Replace the water pump.
d. Defective water pump mechanical seal Replace the water pump.