FORESTER 20MY PubNo: G8270BE Version: 006

COOLING(H4DO) > General Description　

SPECIFICATION

Cooling system					Electric fan + Forced engine coolant circulation system
Total engine coolant capacity		L (US qt, Imp qt)			Approx. 8.5 (9.0, 7.5)
Water pump	Type				Centrifugal impeller type
	Pump characteristics	Discharge rate		L (US gal, Imp gal)/min	256 (67.6, 56.3) or more
		Engine coolant temperature		°C (°F)	80 (176)
		Engine coolant concentration		%	50
		System pressure		kPa (mAq)	88 (9.0)
		Pump speed		r/min	8,580
	Impeller diameter		mm (in)		56 (2.20)
	Number of impeller vanes			pcs.	7
	Pump pulley effective diameter		mm (in)		100 (3.94)
Thermo control valve assembly	Flow rate characteristics	Position 1		Radiator port	20.9 kPa (2.1 mAq) @ 100 L (26.4 US gal, 22.0 Imp gal) /min
		Position 2		Bottom port	41.6 kPa (4.2 mAq) @ 100 L (26.4 US gal, 22.0 Imp gal) /min
		Position 3 (fully closed)		-	-
		Position 4		Bottom port	15.7 kPa (1.6 mAq) @ 30 L (7.9 US gal, 6.6 Imp gal) /min
				Heater port	28.5 kPa (2.9 mAq) @ 20 L (5.3 US gal, 4.4 Imp gal) /min
		Position 5		Radiator port	9.7 kPa (1.0 mAq) @ 100 L (26.4 US gal, 22.0 Imp gal) /min
				Heater port	12.0 kPa (1.2 mAq) @ 20 L (5.3 US gal, 4.4 Imp gal) /min
	Responsiveness	Fully closed — Fully open		sec	2 or less
	Sensor output range			V	0.539 — 4.141 (mechanical stop position: 4.297)
	Rotor operation range		deg		174
	Failsafe thermostat	Type			Temperature, pressure relief
		Starting temperature to open		°C (°F)	105 — 109 (221 — 228)
		Starting pressure to open		kPa (mAq)	210 — 290 (21.4 — 29.6)
Thermostat	Type		Water tank pipe side		Wax pellet type
	Starting temperature to open	°C (°F)	Water tank pipe side		63 — 67 (145 — 153)
	Full open temperature	°C (°F)	Water tank pipe side		80 (176)
	Valve lift	mm (in)	Water tank pipe side		5.5 (0.217) or more
	Valve opening size	mm (in)	Water tank pipe side		22 (0.87)
Radiator fan	Motor input	W	Main fan		120
			Sub fan		120
	Fan outer diameter	mm (in)	Main fan		320 (12.6)
			Sub fan		320 (12.6)
	Number of fan blades	pcs.	Main fan		9
			Sub fan		11
Radiator	Type				Down flow, pressure type
	Core dimensions	mm (in)	Width × Height × Thickness		687.4 × 390 × 16 (27.06 × 15.35 × 0.63)
	Pressure range in which cap valve is open	kPa (kg/cm², psi)	Positive pressure side	Standard	93 — 123 (0.95 — 1.25, 14 — 18)
				Limit	83 (0.85, 12)
			Negative pressure side	Standard	−1.0 — −4.9 or less (−0.01 — −0.05, −0.1 — −0.7)
	Fin shape				Corrugated fin
Reservoir tank	Capacity		L (US qt, Imp qt)		0.45 (0.476, 0.396)

Engine coolant:

Refer to “RECOMMENDED MATERIALS” for engine coolant. RECOMMENDED MATERIALS>GREASE>ENGINE COOLANT

COOLING(H4DO) > General Description　

COMPONENT

1. ENGINE COOLING SYSTEM

(1)	Water pipe RH	(16)	Clip	(31)	Water hose
(2)	Clip	(17)	Preheater hose	(32)	Gasket
(3)	Water hose	(18)	Heater hose pipe	(33)	Clip
(4)	Center water pipe	(19)	Water tank pipe ASSY No. 2	(34)	Water hose
(5)	O-ring	(20)	Clip	(35)	Water hose
(6)	Inlet engine coolant temperature sensor	(21)	Water hose	(36)	Water tank pipe ASSY No. 1
(7)	Clip	(22)	O-ring
(8)	Gasket	(23)	Outlet engine coolant temperature sensor	Tightening torque: N·m (kgf-m, ft-lb)
(9)	Harness stay	(24)	Thermostat cover	T1:	6.4 (0.7, 4.7)
(10)	Water pump pulley	(25)	Gasket	T2:	8.5 (0.9, 6.3)
(11)	Water pump	(26)	Thermostat	T3:	14 (1.4, 10.3)
(12)	Gasket	(27)	Water hose	T4:	16 (1.6, 11.8)
(13)	Gasket	(28)	Preheater hose	T5:	18 (1.8, 13.3)
(14)	Thermostat cover	(29)	Thermo control valve ASSY	T6:	COOLING(H4DO)>Water Pipe>INSTALLATION > WATER PIPE LH
(15)	Water pipe LH	(30)	Clip

2. RADIATOR & RADIATOR FAN

(1)	Radiator lower cushion	(11)	Nut (with locking agent)	(21)	Reservoir tank cap
(2)	Radiator	(12)	Radiator sub fan	(22)	Over flow hose
(3)	Radiator upper cushion	(13)	Radiator main fan
(4)	Radiator upper bracket	(14)	Radiator sub fan shroud side gasket	Tightening torque: N·m (kgf-m, ft-lb)
(5)	Radiator hose clip	(15)	Radiator main fan shroud side gasket	T1:	3.4 (0.3, 2.5)
(6)	Radiator inlet hose	(16)	Radiator sub fan shroud	T2:	4.4 (0.4, 3.2)
(7)	Radiator outlet hose	(17)	Radiator main fan shroud	T3:	7.5 (0.8, 5.5)
(8)	O-ring	(18)	Sub fan motor	T4:	12 (1.2, 8.9)
(9)	Radiator drain plug	(19)	Main fan motor
(10)	Radiator cap	(20)	Reservoir tank

3. ACTIVE GRILLE SHUTTER

(1)	Active grille shutter			Tightening torque: N·m (kgf-m, ft-lb)
				T:	COOLING(H4DO)>Active Grille Shutter>INSTALLATION

COOLING(H4DO) > General Description　

CAUTION

When performing service operation, refer to “Repair Contents” in “General Description”. REPAIR CONTENTS>Repair Contents
Prior to starting work, pay special attention to the following:
1. Always wear work clothes, a work cap, and protective shoes. Additionally, wear a helmet, protective goggles, etc. if necessary.
2. Protect the vehicle using a seat cover, fender cover, etc.
3. Prepare the service tools, clean cloth, containers to catch grease and oil, etc.
Prevent scattering of grease and oil. If it scatters, wipe it off immediately to prevent it from penetrating the floor or flowing out, to protect the environmental.
If the grease and oil is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.
Vehicle components are extremely hot immediately after driving. Be wary of receiving burns from heated parts.
When performing a repair, identify the cause of trouble and avoid unnecessary work.
Before disconnecting connectors of sensors or units, be sure to disconnect the ground terminal from the battery sensor.
Always use the jack-up point when the lifting device, shop jacks or rigid racks are used to support the vehicle.
Before starting works, remove dirt and corrosion around the target area.
Keep the removed parts in order and protect them from dust and dirt.
All removed parts, if to be reused, should be reinstalled in the original positions with attention to the correct directions, etc.
For the parts except for the non-reusable parts, replace then with new parts if necessary.
Be sure to tighten bolts and nuts to the specified torque.
Follow all government and local regulations concerning disposal of refuse when disposing engine coolant.

COOLING(H4DO) > General Description　

PREPARATION TOOL

1. SPECIAL TOOL

ILLUSTRATION	TOOL NUMBER	DESCRIPTION	REMARKS
	18355AA000	PULLEY WRENCH	Used for removing and installing water pump pulley. Used with PULLEY WRENCH PIN SET (18334AA020).
	18334AA020	PULLEY WRENCH PIN SET	Used for removing and installing water pump pulley. Used together with PULLEY WRENCH (18355AA000).
	18360AA040	HANGER	Used for removing and installing the water pipe LH. Used together with BOLT (18363AA050).
	18363AA050	BOLT	Used for removing and installing the water pipe LH. Used together with HANGER (18360AA040).
	18460AA180	CHECK BOARD	Used for measuring voltage and resistance of ECM terminals.
	45099SJ000	ST COOLANT CHARGER	Used for filling the radiator with engine coolant.
	—	SUBARU SELECT MONITOR 4	Used for setting of each function and troubleshooting for electrical system. For detailed operation procedures, refer to “Help” of application.

2. GENERAL TOOL

TOOL NAME	REMARKS
Circuit tester	Used for measuring resistance, voltage and current.
Radiator cap tester	Used for checking radiator and radiator cap.
DST-i	Used together with Subaru Select Monitor 4.

COOLING(H4DO) > Radiator Fan System　

WIRING DIAGRAM

COOLING(H4DO) > Radiator Fan System　

INSPECTION

Be careful not to let your hands or other objects get caught in the rotating parts.
Since some of the power supply circuits are shared with other system, check such system other than the radiator fan system for faulty conditions before proceeding any further.
Since more than one faulty conditions may occur simultaneously, once work is done perform “Basic Inspection of Radiator Fan System” to confirm that the system is working properly.
Since battery discharge may occur, charge the battery as necessary. STARTING/CHARGING SYSTEMS(H4DO)>Battery>CHARGE
Use the check board when measuring the ECM terminal voltage and resistance. ENGINE (DIAGNOSTICS)(H4DO)>General Description>PREPARATION TOOL > HOW TO USE CHECK BOARD

Operating condition:

Radiator fan operates depending on the radiator fan operation mode related to engine coolant temperature or the radiator fan operation mode related to A/C compressor load, whichever is higher as an operation mode.

Radiator fan operation mode related to engine coolant temperature (idle stop state)

(A)	Radiator fan operation mode	(B)	Engine coolant temperature

(1)	High-Speed	(4)	92°C (198°F)	(7)	100°C (212°F)
(2)	Low-Speed	(5)	95°C (203°F)
(3)	OFF	(6)	97°C (207°F)

Radiator fan operation mode related to A/C compressor load

(A)	Radiator fan operation mode	(B)	A/C compressor refrigerant pressure

(1)	High-Speed	(4)	0.8 MPa (8.16 kg/cm², 116 psi)	(7)	1.4 MPa (14.28 kg/cm², 203 psi)
(2)	Low-Speed	(5)	1.1 MPa (11.22 kg/cm², 159 psi)
(3)	OFF	(6)	1.2 MPa (12.24 kg/cm², 174 psi)

1. BASIC INSPECTION OF RADIATOR FAN SYSTEM

1. CHECK DTC.

Read the DTC using Subaru Select Monitor. COMMON(diag)>Diagnostic Trouble Code (DTC)>OPERATION

Is DTC detected?

(1) Repair the corresponding system.

(2) 2

2

2. RADIATOR FAN SYSTEM OPERATION CHECK.

If the radiator fans are always running, go to “INSPECTION WHEN RADIATOR FANS DO NOT STOP”. COOLING(H4DO)>Radiator Fan System>INSPECTION > INSPECTION WHEN RADIATOR FANS DO NOT STOP

1.

Using the Subaru Select Monitor, perform the active test for the radiator fan relay. (When using the Subaru Select Monitor) ENGINE (DIAGNOSTICS)(H4DO)>Active Test

2.

Install the delivery mode fuse, and turn to IG ON. (When not using the Subaru Select Monitor) PRE-DELIVERY INSPECTION>PRE-DELIVERY INSPECTION (PDI) PROCEDURE > DELIVERY MODE

3.

Check the radiator fan operation.

Do the radiator main fan and sub fan rotate in the order of “OFF → Low speed revolution → High speed revolution”?

System is normal.

Restore the vehicle to its original state.

Inspect corresponding malfunction using “Table for Diagnostics Procedure with Phenomenon”.

Table for Diagnostics Procedure with Phenomenon

If phenomenon does not match with any of the phenomenon described below, inspect fuse, relay and ground contacts for failure.

	Sub fan	Main fan	Sub fan	Main fan	Sub fan	Main fan	Sub fan	Main fan
Stop control	Stop	Stop	Stop	Stop	Stop	Stop	Stop	Stop
Low speed control	Stop	Stop	At high speed	Stop	At low speed	At low speed	At low speed	At low speed
High speed control	Stop or high speed	Stop or high speed	At high speed	Stop or high speed	At high speed	Stop	Stop	At high speed
Reference	Inspection when radiator fans do not rotate (A) COOLING(H4DO)>Radiator Fan System>INSPECTION>INSPECTION WHEN RADIATOR FANS DO NOT ROTATE>INSPECTION WHEN RADIATOR FANS DO NOT ROTATE (A)		Inspection when radiator fans do not rotate (B) COOLING(H4DO)>Radiator Fan System>INSPECTION>INSPECTION WHEN RADIATOR FANS DO NOT ROTATE>INSPECTION WHEN RADIATOR FANS DO NOT ROTATE (B)		Inspection when radiator fans do not rotate (C) COOLING(H4DO)>Radiator Fan System>INSPECTION>INSPECTION WHEN RADIATOR FANS DO NOT ROTATE>INSPECTION WHEN RADIATOR FANS DO NOT ROTATE (C)		Inspection when radiator fans do not rotate (D) COOLING(H4DO)>Radiator Fan System>INSPECTION>INSPECTION WHEN RADIATOR FANS DO NOT ROTATE>INSPECTION WHEN RADIATOR FANS DO NOT ROTATE (D)

2. INSPECTION WHEN RADIATOR FANS DO NOT ROTATE

•

INSPECTION WHEN RADIATOR FANS DO NOT ROTATE (A)

1. CHECK SUB FAN FUSE.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the sub fan fuse.

3.

Check sub fan fuse.

Is the sub fan fuse OK?

2

13

2. CHECK SUB FAN RELAY.

1.

Remove the sub fan relay. COOLING(H4DO)>Radiator Fan Relay>LOCATION

2.

Perform unit check for the sub fan relay. COOLING(H4DO)>Radiator Fan Relay>INSPECTION

Is the sub fan relay OK?

3

(1) Replace the sub fan relay.

(2) Restore the vehicle to its original state.

3. CHECK MAIN FAN RELAY 2.

1.

Remove the main fan relay 2. COOLING(H4DO)>Radiator Fan Relay>LOCATION

2.

Perform unit check for the main fan relay 2. COOLING(H4DO)>Radiator Fan Relay>INSPECTION

Is the main fan relay 2 OK?

4

(1) Replace the main fan relay 2.

(2) Restore the vehicle to its original state.

4. CHECK SUB FAN MOTOR.

1.

Disconnect the connector from the sub fan motor.

2.

Connect the battery terminal to the sub fan motor.

Does the sub fan motor rotate properly?

5

(1) Replace the sub fan motor. COOLING(H4DO)>Radiator Sub Fan and Fan Motor

(2) Restore the vehicle to its original state.

5. CHECK MAIN FAN MOTOR.

1.

Disconnect the connector from the main fan motor.

2.

Connect the battery terminal to the main fan motor.

Does the main fan motor rotate properly?

6

(1) Replace the main fan motor. COOLING(H4DO)>Radiator Main Fan and Fan Motor

(2) Restore the vehicle to its original state.

6. CONTINUITY CHECK OF HARNESS BETWEEN MAIN FAN MOTOR AND CHASSIS GROUND.

Check continuity of harness between the main fan motor and chassis ground.

Is there continuity?

7

(1) Repair the harness between the main fan motor and chassis ground.

(2) Restore the vehicle to its original state.

7. CONTINUITY CHECK OF HARNESS BETWEEN MAIN FAN RELAY 2 AND MAIN FAN MOTOR.

Check continuity of harness between main fan relay 2 and the main fan motor.

Is there continuity?

8

(1) Repair the harness between main fan relay 2 and the main fan motor.

(2) Restore the vehicle to its original state.

8. CONTINUITY CHECK OF HARNESS BETWEEN SUB FAN MOTOR AND MAIN FAN RELAY 2.

Check continuity of harness between the sub fan motor and the main fan relay 2.

Is there continuity?

9

(1) Repair the harness between the sub fan motor and the main fan relay 2.

(2) Restore the vehicle to its original state.

9. CONTINUITY CHECK OF HARNESS BETWEEN SUB FAN RELAY AND SUB FAN MOTOR.

Check continuity of harness between sub fan relay and sub fan motor.

Is there continuity?

10

(1) Repair the harness between sub fan relay and sub fan motor.

(2) Restore the vehicle to its original state.

10. CONTINUITY CHECK OF HARNESS BETWEEN SUB FAN FUSE AND SUB FAN RELAY.

Check continuity of harness between sub fan fuse and sub fan relay.

Is there continuity?

11

(1) Repair the harness between sub fan fuse and sub fan relay.

(2) Restore the vehicle to its original state.

11. CONTINUITY CHECK OF HARNESS BETWEEN A/C IG FUSE AND SUB FAN RELAY.

Check continuity of harness between A/C IG fuse and sub fan relay.

Is there continuity?

12

(1) Repair the harness between A/C IG fuse and sub fan relay.

(2) Restore the vehicle to its original state.

12. CONTINUITY CHECK OF HARNESS BETWEEN SUB FAN RELAY AND ECM.

1.

Disconnect the ECM connector. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>REMOVAL

2.

Check continuity of harness between sub fan relay and ECM.

Is there continuity?

(1) Check for poor contact of the connectors due to wear damage of connector pins. If they are OK, replace the ECM. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)

(2) Restore the vehicle to its original state.

(1) Repair the harness between sub fan relay and ECM.

(2) Restore the vehicle to its original state.

13. CHECK SUB FAN RELAY.

1.

Remove the sub fan relay. COOLING(H4DO)>Radiator Fan Relay>LOCATION

2.

Perform unit check for the sub fan relay. COOLING(H4DO)>Radiator Fan Relay>INSPECTION

Is the sub fan relay OK?

14

(1) Replace the sub fan relay.

(2) Replace the sub fan fuse.

(3) Restore the vehicle to its original state.

14. INSULATION CHECK OF HARNESS BETWEEN SUB FAN FUSE AND SUB FAN RELAY.

Check insulation of harness and chassis ground between sub fan fuse and sub fan relay.

Are they insulated?

(1) Replace the sub fan fuse.

(2) Restore the vehicle to its original state.

(1) Repair the harness between sub fan fuse and sub fan relay.

(2) Replace the sub fan fuse.

(3) Restore the vehicle to its original state.

•

INSPECTION WHEN RADIATOR FANS DO NOT ROTATE (B)

1. CHECK MAIN FAN RELAY 2.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the main fan relay 2. COOLING(H4DO)>Radiator Fan Relay>LOCATION

3.

Perform unit check for the main fan relay 2. COOLING(H4DO)>Radiator Fan Relay>INSPECTION

Is the main fan relay 2 OK?

2

(1) Replace the main fan relay 2.

(2) Restore the vehicle to its original state.

2. CHECK MAIN FAN RELAY 1.

1.

Remove the main fan relay 1. COOLING(H4DO)>Radiator Fan Relay>LOCATION

2.

Perform unit check for the main fan relay 1. COOLING(H4DO)>Radiator Fan Relay>INSPECTION

Is the main fan relay 1 OK?

3

(1) Replace the main fan relay 1.

(2) Restore the vehicle to its original state.

3. INSULATION CHECK OF HARNESS BETWEEN SUB FAN MOTOR AND MAIN FAN RELAY 2.

1.

Disconnect the connector from the sub fan motor.

2.

Check insulation of harness and chassis ground between the sub fan motor and the main fan relay 2.

Are they insulated?

4

(1) Repair the harness between the sub fan motor and the main fan relay 2.

(2) Restore the vehicle to its original state.

4. INSULATION CHECK OF HARNESS BETWEEN MAIN FAN RELAY 2 AND MAIN FAN MOTOR.

1.

Disconnect the connector from the main fan motor.

2.

Check insulation of harness and chassis ground between main fan relay 2 and the main fan motor.

Are they insulated?

(1) Replace the main fan motor. COOLING(H4DO)>Radiator Main Fan and Fan Motor

(2) Restore the vehicle to its original state.

(1) Repair the harness between main fan relay 2 and the main fan motor.

(2) Restore the vehicle to its original state.

•

INSPECTION WHEN RADIATOR FANS DO NOT ROTATE (C)

1. CHECK MAIN FAN FUSE.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the main fan fuse.

3.

Check the main fan fuse.

Is the fuse OK?

2

3

2. CHECK MAIN FAN RELAY 1.

1.

Remove the main fan relay 1. COOLING(H4DO)>Radiator Fan Relay>LOCATION

2.

Perform unit check for the main fan relay 1. COOLING(H4DO)>Radiator Fan Relay>INSPECTION

Is the main fan relay 1 OK?

(1) Repair the harness between the main fan fuse and the main fan relay 1.

(2) Restore the vehicle to its original state.

(1) Replace the main fan relay 1.

(2) Restore the vehicle to its original state.

3. CHECK MAIN FAN RELAY 1.

1.

Remove the main fan relay 1. COOLING(H4DO)>Radiator Fan Relay>LOCATION

2.

Perform unit check for the main fan relay 1. COOLING(H4DO)>Radiator Fan Relay>INSPECTION

Is the main fan relay 1 OK?

4

(1) Replace the main fan relay 1.

(2) Replace the main fan fuse.

(3) Restore the vehicle to its original state.

4. INSULATION CHECK OF HARNESS BETWEEN MAIN FAN FUSE AND MAIN FAN RELAY 1.

Check insulation of harness and chassis ground between the main fan fuse and the main fan relay 1.

Are they insulated?

(1) Replace the main fan fuse.

(2) Restore the vehicle to its original state.

(1) Repair the harness between the main fan fuse and the main fan relay 1.

(2) Replace the main fan fuse.

(3) Restore the vehicle to its original state.

•

INSPECTION WHEN RADIATOR FANS DO NOT ROTATE (D)

1. CHECK MAIN FAN RELAY 2.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the main fan relay 2. COOLING(H4DO)>Radiator Fan Relay>LOCATION

3.

Perform unit check for the main fan relay 2. COOLING(H4DO)>Radiator Fan Relay>INSPECTION

Is the main fan relay 2 OK?

2

(1) Replace the main fan relay 2.

(2) Restore the vehicle to its original state.

2. CONTINUITY CHECK OF HARNESS BETWEEN MAIN FAN RELAY 1 AND MAIN FAN RELAY 2.

1.

Remove the main fan relay 1. COOLING(H4DO)>Radiator Fan Relay>LOCATION

2.

Check continuity of harness between the main fan relay 1 and the main fan relay 2.

Is there continuity?

(1) Repair the harness between the main fan relay 2 and the chassis ground.

(2) Restore the vehicle to its original state.

(1) Repair the harness between the main fan relay 1 and the main fan relay 2.

(2) Restore the vehicle to its original state.

3. INSPECTION WHEN RADIATOR FANS DO NOT STOP

•

INSPECTION WHEN MAIN FAN AND SUB FAN DO NOT STOP

1. CHECK SUB FAN RELAY.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the sub fan relay. COOLING(H4DO)>Radiator Fan Relay>LOCATION

3.

Perform unit check for the sub fan relay. COOLING(H4DO)>Radiator Fan Relay>INSPECTION

Is the sub fan relay OK?

2

(1) Replace the sub fan relay.

(2) Restore the vehicle to its original state.

2. INSULATION CHECK OF HARNESS BETWEEN SUB FAN RELAY AND SUB FAN MOTOR.

1.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

Sub fan relay is removed.

2.

Turn to IG ON.

3.

Check the radiator fan operation.

Do the sub fan motor and the main fan motor rotate?

(1) Repair the harness between sub fan relay and sub fan motor.

(2) Restore the vehicle to its original state.

3

3. INSULATION CHECK OF HARNESS BETWEEN SUB FAN RELAY AND ECM.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Disconnect the ECM connector. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)>REMOVAL

3.

Check insulation of harness and chassis ground between sub fan relay and ECM.

Are they insulated?

(1) Replace the ECM. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)

(2) Restore the vehicle to its original state.

(1) Repair the harness between sub fan relay and ECM.

(2) Restore the vehicle to its original state.

•

INSPECTION WHEN ONLY MAIN FAN DOES NOT STOP

1. CHECK MAIN FAN RELAY 1.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the main fan relay 1. COOLING(H4DO)>Radiator Fan Relay>LOCATION

3.

Perform unit check for the main fan relay 1. COOLING(H4DO)>Radiator Fan Relay>INSPECTION

Is the main fan relay 1 OK?

2

(1) Replace the main fan relay 1.

(2) Restore the vehicle to its original state.

2. INSULATION CHECK OF HARNESS BETWEEN MAIN FAN MOTOR AND SUB FAN MOTOR.

1.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

Main fan relay 1 is removed.

2.

Turn to IG ON.

3.

Check the radiator fan operation.

Does the main fan motor rotate?

(1) Repair the harness between the main fan motor and the sub fan motor.

(2) Restore the vehicle to its original state.

(1) Replace the ECM. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Control Module (ECM)

(2) Restore the vehicle to its original state.

COOLING(H4DO) > Engine Coolant　

INSPECTION

The engine coolant is pressurized when it is hot. Wait until engine coolant cools down before proceeding the work.
If the engine coolant is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

Engine coolant:

Refer to “RECOMMENDED MATERIALS” for engine coolant. RECOMMENDED MATERIALS>GREASE>ENGINE COOLANT

Engine coolant concentration:

Refer to “ADJUSTMENT” for the recommended engine coolant concentration. COOLING(H4DO)>Engine Coolant>ADJUSTMENT

The SUBARU Super Coolant contains anti-freeze and anti-rust agents, and is especially made for Subaru engines with an aluminum cylinder block. Be sure to use SUBARU Super Coolant, since other coolant may cause corrosion.

1.

Park the vehicle on a level surface.

2.

Check the engine coolant amount, and add the engine coolant if the coolant level is low.

If it is necessary to add the coolant, make sure that there are no engine coolant leaks.

(1)

Make sure the engine coolant level in the reservoir tank is between “FULL” and “LOW” with the engine in a cold condition.

(2)

Open the radiator cap and make sure that the radiator is filled with the engine coolant up to its filler neck position.

COOLING(H4DO) > Engine Coolant　

REPLACEMENT

1. DRAINING OF ENGINE COOLANT

The engine coolant is pressurized when it is hot. Wait until engine coolant cools down before proceeding the work.
If the engine coolant is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

1.

Remove the radiator cap.

2.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

3.

Connect hose (A) to the drain pipe of the radiator.

Use a hose with an inner diameter of 8.0 mm (0.315in).

4.

Loosen the radiator drain plug to drain engine coolant.

5.

After draining the engine coolant, remove the radiator drain plug.

6.

Install the radiator drain plug with a new O-ring.

7.

Remove the hose.

8.

Install the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>INSTALLATION

9.

Drain the coolant from reservoir tank.

2. FILLING OF ENGINE COOLANT

During work, set the select lever to “P” or “N” range and do not shift the lever.
If the engine coolant is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

Engine coolant:

Refer to “RECOMMENDED MATERIALS” for engine coolant. RECOMMENDED MATERIALS>GREASE>ENGINE COOLANT

Engine coolant concentration:

Refer to “ADJUSTMENT” for the recommended engine coolant concentration. COOLING(H4DO)>Engine Coolant>ADJUSTMENT

Engine coolant level:

Refer to “SPECIFICATION” for engine coolant level. COOLING(H4DO)>General Description>SPECIFICATION

Cooling system protective agent:

Refer to “RECOMMENDED MATERIALS” for cooling system protective agent. RECOMMENDED MATERIALS>GREASE>ENGINE COOLANT

The SUBARU Super Coolant contains anti-freeze and anti-rust agents, and is especially made for Subaru engines with an aluminum cylinder block. Be sure to use SUBARU Super Coolant, since other coolant may cause corrosion.

1.

Using the Subaru Select Monitor, navigate to the coolant filling control mode. (When using the Subaru Select Monitor) ENGINE (DIAGNOSTICS)(H4DO)>Work Support

If the following conditions are met, coolant filling control mode is deactivated.

Shift into D range
Water temperature 80°C or more
Vehicle speed 0 km/h or more
MIL illuminating
EPB not in operation
Small switch ON

2.

Use the following procedure to navigate to the coolant filling control mode. (When not using the Subaru Select Monitor)

If the following conditions are met, coolant filling control mode is deactivated.

Shift into D range
Water temperature 80°C or more
Vehicle speed 0 km/h or more
MIL illuminating
EPB not in operation
Small switch ON

(1)

Turn the ignition switch to ON.

(2)

With the shift lever in “P” range, fully depress the accelerator twice. Accelerator fully depressed (1st) → Accelerator OFF → Accelerator fully depressed (2nd)

(3)

With the shift lever in “N” range, fully depress the accelerator twice. Accelerator fully depressed (1st) → Accelerator OFF → Accelerator fully depressed (2nd)

(4)

With the shift lever in “P” range, fully depress the accelerator twice. Accelerator fully depressed (1st) → Accelerator OFF → Accelerator fully depressed (2nd)

(5)

With the shift lever in “N” range, fully depress the accelerator twice. Accelerator fully depressed (1st) → Accelerator OFF → Accelerator fully depressed (2nd)

(6)

With the shift lever in “P” range, fully depress the accelerator twice. Accelerator fully depressed (1st) → Accelerator OFF → Accelerator fully depressed (2nd)

(7)

Water temperature indicator light blinks in blue in the combination meter and the coolant filling control mode takes place. If the coolant filling control mode fails due to improper operation, turn the ignition switch to OFF and perform the steps (1) to (6) again.

3.

Attach the ST to the radiator filler neck.

Preparation tool:

ST: ST COOLANT CHARGER (45099SJ000)

4.

Fill the ST with cooling system conditioner.

5.

Fill engine coolant into the ST.

6.

Install the reservoir tank cap.

7.

Charge refrigerant. (When the refrigerant has been recollected) AIR CONDITIONER>Refrigerant Charging Procedure>PROCEDURE

8.

Start the engine, and race 5 to 6 times at 3,000r/min or less, then stop the engine.

Complete this operation within 40 seconds.

9.

Wait for one minute after the engine stops. If the engine coolant level drops, add the engine coolant into the ST.

10.

Perform the steps 8 and 9 again.

11.

Start the engine and operate the A/C at maximum hot position, with the blower speed setting at “LO”, and the A/C switch at “OFF”.

12.

Run the engine at 3,000r/min or less until the water temperature indicator light goes off in the combination meter.

Coolant filling control mode is deactivated at or above 80°C.

13.

Run the engine at 3,000r/min or less until the radiator fan starts and stops.

Frequently check the engine coolant temperature in order to avoid overheat.

14.

Stop the engine and wait until the engine coolant temperature lowers to 30°C (86°F) or less.

15.

If the engine coolant level drops, add the engine coolant into the ST.

16.

Keep the A/C setting to maximum hot position, the blower speed setting to “LO”, and the A/C switch to “OFF”, and start the engine. Perform racing at 3,000r/min or less. If the flowing sound of engine coolant is heard from the heater core, repeat the procedures from step 13.

17.

Stop the engine, remove the ST, and install the radiator cap.

Prepare a container and cloth when performing the work in order to prevent scattering of engine coolant. If the oil spills, wipe it off immediately to prevent from penetrating into floor or flowing out for environmental protection.

18.

Make sure the engine coolant level in the reservoir tank is between “FULL” and “LOW”, and adjust if necessary.

COOLING(H4DO) > Engine Coolant　

ADJUSTMENT

1. PROCEDURE TO ADJUST THE SUBARU SUPER COOLANT CONCENTRATION

Use the SUBARU Super Coolant with a 50 — 60% concentration in order to obtain maximum anti-freeze and anti-rust performance.

Engine coolant and diluting water:

Refer to “RECOMMENDED MATERIALS” for the engine coolant and diluting water. RECOMMENDED MATERIALS>GREASE>ENGINE COOLANT

To adjust the concentration of SUBARU Super Coolant according to temperature, find the proper SUBARU Super Coolant concentration in the table, and add dilution water to the SUBARU Super Coolant (concentrated type) until it reaches the proper dilution.

Relationship of SUBARU Super Coolant concentration and freezing temperature
SUBARU Super Coolant concentration	50%	55%	60%
Freezing temperature	−36°C (−33°F)	−41°C (−42°F)	−50°C (−58°F)

COOLING(H4DO) > Water Pump　

REMOVAL

1. WATER PUMP PULLEY

1.

Remove the V-belts. MECHANICAL(H4DO)>V-belt>REMOVAL > V-BELT

2.

Using the ST1 and ST2, remove the water pump pulley.

Preparation tool:

ST1: PULLEY WRENCH (18355AA000)

ST2: PULLEY WRENCH PIN SET (18334AA020)

2. WATER PUMP

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the water pump pulley. COOLING(H4DO)>Water Pump>REMOVAL > WATER PUMP PULLEY

3.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

4.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

5.

Remove the harness stay.

6.

Remove the water pump.

COOLING(H4DO) > Water Pump　

INSTALLATION

1. WATER PUMP PULLEY

1.

Using the ST1 and ST2, install the water pump pulley.

Preparation tool:

ST1: PULLEY WRENCH (18355AA000)

ST2: PULLEY WRENCH PIN SET (18334AA020)

Tightening torque:

14 N·m (1.4kgf-m, 10.3ft-lb)

2.

Install the V-belts. MECHANICAL(H4DO)>V-belt>INSTALLATION > V-BELT

2. WATER PUMP

1.

Set a new gasket, and install the water pump.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Install the harness stay.

Tightening torque:

8.5N·m (0.9kgf-m, 6.3ft-lb)

3.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

4.

Install the water pump pulley. COOLING(H4DO)>Water Pump>INSTALLATION > WATER PUMP PULLEY

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

6.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

COOLING(H4DO) > Water Pump　

INSPECTION

1. WATER LEAK CHECK

The engine coolant is pressurized when it is hot. Wait until engine coolant cools down before proceeding the work.
If the engine coolant is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

1.

Remove the radiator cap.

2.

Fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.

Be careful not to deform the filler neck of radiator when installing and removing the radiator cap tester.

3.

Apply a pressure of 157 kPa (1.6 kg/cm², 23 psi) to the radiator and check the following points:

Leakage from the flow path of the engine coolant or its vicinity
Leakage from the hose or its connections
Significant pressure drop

Be careful of engine coolant from spurting out when removing the radiator cap tester.

2. OTHER INSPECTIONS

1.

Check that there is no deformation, cracks or other damages.

2.

Check that the hose has no cracks, damage or loose part.

3.

Check the water pump bearing for smooth rotation.

COOLING(H4DO) > Thermo Control Valve Assembly　

REMOVAL

1.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

2.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

4.

Remove the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>REMOVAL > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

5.

Remove the bolt securing the engine ground and the harness case and remove the clip (A), clip (B) and clip (C).

6.

Remove the connector (A) and connector (B).

7.

Remove the engine wiring harness stay.

8.

When thermo control valve assembly is replaced

Remove the bolts that hold the thermo control valve assembly and disconnect the water hose (A), water hose (B), water hose (C) and preheater hose (D) to remove the thermo control valve assembly.

9.

When thermo control valve assembly is not replaced

(1)

Remove the bolts securing the thermo control valve assembly and disconnect the water hose (A), water hose (B) and water hose (C), and remove them as a unit.

Water hoses should not be disconnected unless the thermo control valve assembly is replaced. This may cause damage to the thermo control valve assembly.

(2)

Disconnect the water hose (A), water hose (B), water hose (C) and preheater hose (D) from the thermo control valve assembly.

Perform this procedure only when required.
To avoid excessive load to the thermo control valve assembly during removal, cut through the hoses.

COOLING(H4DO) > Thermo Control Valve Assembly　

INSTALLATION

1.

When thermo control valve assembly is replaced

(1)

Install a new gasket to the thermo control valve assembly.

(2)

Connect the thermo control valve assembly to the water hose (A), water hose (B) and water hose (C), and install the bolts that hold the thermo control valve assembly.

Tightening torque:

16 N·m (1.6 kgf-m, 11.8 ft-lb)

(3)

Connect the preheater hose (D).

2.

When thermo control valve assembly is not replaced

(1)

Connect each new hose to the thermo control valve assembly.

(A)	Water hose	(C)	Water hose	(D)	Preheater hose
(B)	Water hose

(2)

Install a new gasket to the thermo control valve assembly.

(3)

Connect the water hose (A), water hose (B) and water hose (C), and install the bolts that hold the thermo control valve assembly.

Tightening torque:

16 N·m (1.6 kgf-m, 11.8 ft-lb)

3.

Install the engine wiring harness stay.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

4.

Connect the connector (A) and connector (B).

5.

Install the clip (A), clip (B) and clip (C) and install the bolt securing the engine ground and the harness case.

Tightening torque:

19 N·m (1.9kgf-m, 14.0ft-lb)

6.

Install the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

8.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

COOLING(H4DO) > Thermo Control Valve Assembly　

INSPECTION

1. WATER LEAK CHECK

The engine coolant is pressurized when it is hot. Wait until engine coolant cools down before proceeding the work.
If the engine coolant is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

1.

Remove the radiator cap.

2.

Fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.

Be careful not to deform the filler neck of radiator when installing and removing the radiator cap tester.

3.

Apply a pressure of 157 kPa (1.6 kg/cm², 23 psi) to the radiator and check the following points:

Leakage from the flow path of the engine coolant or its vicinity
Leakage from the hose or its connections
Significant pressure drop

Be careful of engine coolant from spurting out when removing the radiator cap tester.

2. CHECK THERMO CONTROL VALVE ASSEMBLY

Measure the resistance between thermo control valve assembly terminals.

Terminals No.	Standard
4 and 5	1.76±0.528 Ω (at 25°C (77°F))

3. OTHER INSPECTIONS

1.

Check that there is no deformation, cracks or other damages.

2.

Check that the hose has no cracks, damage or loose part.

COOLING(H4DO) > Water Pipe　

REMOVAL

1. WATER PIPE RH

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

3.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

4.

Disconnect the water hoses (rear side).

5.

Remove the bolts securing the water pipe RH, and remove the water hose (front side) and the water pipe RH as an assembly.

2. WATER PIPE LH

1.

Remove the striker assembly front hood. EXTERIOR BODY PANELS>Front Hood>DISASSEMBLY

2.

Fully open the panel COMPL front hood. REPAIR CONTENTS>NOTE > STAY ASSEMBLY FRONT HOOD

3.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

4.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

5.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

6.

Remove the air intake duct (rear). INTAKE (INDUCTION)(H4DO)>Air Intake Duct>REMOVAL

7.

Remove the clip from the air intake boot, and loosen the clamp.

8.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

9.

Disconnect the preheater hose (A) and the hose heater outlet (B) from the water pipe LH.

10.

Remove the TCM. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module (TCM)>REMOVAL

11.

Remove the bolt which holds the transmission harness to the valve cover, and turn the transmission harness clockwise till the bolt hole can be seen as shown in the figure, and tighten the bolt to temporary lock the harness.

This procedure is required to prevent the transmission harness from touching the vehicle body during engine removal/installation.

12.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

13.

Remove the nuts which secure the engine mounting to the crossmember COMPL front.

14.

Using the ST1, install the ST2 to the engine unit.

Preparation tool:

ST1: BOLT (18363AA050)

ST2: HANGER (18360AA040)

Tightening torque:

43 N·m (4.4 kgf-m, 31.7 ft-lb)

15.

Lift up the engine with a lifting device and wire ropes.

When lifting up the engine, pay attention to the clearance of each part and be careful not to lift the engine too much, in order to prevent damaging the vehicle.

(A)

To engine rear hanger

(B)

To special tool

16.

Remove the water pipe LH.

3. CENTER WATER PIPE

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

3.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

4.

Remove the center water pipe from the oil pan upper, and remove the center water pipe from the water hose.

4. HEATER HOSE PIPE

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

3.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

4.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

5.

Remove the clip from the air intake boot, and loosen the clamp.

6.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

7.

Remove the bolts securing the heater hose pipe, and disconnect the water hose (A) and hose heater inlet (B) to remove the heater hose pipe.

5. WATER TANK PIPE ASSEMBLY

If the engine coolant is spilt over the engine or the exhaust pipe, completely wipe it off to avoid emission of smoke or causing a fire.

1.

Release the fuel pressure. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Fuel>PROCEDURE > RELEASING OF FUEL PRESSURE

2.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

3.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

4.

Remove the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>REMOVAL > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

5.

Remove the clip (A) and clip (B) and disconnect the radiator inlet hose.

6.

Disconnect the water hose (A), and remove the water tank pipe assembly No. 1.

For the bolt (B), use a crowfoot wrench for removal.

7.

Remove the thermo control valve assembly. COOLING(H4DO)>Thermo Control Valve Assembly>REMOVAL

8.

Remove the clip (A) and remove the bolts securing the water tank pipe assembly No. 2.

9.

Disconnect the water hose (A), water hose (B) and water hose (C) and remove the water tank pipe assembly No. 2.

10.

Remove the outlet engine coolant temperature sensor from the water tank pipe assembly No. 2. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Coolant Temperature Sensor>REMOVAL > OUTLET ENGINE COOLANT TEMPERATURE SENSOR

11.

Disconnect the water hose (A) and the water hose (B).

Perform this procedure only when required.

COOLING(H4DO) > Water Pipe　

INSTALLATION

1. WATER PIPE RH

1.

Set the water hose (front side) and the water pipe RH as an assembly.

2.

Install the bolts securing the water pipe RH.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

3.

Connect the water hose (rear side).

4.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

6.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

2. WATER PIPE LH

1.

Temporarily install the water pipe LH with a new O-ring.

2.

Tighten the bolts in the numerical order as shown in the figure.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

3.

Lower the engine and remove the lifting device and wire ropes.

4.

Remove the ST1 and ST2 from the engine unit.

5.

Install the nuts which hold the engine mounting to the crossmember COMPL front.

Be sure to use a new nut.

Make sure that locators (a) of the engine mounting are securely inserted.

Tightening torque:

90 N·m (9.2kgf-m, 66.4ft-lb)

6.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

7.

Remove the bolt and turn the transmission harness counterclockwise to install the transmission harness to the valve cover.

Tightening torque:

7 N·m (0.7kgf-m, 5.2ft-lb)

8.

Install the TCM. CONTINUOUSLY VARIABLE TRANSMISSION(TR580)>Transmission Control Module (TCM)>INSTALLATION

9.

Connect the preheater hose (A) and the hose heater outlet (B) to the water pipe LH.

10.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

11.

Install the air intake duct (rear). INTAKE (INDUCTION)(H4DO)>Air Intake Duct>INSTALLATION

12.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

13.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

14.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

15.

Set the panel COMPL front hood to the normal position. REPAIR CONTENTS>NOTE > STAY ASSEMBLY FRONT HOOD

16.

Install the striker assembly front hood. EXTERIOR BODY PANELS>Front Hood>ASSEMBLY

3. CENTER WATER PIPE

1.

Connect the center water pipe to the water hose.

2.

Install the center water pipe to the oil pan upper with a new O-ring.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

3.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

4.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

5.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

4. HEATER HOSE PIPE

1.

Connect the heater hose pipe to the water hose (A) and hose heater inlet (B) and install the bolt securing the heater hose pipe.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

2.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

3.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

4.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

6.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

5. WATER TANK PIPE ASSEMBLY

If the engine coolant is spilt over the engine or the exhaust pipe, completely wipe it off to avoid emission of smoke or causing a fire.

1.

Connect the water hose (A) and the water hose (B).

2.

Install the outlet engine coolant temperature sensor to the water tank pipe assembly No. 2. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>Engine Coolant Temperature Sensor>INSTALLATION > OUTLET ENGINE COOLANT TEMPERATURE SENSOR

3.

Set new O-rings.

4.

Connect the water tank pipe assembly No. 2 to the water hose (A), water hose (B) and water hose (C).

5.

Install the bolts securing the water tank pipe assembly No. 2 and install the clip (A).

Tightening torque:

16 N·m (1.6 kgf-m, 11.8 ft-lb)

6.

Install the thermo control valve assembly. COOLING(H4DO)>Thermo Control Valve Assembly>INSTALLATION

7.

Install the water tank pipe assembly No. 1 and connect the water hose (A).

For the bolt (B), use a crowfoot wrench for tightening.
Use the following formula to calculate the reading of a torque wrench when tightening with a crowfoot wrench.

Calculation formula

T = 6.4N·m (0.7kgf-m, 4.7ft-lb) × L1/ (L1 + L2)

T: Reading of the torque wrench

L1: Effective length of the torque wrench

L2: Effective length of the crowfoot wrench

If the effective length of the tool used is unknown, consult the manufacturer of the tool.

(a) Effective length of the crowfoot wrench

(b) Effective length of the torque wrench

(c) Center of the open end of crowfoot wrench

(d) Center of drive square of the torque wrench

(e) Center of the position where a force is applied by hand

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

8.

Install the clip (A) and clip (B) and connect the radiator inlet hose.

9.

Install the high-pressure fuel delivery pipe assembly. FUEL INJECTION (FUEL SYSTEMS)(H4DO)>High Pressure Fuel Delivery Pipe>INSTALLATION > HIGH-PRESSURE FUEL DELIVERY PIPE ASSEMBLY

10.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

11.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

COOLING(H4DO) > Water Pipe　

INSPECTION

1. WATER LEAK CHECK

The engine coolant is pressurized when it is hot. Wait until engine coolant cools down before proceeding the work.
If the engine coolant is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

1.

Remove the radiator cap.

2.

Fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.

Be careful not to deform the filler neck of radiator when installing and removing the radiator cap tester.

3.

Apply a pressure of 157 kPa (1.6 kg/cm², 23 psi) to the radiator and check the following points:

Leakage from the flow path of the engine coolant or its vicinity
Leakage from the hose or its connections
Significant pressure drop

Be careful of engine coolant from spurting out when removing the radiator cap tester.

2. OTHER INSPECTIONS

1.

Check that there is no deformation, cracks or other damages.

2.

Check that the hose has no cracks, damage or loose part.

COOLING(H4DO) > Thermostat　

REMOVAL

1. THERMOSTAT COVER

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

3.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

4.

Disconnect radiator outlet hose.

5.

Remove the thermostat cover.

6.

Remove the gasket from the oil pan upper.

2. THERMOSTAT

1.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the clip from the air intake boot, and loosen the clamp.

4.

Remove the air intake boot, and place it aside so that it does not interfere with the work.

Be careful not to pull out the PCV hose.

5.

Remove the EGR cooler. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Cooler>REMOVAL

6.

Disconnect the water hoses.

7.

Remove the thermostat cover, and then remove the thermostat.

8.

Remove the gasket from thermostat.

COOLING(H4DO) > Thermostat　

INSTALLATION

1. THERMOSTAT COVER

1.

Install a new gasket to the oil pan upper.

Align the positions of groove (a) of the oil pan upper and the positioning rib (b) of the gasket.

2.

Install the thermostat cover.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

3.

Connect the radiator outlet hose.

4.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

5.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

6.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

2. THERMOSTAT

1.

Install a new gasket to the thermostat.

2.

Install the thermostat and thermostat cover.

When installed, the air vent hole should face upward.

Tightening torque:

6.4N·m (0.7kgf-m, 4.7ft-lb)

3.

Connect the water hose.

4.

Install the EGR cooler. EMISSION CONTROL (AUX. EMISSION CONTROL DEVICES)(H4DO)>EGR Cooler>INSTALLATION

5.

Install the air intake boot. INTAKE (INDUCTION)(H4DO)>Air Intake Boot>INSTALLATION

6.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

7.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

COOLING(H4DO) > Thermostat　

INSPECTION

1. WATER LEAK CHECK

The engine coolant is pressurized when it is hot. Wait until engine coolant cools down before proceeding the work.
If the engine coolant is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

1.

Remove the radiator cap.

2.

Fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.

Be careful not to deform the filler neck of radiator when installing and removing the radiator cap tester.

3.

Apply a pressure of 157 kPa (1.6 kg/cm², 23 psi) to the radiator and check the following points:

Leakage from the flow path of the engine coolant or its vicinity
Leakage from the hose or its connections
Significant pressure drop

Be careful of engine coolant from spurting out when removing the radiator cap tester.

2. CHECK THERMOSTAT.

1.

Check that the thermostat valve closes completely at an ambient temperature.

2.

Immerse the thermostat and a thermometer in water. Raise water temperature gradually, and check the temperature and the valve lift amount when the valve begins to open and when the valve is fully opened. Replace the thermostat if faulty.

During the test, agitate the water for even temperature distribution.
Leave the thermostat in the boiling water for five minutes or more before measuring the valve lift.
Hold the thermostat with a wire or the like to avoid contacting with container bottom.

Starting temperature to open:

Water tank pipe side

63 — 67°C (145 — 153°F)

Full open temperature:

Water tank pipe side

80°C (176°F)

Total valve lift:

Water tank pipe side

5.5 mm (0.217in) or more

(A)

Thermometer

(B)

Thermostat

3. OTHER INSPECTIONS

1.

Check that there is no deformation, cracks or other damages.

2.

Check that the hose has no cracks, damage or loose part.

COOLING(H4DO) > Radiator　

REMOVAL

The engine coolant is pressurized when it is hot. Wait until engine coolant cools down before proceeding the work.
If the engine coolant is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the air intake duct. INTAKE (INDUCTION)(H4DO)>Air Intake Duct>REMOVAL

4.

Remove the reservoir tank. COOLING(H4DO)>Reservoir Tank>REMOVAL

5.

Drain engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > DRAINING OF ENGINE COOLANT

6.

Remove the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>REMOVAL

7.

Disconnect radiator outlet hose.

8.

Remove the bracket grille front.

(1)

Apply the protective tapes on the bracket grille front and the grille assembly front UPR.

(2)

Remove the bracket grille front.

9.

Remove the bracket hood stay.

10.

Disconnect the connector (A) from the main fan motor assembly and the connector (B) from the sub fan motor assembly.

11.

Disconnect the radiator inlet hose.

12.

Remove the radiator upper bracket.

13.

Remove the bolts at the lower side of the condenser assembly.

14.

Remove the bolts at the upper side of the condenser assembly.

15.

Secure the condenser assembly to the vehicle using ropes or other items.

This procedure is required to prevent the condenser assembly from dropping off and also damage to the air conditioner pipes.

16.

Lift the radiator up and away from vehicle.

17.

Remove the radiator lower cushion.

COOLING(H4DO) > Radiator　

INSTALLATION

1.

Install the radiator lower cushion.

2.

Install the radiator to the vehicle.

Insert the pin on the lower side of the radiator into the radiator lower cushions.

3.

Remove the ropes or other items used to secure the condenser assembly to the vehicle.

4.

Install the bolts at the upper side of the condenser assembly.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

5.

Install the bolts at the lower side of the condenser assembly.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

6.

Install the radiator upper bracket.

Tightening torque:

12 N·m (1.2kgf-m, 8.9ft-lb)

7.

Connect the radiator inlet hose.

8.

Connect the connector (A) to the main fan motor assembly and the connector (B) to the sub fan motor assembly.

9.

Install the bracket hood stay.

Tightening torque:

18 N·m (1.8kgf-m, 13.3ft-lb)

10.

Install the bracket grille front.

11.

Connect the radiator outlet hose.

12.

Install the front exhaust pipe. EXHAUST(H4DO)>Front Exhaust Pipe>INSTALLATION

13.

Install the reservoir tank. COOLING(H4DO)>Reservoir Tank>INSTALLATION

14.

Install the air intake duct. INTAKE (INDUCTION)(H4DO)>Air Intake Duct>INSTALLATION

15.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

16.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

17.

Fill engine coolant. COOLING(H4DO)>Engine Coolant>REPLACEMENT > FILLING OF ENGINE COOLANT

COOLING(H4DO) > Radiator　

INSPECTION

1. WATER LEAK CHECK

The engine coolant is pressurized when it is hot. Wait until engine coolant cools down before proceeding the work.
If the engine coolant is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

1.

Remove the radiator cap.

2.

Fill the radiator with engine coolant, and then install the radiator cap tester to the filler neck of radiator.

Be careful not to deform the filler neck of radiator when installing and removing the radiator cap tester.

3.

Apply a pressure of 157 kPa (1.6 kg/cm², 23 psi) to the radiator and check the following points:

Leakage from the flow path of the engine coolant or its vicinity
Leakage from the hose or its connections
Significant pressure drop

Be careful of engine coolant from spurting out when removing the radiator cap tester.

2. OTHER INSPECTIONS

1.

Check that there is no deformation, cracks or other damages.

2.

Check that the hose has no cracks, damage or loose part.

3.

Check the radiator fins for clogging.

COOLING(H4DO) > Radiator Cap　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the opening pressure of the radiator cap.

(1)

Remove the radiator cap.

The engine coolant is pressurized when it is hot. Wait until engine coolant cools down before proceeding the work.
If the engine coolant is spilt over the engine, exhaust pipe or the under cover, completely wipe it off to avoid emission of smoke or causing a fire.

(2)

Attach radiator cap tester.

(3)

Increase pressure until the radiator cap tester gauge needle stops. Radiator cap is functioning properly if it holds the service limit pressure for 5 — 6 seconds. Replace the radiator cap if its valve opens at less than the service limit.

Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will be incorrect.

Specification:

93 — 123 kPa (0.95 — 1.25 kg/cm², 14 — 18 psi)

Service limit:

83 kPa (0.85 kg/cm², 12 psi)

COOLING(H4DO) > Radiator Main Fan and Fan Motor　

REMOVAL

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the reservoir tank. COOLING(H4DO)>Reservoir Tank>REMOVAL

4.

Disconnect the connector from the main fan motor assembly.

5.

Remove the bolts which hold the radiator main fan shroud onto the radiator.

6.

Remove the radiator main fan and fan motor from the vehicle.

COOLING(H4DO) > Radiator Main Fan and Fan Motor　

INSTALLATION

1.

Install the radiator main fan and fan motor to the vehicle.

Confirm that the radiator hose is securely connected.

2.

Install the bolts which hold the radiator main fan shroud onto the radiator.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

3.

Connect the connector to the main fan motor assembly.

4.

Install the reservoir tank. COOLING(H4DO)>Reservoir Tank>INSTALLATION

5.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

6.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

COOLING(H4DO) > Radiator Main Fan and Fan Motor　

DISASSEMBLY

1.

Disconnect the main fan motor connector from the radiator main fan shroud.

2.

Disconnect the radiator main fan from the main fan motor.

Remove locking agent from the thread of the main fan motor.

3.

Disconnect the main fan motor from the radiator main fan shroud.

4.

Remove the radiator main fan shroud side gasket from the radiator main fan shroud.

This operation is required only when replacing the radiator main fan shroud side gasket.

COOLING(H4DO) > Radiator Main Fan and Fan Motor　

ASSEMBLY

1.

Install the new radiator main fan shroud side gasket to the radiator main fan shroud.

Install the radiator main fan shroud side gasket by aligning its cutout portion with the L-shaped rib (a) at the top of the radiator main fan shroud.

2.

Install the main fan motor to the radiator main fan shroud.

Tightening torque:

4.4N·m (0.4kgf-m, 3.2ft-lb)

3.

Install the radiator main fan to the main fan motor.

Always use new nuts (with locking agent).

Tightening torque:

3.4N·m (0.3kgf-m, 2.5ft-lb)

4.

Install the main fan motor connector to the radiator main fan shroud.

COOLING(H4DO) > Radiator Main Fan and Fan Motor　

INSPECTION

Check that there is no deformation, cracks or other damages.

For information about operation confirmation, refer to the radiator fan system. COOLING(H4DO)>Radiator Fan System>INSPECTION

COOLING(H4DO) > Radiator Sub Fan and Fan Motor　

REMOVAL

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>REMOVAL

3.

Remove the air intake duct (rear). INTAKE (INDUCTION)(H4DO)>Air Intake Duct>REMOVAL

4.

Remove the radiator main fan and fan motor. COOLING(H4DO)>Radiator Main Fan and Fan Motor>REMOVAL

5.

Disconnect the connector from the sub fan motor assembly.

6.

Remove the bolts which hold the radiator sub fan shroud onto the radiator.

7.

Remove the radiator sub fan and fan motor from vehicle.

COOLING(H4DO) > Radiator Sub Fan and Fan Motor　

INSTALLATION

1.

Install the radiator sub fan and fan motor to the vehicle.

Confirm that the radiator hose is securely connected.

2.

Install the bolts which hold the radiator sub fan shroud onto the radiator.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

3.

Connect the connector to the sub fan motor assembly.

4.

Install the radiator main fan and fan motor. COOLING(H4DO)>Radiator Main Fan and Fan Motor>INSTALLATION

5.

Install the air intake duct (rear). INTAKE (INDUCTION)(H4DO)>Air Intake Duct>INSTALLATION

6.

Install the collector cover. INTAKE (INDUCTION)(H4DO)>Collector Cover>INSTALLATION

7.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

COOLING(H4DO) > Radiator Sub Fan and Fan Motor　

DISASSEMBLY

1.

Disconnect the sub fan motor connector from the radiator sub fan shroud.

2.

Disconnect the radiator sub fan from the sub fan motor.

Remove locking agent from the thread of the sub fan motor.

3.

Disconnect the sub fan motor from the radiator sub fan shroud.

4.

Remove the radiator sub fan shroud side gasket from the radiator sub fan shroud.

This operation is required only when replacing the radiator sub fan shroud side gasket.

COOLING(H4DO) > Radiator Sub Fan and Fan Motor　

ASSEMBLY

1.

Install the new radiator sub fan shroud side gasket to the radiator sub fan shroud.

Install the radiator sub fan shroud side gasket by aligning its cutout portion (a) with the boss at the top of the radiator sub fan shroud.

2.

Install the sub fan motor to the radiator sub fan shroud.

Tightening torque:

4.4N·m (0.4kgf-m, 3.2ft-lb)

3.

Install the radiator sub fan to the sub fan motor.

Always use new nuts (with locking agent).

Tightening torque:

3.4N·m (0.3kgf-m, 2.5ft-lb)

4.

Install the sub fan motor connector to the radiator sub fan shroud.

COOLING(H4DO) > Radiator Sub Fan and Fan Motor　

INSPECTION

Check that there is no deformation, cracks or other damages.

For information about operation confirmation, refer to the radiator fan system. COOLING(H4DO)>Radiator Fan System>INSPECTION

COOLING(H4DO) > Reservoir Tank　

REMOVAL

1.

Pull out the over flow hose (A) from the reservoir tank.

2.

Release the claw (B) and pull out the reservoir tank in the direction of the arrow.

COOLING(H4DO) > Reservoir Tank　

INSTALLATION

1.

Install the reservoir tank.

2.

Install the over flow hose.

COOLING(H4DO) > Reservoir Tank　

INSPECTION

Check that there is no deformation, cracks or other damages.

COOLING(H4DO) > Radiator Fan Relay　

LOCATION

Main fan relay 1
Main fan relay 2
Sub fan relay

COOLING(H4DO) > Radiator Fan Relay　

INSPECTION

1.

Check that there is no deformation, cracks or other damages.

2.

Check the resistance between terminals.

Main fan relay 1

Terminal No.

Inspection conditions

Standard

3 — 4

Always

1 MΩ or more

3 — 4

Apply battery voltage between terminals 1 and 2.

Less than 1 Ω

Terminal No.	Inspection conditions	Standard
3 — 4	Always	1 MΩ or more
3 — 4	Apply battery voltage between terminals 1 and 2.	Less than 1 Ω

Main fan relay 2

Terminal No.	Inspection conditions	Standard
3 — 4	Always	Less than 1 Ω
3 — 5	Always	1 MΩ or more
3 — 4	Apply battery voltage between terminals 1 and 2.	1 MΩ or more
3 — 5	Apply battery voltage between terminals 1 and 2.	Less than 1 Ω

Sub fan relay

Terminal No.

Inspection conditions

Standard

3 — 4

Always

1 MΩ or more

3 — 4

Apply battery voltage between terminals 1 and 2.

Less than 1 Ω

Terminal No.	Inspection conditions	Standard
3 — 4	Always	1 MΩ or more
3 — 4	Apply battery voltage between terminals 1 and 2.	Less than 1 Ω

COOLING(H4DO) > Active Grille Shutter　

REMOVAL

1.

Disconnect the ground terminal from battery sensor. REPAIR CONTENTS>NOTE > BATTERY

2.

Remove the bumper face front. EXTERIOR/INTERIOR TRIM>Front Bumper>REMOVAL

3.

Remove the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>REMOVAL

4.

Disconnect the connector from ambient sensor.

5.

Disconnect the connector from the active grille shutter actuator.

6.

Remove the active grille shutter and the bracket active grille shutter front as a unit.

7.

Remove the clip and remove the active grille shutter from the bracket active grille shutter front.

8.

Remove the clip (A) to remove the ambient sensor.

COOLING(H4DO) > Active Grille Shutter　

INSTALLATION

1.

Install the ambient sensor.

2.

Install the active grille shutter to the bracket active grille shutter front.

3.

Install the active grille shutter and the bracket active grille shutter front as a unit in the order as shown in the figure.

Tightening torque:

7.5N·m (0.8kgf-m, 5.5ft-lb)

4.

Connect the connector to the active grille shutter actuator.

5.

Connect the connector to the ambient sensor.

6.

Install the under cover front. EXTERIOR/INTERIOR TRIM>Front Under Cover>INSTALLATION

7.

Install the bumper face front. EXTERIOR/INTERIOR TRIM>Front Bumper>INSTALLATION

8.

Connect the ground terminal to battery sensor. REPAIR CONTENTS>NOTE > BATTERY

9.

When the active grille shutter has been replaced, perform the calibration (execute the system operation check for ACTGS control). ENGINE (DIAGNOSTICS)(H4DO)>Active Test

COOLING(H4DO) > Active Grille Shutter　

INSPECTION

Check that there is no deformation, cracks or other damages.

COOLING(H4DO) > Symptoms and causes　

INSPECTION

Symptoms	Problem parts etc.	Possible cause
Over-heating	Insufficient engine coolant	Engine coolant leaks
	Engine coolant passage	Clogged engine coolant passage
	Radiator cap	Damage or deterioration of radiator cap
	Thermostat	Thermostat stuck
	Thermo control valve assembly	Thermo control valve assembly malfunctioning
	Water pump	Damage of water pump
	Water pump	Damage of V-belt or defective V-belt tensioner
	Radiator	Clogged radiator fin
	Radiator fan system	Radiator fan system malfunction
	Exhaust pipe	Excessive back pressure in exhaust pipe
	Cylinder block or cylinder head gasket etc.	Engine oil leaking into engine coolant passage
Over cooling	-	Ambient temperature extremely low
	Thermostat	Stuck or damaged thermostat
	Thermo control valve assembly	Thermo control valve assembly stuck
Engine coolant leaks	Thermostat cover	Thermostat cover damaged
	Thermostat cover	Gasket deterioration
	Thermo control valve assembly	Thermo control valve assembly damaged
	Thermo control valve assembly	Gasket deterioration
	Water pump	Damage of water pump
	Water pump	Gasket deterioration
	Water hose	Water hose damaged or deteriorated
	Water hose	Water hose connection loose
	Water pipe	Water pipe damaged
	Water pipe	O-ring deterioration
	Radiator	Radiator damaged
		Radiator drain plug O-ring deterioration
		Damage or deterioration of radiator cap
	Heater core	Heater core damaged
	Cylinder head or cylinder block	Cylinder head or cylinder block damaged
	Cylinder head or cylinder block	Cylinder head or cylinder block warpage
	Cylinder head gasket	Cylinder head gasket deterioration
Noise	Air mixed in the engine coolant passage	Insufficient air bleeding
	Thermo control valve assembly	Thermo control valve assembly malfunctioning
	Water pump	Worn or damaged bearing
	Radiator fan	Deformation, cracks or other damage of radiator fan
	Radiator fan motor	Wear or damage inside the motor