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Section 137 (Engine Cooling System (H4DO)): Radiator: Installation

WARNING: This page is about a different car, the 2016 Subaru Outback and 2016 Subaru Legacy. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the radiator lower cushion to the vehicle body.
    Fig 1: Locating Radiator Lower Cushion
    G10263020Courtesy of SUBARU OF AMERICA, INC.
  2. Install the radiator to vehicle.
    NOTE: Make pins on the lower side of radiator be fitted into the radiator lower cushions.
  3. Remove the ropes or other means used to secure the condenser to the vehicle.
    Fig 2: Securing Condenser To Vehicle Using Ropes
    G10263019Courtesy of SUBARU OF AMERICA, INC.
  4. Temporarily tighten the bolts securing the condenser upper bracket to the radiator.
    Fig 3: Locating Condenser Upper Bracket Bolts
    G10263018Courtesy of SUBARU OF AMERICA, INC.
  5. Position the condenser lower bracket, and install the bolts securing the condenser lower bracket to the condenser.

    Tightening torque: 

    3.9 N.m (0.4 kgf-m, 2.9 ft-lb) 

    Fig 4: Locating Condenser Lower Bracket Screws
    G10263017Courtesy of SUBARU OF AMERICA, INC.
  6. Using the ST, tighten the bolts securing the condenser lower bracket to the radiator.

    ST 73099SG000 SPECIAL TOOL CONDENSER

    Tightening torque: 

    Calculation formula
    T = L/(100 mm (3.94 in) + L) X 7.5 N.m (0.8 kgf-m, 5.5 ft-lb)
    T: Tightening torque
    L: Effective length of torque wrench
    NOTE: If the effective length of the torque wrench used is unknown, consult the manufacturer of the torque wrench.
    G10308751Courtesy of SUBARU OF AMERICA, INC.
    Fig 5: Securing Condenser Lower Bracket To Radiator
    G10263016Courtesy of SUBARU OF AMERICA, INC.
  7. Tighten the bolts securing the condenser upper bracket to the radiator.

    Tightening torque: 

    7.5 N.m (0.8 kgf-m, 5.5 ft-lb) 

    Fig 6: Locating Condenser Upper Bracket Bolts
    G10263018Courtesy of SUBARU OF AMERICA, INC.
  8. Install the radiator upper brackets.

    Tightening torque: 

    12 N.m (1.2 kgf-m, 8.9 ft-lb) 

    Fig 7: Locating Radiator Upper Brackets Bolts
    G10276811Courtesy of SUBARU OF AMERICA, INC.
  9. Connect the radiator inlet hose to the water pipe assembly.
    Fig 8: Locating Radiator Inlet Hose Clamp
    G10263014Courtesy of SUBARU OF AMERICA, INC.
  10. Connect the connector (A) to the radiator main fan motor and the connector (B) to the radiator sub fan motor connector.
    Fig 9: Identifying Radiator Main Fan Motor Connector
    G10263012Courtesy of SUBARU OF AMERICA, INC.
    Fig 10: Identifying Radiator Sub Fan Motor Connector
    G10263013Courtesy of SUBARU OF AMERICA, INC.
  11. Install the reservoir tank. < Ref. to INSTALLATION , Reservoir Tank. >
  12. Lift up the vehicle.
  13. Connect the radiator outlet hose.
    Fig 11: Locating Radiator Outlet Hose Clamp
    G10262999Courtesy of SUBARU OF AMERICA, INC.
  14. Install the front exhaust pipe. < Ref. to INSTALLATION , Front Exhaust Pipe. >
  15. Attach the grille bracket.
    Fig 12: Locating Grille Bracket Clips
    G10276809Courtesy of SUBARU OF AMERICA, INC.
  16. Install the active grille shutter. < Ref. to INSTALLATION , Active Grille Shutter. >
  17. Install the front bumper. < Ref. to INSTALLATION , Front Bumper. >
  18. Install the air intake duct. < Ref. to INSTALLATION , Air Intake Duct. >
  19. Connect the ground terminal to battery sensor. < Ref. to BATTERY , NOTE, Repair Contents. >
  20. Fill engine coolant. < Ref. to FILLING OF ENGINE COOLANT , REPLACEMENT, Engine Coolant. >
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