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Section 10 (Engine Cooling System (2.4L)): Radiator: Installation

WARNING: This page is about a different variant/trim than selected.
  1. Install the radiator lower cushion.
    G13949303Courtesy of SUBARU OF AMERICA, INC.
  2. Install new radiator upper gasket (A) and radiator lower gasket (B) to the radiator.
    NOTE:
    • Install the radiator upper gasket so that its end part (a) comes inside of the installation section of condenser assembly (c). 
    • Install the radiator lower gasket so that its cutout portion (b) is aligned to the installation section of condenser assembly (c). 
    G13949304Courtesy of SUBARU OF AMERICA, INC.
  3. Connect the radiator outlet hose (A), overflow hose (B) and radiator inlet hose (C) to the radiator.
    G13949305Courtesy of SUBARU OF AMERICA, INC.
  4. Install the radiator fan and fan motor assembly to the radiator. Ref. to COOLING (H4DOTC)>RADIATOR FAN AND FAN MOTOR ASSEMBLY>INSTALLATION .
  5. Install the radiator and the radiator fan and fan motor assembly as an assembly.
    NOTE:

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

  6. Remove the ropes or other items used to secure the condenser assembly to the vehicle.
    G13949306Courtesy of SUBARU OF AMERICA, INC.
  7. Temporarily tighten the bolts that secure the upper side of condenser assembly to the radiator.
    G13949307Courtesy of SUBARU OF AMERICA, INC.
  8. Install the bracket condenser to the condenser assembly.

    Tightening torque: 

    3.9 N.m (0.4 kgf-m, 2.9 ft-lb)

    G13949308Courtesy of SUBARU OF AMERICA, INC.
  9. Using the ST, install the bolts securing the lower side of condenser assembly to the radiator.

    Preparation tool: 

    ST: SPECIAL TOOL CONDENSER (73099SG000)

    Tightening torque: 

    Calculation formula
    T = 7.5 N.m (0.8 kgf-m, 5.5 ft-lb) x L/(100 mm (3.94 in) + L)
    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. 
    G13949309Courtesy of SUBARU OF AMERICA, INC.
    G13949310Courtesy of SUBARU OF AMERICA, INC.
  10. Tighten the bolts which hold the upper side of condenser assembly to the radiator.

    Tightening torque: 

    7.5 N.m (0.8 kgf-m, 5.5 ft-lb)

    G13949311Courtesy of SUBARU OF AMERICA, INC.
  11. Install the radiator upper bracket LH and the radiator upper bracket RH.

    Tightening torque: 

    12 N.m (1.2 kgf-m, 8.9 ft-lb)

    G13949312Courtesy of SUBARU OF AMERICA, INC.
  12. Install the bumper face front. Ref. to EXTERIOR/INTERIOR TRIM>FRONT BUMPER>INSTALLATION .
  13. Install the cover UPR front.
    G13949313Courtesy of SUBARU OF AMERICA, INC.
  14. Connect the radiator inlet hose.
    G13949314Courtesy of SUBARU OF AMERICA, INC.
  15. Connect the radiator outlet hose.
    G13949315Courtesy of SUBARU OF AMERICA, INC.
  16. Install the clip which holds bulkhead wiring harness to the radiator fan shroud.
  17. Connect the connector (A) and connector (B) to the radiator fan harness.
    G13949316Courtesy of SUBARU OF AMERICA, INC.
  18. Install the center exhaust pipe (front). Ref. to CENTER EXHAUST PIPE (FRONT) .
  19. Install the reservoir tank. Ref. to COOLING (H4DOTC)>RESERVOIR TANK>INSTALLATION .
  20. Install the air intake duct. Ref. to INTAKE (INDUCTION) (H4DOTC)>AIR INTAKE DUCT>INSTALLATION .
  21. Install the V-belt cover.
    NOTE:
    • Check the grommet for peel-off or disengagement. 
    • Be careful not to deform the bracket during installation. 

    Tightening torque: 

    7 N.m (0.7 kgf-m, 5.2 ft-lb)

    G13949317Courtesy of SUBARU OF AMERICA, INC.
  22. Connect the ground terminal to battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
  23. Fill engine coolant. Ref. to COOLING (H4DOTC)>ENGINE COOLANT>REPLACEMENT>FILLING OF ENGINE COOLANT .
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