COOLING(H4DOTC DIESEL) > General Description

SPECIFICATION
Electric fan + Forced engine coolant
Cooling system
circulation system
Total engine coolant capacity L (US qt, Imp qt) 6.9 (7.3, 6.1)
Type Centrifugal impeller type
L (US gal, Imp gal)
Discharge rate 240 (63.4, 52.8)
/min
Discharge
Pump speed — Discharge pressure (total
Water performance 7,300 rpm — 238.3 kPa (24.3 mAq)
head)
pump
Engine coolant temperature 80°C (176°F)
Impeller diameter mm (in) 60 (2.36)
Number of impeller vanes 7
Pump pulley diameter mm (in) 80 (3.15)
Type Wax pellet type
Starting temperature to open 84 — 88°C (183 — 190°F)
Thermostat Fully opens 93°C (199°F)
Valve lift mm (in) 9.0 (0.354) or more
Valve bore mm (in) 35 (1.38)
Main fan W 120
Motor input
Radiator Sub fan W 120
fan Fan diameter / Main fan 320 mm (12.6 in)/5
Blade Sub fan 320 mm (12.6 in)/7
Type Down flow
Width × Height ×
Core dimensions mm (in) 691.3 × 340 × 27 (27.22 × 13.39 × 1.06)
Thickness
Above: 108±15
Radiator
Pressure range in which cap valve is (1.1±0.15, 16±2)
kPa (kg/cm2, psi)
open Below: −1.0 — −4.9
(−0.01 — −0.05, −0.1 — −0.7)
Fins Corrugated fin type
Reservoir
Capacity L (US qt, Imp qt) 0.45 (0.48, 0.40)
tank
Recommended materials Item number Alternative
SUBARU SUPER COOLANT
—
(Concentrated type)
Coolant Non-amine type
SUBARU SUPER COOLANT
K0670Y0000
(Diluted type)
Water for dilution Distilled water — Soft water or tap water
Engine coolant temperature
Increase: 94°C Increase: 95 — 96°C Increase: 97°C
A/C (201°F) or less (203 — 205°F) (207°F) or more
Vehicle speed compressor Decrease: 91°C Decrease: 92 — 94°C Decrease: 95°C
load (196°F) or less (198 — 201°F) (203°F) or more
Radiator fan Radiator fan
Radiator fan operation
operation operation
 Engine coolant temperature
Increase: 94°C Increase: 95 — 96°C Increase: 97°C
A/C (201°F) or less (203 — 205°F) (207°F) or more
Vehicle speed compressor Decrease: 91°C Decrease: 92 — 94°C Decrease: 95°C
load (196°F) or less (198 — 201°F) (203°F) or more
Radiator fan Radiator fan
Radiator fan operation
operation operation
When accelerating: 19 km/h (12 OFF OFF Low-Speed High-Speed
MPH) or less
Low Low-Speed Low-Speed High-Speed
When decelerating: 10 km/h (6
MPH) or less High High-Speed High-Speed High-Speed
When accelerating: 20 — 69 OFF OFF Low-Speed High-Speed
km/h (12 — 43 MPH)
Low High-Speed High-Speed High-Speed
When decelerating: 11 — 64
km/h (7 — 40 MPH) High High-Speed High-Speed High-Speed
When accelerating: 70 — 105 OFF OFF Low-Speed High-Speed
km/h (43 — 65 MPH)
Low High-Speed High-Speed High-Speed
When decelerating: 65 — 103
km/h (40 — 64 MPH) High High-Speed High-Speed High-Speed
When accelerating: 106 km/h (66 OFF OFF High-Speed High-Speed
MPH) or more
Low High-Speed High-Speed High-Speed
When decelerating: 104 km/h (65
MPH) or more High High-Speed High-Speed High-Speed
COOLING(H4DOTC DIESEL) > General Description
COMPONENT

1. WATER PUMP AND THERMOSTAT

(1) Water pump ASSY (4) Thermostat Tightening torque:N·m (kgf-m, ft-lb)

(2) Gasket T1: 6.4 (0.7, 4.7)

(3) Thermostat cover T2: 16 (1.6, 11.8)

2. WATER PIPE AND HOSES (ENGINE LH)

 (1) Clamp (5) Water pipe Tightening torque:N·m (kgf-m, ft-lb)

(2) Water hose (6) Clamp T: 6.4 (0.7, 4.7)

(3) Return pipe (7) Heater pipe

(4) Water hose

3. WATER PIPE AND HOSES (ENGINE TOP)

 (A) To EGR control valve (B) To EGR control valve

(1) Water pipe (6) Heater pipe Tightening torque:N·m (kgf-m, ft-lb)

(2) Clamp (7) Heater hose T1: 6.4 (0.7, 4.7)

(3) Water hose (8) Water pipe T2: 19 (1.9, 14.0)

(4) Water hose (9) Water hose

(5) Water pipe

4. WATER PIPE AND HOSES (ENGINE RH)

 (1) Clamp (6) Gasket Tightening torque:N·m (kgf-m, ft-lb)

(2) Water hose (7) Outlet housing T1: 6.4 (0.7, 4.7)

(3) Water pipe (8) O-ring T2: 8.0 (0.8, 5.9)

(4) Water hose (9) Water pipe

(5) Water pipe

5. RADIATOR AND RADIATOR FAN

(1) Radiator sub fan shroud (10) Radiator lower bracket (19) Radiator inlet hose LH

(2) Radiator sub fan (11) Radiator lower cushion (20) Radiator sub fan motor

(3) Radiator main fan shroud (12) O-ring (21) Radiator main fan motor

(4) Radiator main fan (13) Radiator drain plug

(5) Over flow hose (14) Radiator Tightening torque:N·m (kgf-m, ft-lb)

(6) Engine coolant reservoir tank cap (15) Radiator cap T1: 3.4 (0.3, 2.5)

(7) Engine coolant reservoir tank (16) Radiator upper cushion T2: 5 (0.5, 3.7)

(8) Radiator outlet hose (17) Radiator upper bracket T3: 7.5 (0.8, 5.5)

(9) Clamp (18) Radiator inlet hose RH T4: 12 (1.2, 8.9)

COOLING(H4DOTC DIESEL) > General Description
CAUTION
• Wear appropriate work clothing, including a cap, protective goggles and protective shoes when performing any work.
• Remove contamination including dirt and corrosion before removal, installation or disassembly.
• Keep the disassembled parts in order and protect them from dust and dirt.
• Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation,
disassembly and replacement.
• Vehicle components are extremely hot after driving. Be wary of receiving burns from heated parts.
• Be sure to tighten fasteners including bolts and nuts to the specified torque.
• Place shop jacks or rigid racks at the specified points.
• Before disconnecting connectors of sensors or units, be sure to disconnect the ground cable from the battery.
• Prepare a container and cloth to prevent scattering of engine coolant when performing work where engine coolant
can be spilled. If the fuel spills, wipe it off immediately to prevent from penetrating into floor or flowing out for
environmental protection.
• Follow all government and local regulations concerning disposal of refuse when disposing engine coolant.
COOLING(H4DOTC DIESEL) > General Description
PREPARATION TOOL

1. SPECIAL TOOL
ILLUSTRATION TOOL DESCRIPTION REMARKS
NUMBER
1B023XG0 SUBARU SELECT MONITOR III Used for troubleshooting the electrical
KIT system.

2. GENERAL TOOL
TOOL NAME REMARKS
Radiator cap tester Used for measuring pressure.
 TO POWER SUPPLY CIRCUIT

MB-11 MB-4 FB-46

MB-8 MB-10 MB-7 MB-9
F/B FUSE NO. 26 M/B FUSE NO. 3 F/B FUSE NO. 22
MAIN FAN RELAY 1 MAIN FAN RELAY 1 MAIN FAN RELAY 1 MAIN FAN RELAY 1
(IG) (B) (IG)

THROUGH JOINT
CONNECTOR
10 1

F109 B360

20

21

10
13
1

MAIN FAN

MAIN FAN

SUB FAN
RELAY 2

RELAY
MOTOR RELAY HOLDER

F17 F27
3

22
19
18

11
12
THROUGH
JOINT
CONNECTOR
16 7

F108 B361

24

25
4

F16

ECM
B455

SUB FAN MOTOR

F16 B361 B360 F108

F27
F17 1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8
7 8 9 10 11 12 13 14 8 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 17 18
1 2
3 4 1
3 4 5
6 2
F109 B455 8 9 7
18
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 12 16 19
10 11 14 15
12 13 14 15 16 17 18 19 20 21 22 23 24 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 13 17 20 21 22
41
42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 RELAY HOLDER
CO-02456
COOLING(H4DOTC DIESEL) > Radiator Fan System
INSPECTION
TROUBLE SYMPTOMS:
Radiator main and sub fans do not operate.
STEP CHECK YES NO
1.CHECK OPERATION OF RADIATOR FAN. Do the
1) Connect the test mode connector. radiator main
2) Turn the ignition switch to ON. and sub fans
3) Using the Subaru Select Monitor, check the forced rotate at low
operation of the radiator fan relay. speed?
NOTE:
• When performing a forced operation radiator fan
relay check using the Subaru Select Monitor, the
radiator main fan and sub fan will repeat low speed
revolution → high speed revolution → OFF in this
order.
• Subaru Select Monitor
Refer to Compulsory Valve Operation Check Mode
for more operation procedure.
2.CHECK OPERATION OF RADIATOR FAN. Do the Radiator
1) Connect the test mode connector. radiator main main fan
2) Turn the ignition switch to ON. and sub fans system is
3) Using the Subaru Select Monitor, check the forced rotate at high normal.
operation of the radiator fan relay. speed?
NOTE:
• When performing a forced operation radiator fan
relay check using the Subaru Select Monitor, the
radiator main fan and sub fan will repeat low speed
revolution → high speed revolution → OFF in this
order.
• Subaru Select Monitor
Refer to Compulsory Valve Operation Check Mode
for more operation procedure.
3.CHECK POWER SUPPLY TO SUB FAN RELAY. Is the voltage
1) Turn the ignition switch to OFF. 10 V or
2) Remove the sub fan relay from the relay holder. more?
3) Measure the voltage between the sub fan relay
terminal and chassis ground.
Connector & terminal
(F27) No. 10 (+) — Chassis ground (−):
4.CHECK POWER SUPPLY TO SUB FAN RELAY. Is the voltage
1) Turn the ignition switch to ON. 10 V or
2) Measure the voltage between the sub fan relay more?
terminal and chassis ground.
Connector & terminal
(F27) No. 13 (+) — Chassis ground (−):
5.CHECK FUSE. Is the fuse Replace the Repair the power supply
1) Turn the ignition switch to OFF. blown out? fuse. line.
2) Remove the fuse No. 3.
3) Check the condition of fuse.
6.CHECK FUSE. Is the fuse Replace the Repair the power supply
1) Turn the ignition switch to OFF. blown out? fuse. line.
2) Remove the fuse No. 22.
3) Check the condition of fuse.
7.CHECK SUB FAN RELAY Is the Replace the sub fan relay.
1) Turn the ignition switch to OFF. resistance 1
2) Measure the resistance between sub fan relay MΩ or more?
terminals.
Terminals
(F27) No. 10 — (F27) No. 11:
 STEP CHECK YES NO
8.CHECK SUB FAN RELAY Is the Replace the sub fan relay.
1) Connect the battery to terminals No. 12 and No. 13 resistance
of the sub fan relay. less than 1
2) Measure the resistance between sub fan relay Ω?
terminals.
Terminals
(F27) No. 10 — (F27) No. 11:
9.CHECK HARNESS BETWEEN SUB FAN RELAY Is the Repair the open circuit of
TERMINAL AND SUB FAN MOTOR CONNECTOR. resistance harness between sub fan
1) Disconnect the connector from the sub fan motor. less than 1 relay terminal and sub fan
2) Measure the resistance of harness between the sub Ω? motor connector.
fan relay terminal and sub fan motor connector.
Connector & terminal
(F16) No. 1 — (F27) No. 11:
(F16) No. 2 — (F27) No. 11:
10.CHECK HARNESS BETWEEN SUB FAN MOTOR Is the Repair the open circuit of
CONNECTOR AND MAIN FAN RELAY 2 CONNECTOR. resistance the harness between sub
1) Remove main fan relay 2 from the relay holder. less than 1 fan motor connector and
2) Measure the resistance of harness between sub fan Ω? main fan relay 2
motor connector and main fan relay 2 connector. connector.
Connector & terminal
(F16) No. 3 — (F27) No. 18:
(F16) No. 4 — (F27) No. 18:
11.CHECK POOR CONTACT. Is there poor Repair the
Check for poor contact of sub fan motor connector. contact in sub poor contact
fan motor of sub fan
connector? motor
connector.
12.CHECK SUB FAN MOTOR. Does the sub Replace the sub fan motor.
Connect the battery positive (+) terminal to terminal No. 1 fan rotate?
of the sub fan motor, and the ground (−) terminal to
terminal No. 4.
13.CHECK MAIN FAN RELAY 2. Is the Replace the main fan relay
Measure the resistance of main fan relay 2. resistance 2.
Terminals less than 1
(F27) No. 21 — (F27) No. 18: Ω?
14.CHECK HARNESS BETWEEN MAIN FAN RELAY 2 Is the Repair the open circuit of
AND MAIN FAN MOTOR CONNECTOR. resistance the harness between main
1) Disconnect the connector from the main fan motor. less than 1 fan relay 2 terminal and
2) Measure the resistance of the harness between Ω? main fan motor connector.
main fan relay 2 terminal and main fan motor
connector.
Connector & terminal
(F17) No. 3 — (F27) No. 19:
(F17) No. 4 — (F27) No. 19:
15.CHECK MAIN FAN MOTOR AND GROUND Is the Repair the open circuit of
CIRCUIT. resistance the harness between main
Measure the resistance between main fan motor less than 5 fan motor connector and
connector and chassis ground. Ω? chassis ground.
Connector & terminal
(F17) No. 3 — Chassis ground:
(F17) No. 4 — Chassis ground:
16.CHECK POOR CONTACT. Is there poor Repair the
Check for poor contact of main fan motor connector. contact in poor contact
main fan of main fan
motor motor
connector? connector.
17.CHECK MAIN FAN MOTOR. Does the Replace the main fan
Connect the battery positive (+) terminal to terminal No. 1 main fan motor.
of the main fan motor, and the ground (−) terminal to rotate?
terminal No. 3.
 STEP CHECK YES NO
18.CHECK HARNESS BETWEEN SUB FAN RELAY Is the Repair the open circuit of
AND ECM. resistance harness between sub fan
1) Disconnect the connectors from ECM. less than 1 relay terminal and ECM.
2) Measure the resistance between the sub fan relay Ω?
terminal and ECM connector.
Connector & terminal
(B455) No. 24 — (F27) No. 12:
19.CHECK POOR CONTACT. Is there poor Repair the Check the DTC. Repair the
Check for poor contact of the ECM connector. contact in poor contact trouble cause.
ECM of ECM
connector? connector.
20.CHECK MAIN FAN RELAY 1. Is the Replace the main fan relay
1) Turn the ignition switch to OFF. resistance 1 1.
2) Remove main fan relay 1 from the main fuse box. MΩ or more?
3) Measure the resistance of terminal in main fan relay
1 switch.
21.CHECK MAIN FAN RELAY 1. Is the Replace the main fan relay
1) Connect the main fan relay 1 coil side terminal to the resistance 1.
battery. less than 1
2) Measure the resistance between terminals of main Ω?
fan relay 1 switch.
22.CHECK HARNESS BETWEEN MAIN FAN RELAY 1 Is the Repair the open circuit of
AND MAIN FAN MOTOR CONNECTOR. resistance the harness between main
1) Disconnect the connector from the main fan motor. less than 1 fan relay 1 terminal and
2) Measure the resistance of the harness between Ω? main fan motor connector.
main fan relay 1 terminal and main fan motor
connector.
Connector & terminal
(F17) No. 1 — (F36) No. 6:
(F17) No. 2 — (F36) No. 6:
23.CHECK HARNESS BETWEEN MAIN FAN RELAY 1 Is the Repair the open circuit of
AND ECM. resistance the harness between main
1) Disconnect the connectors from ECM. less than 1 fan relay 1 terminal and
2) Measure the resistance between main fan relay 1 Ω? ECM.
terminal and ECM connector.
Connector & terminal
(B455) No. 25 — (B143) No. 7:
24.CHECK HARNESS BETWEEN MAIN FAN RELAY 2 Is the Repair the open circuit of
AND ECM. resistance the harness between main
Measure the resistance between main fan relay 2 less than 1 fan relay 2 terminal and
terminal and ECM connector. Ω? ECM.
Connector & terminal
(B455) No. 25 — (F27) No. 22:
25.CHECK FUSE. Is the fuse Replace the
1) Turn the ignition switch to OFF. blown out? fuse.
2) Remove the fuse No. 3 and 26.
3) Check the condition of fuse.
26.CHECK POOR CONTACT. Is there poor Repair the Repair the power supply
Check for poor contact of the ECM connector. contact in poor contact circuit to the main fuse
ECM of ECM box.
connector? connector.
27.CHECK OPERATION OF RADIATOR FAN. Does the sub
If the both fans do not rotate at high speed in the fan rotate?
condition of step 2, check whether the sub fan is rotating.
28.CHECK GROUND CIRCUIT OF MAIN FAN RELAY 2. Is the Repair the open circuit of
1) Remove main fan relay 2 from the relay holder. resistance harness between main fan
2) Measure the resistance between main fan relay 2 less than 1 relay 2 and chassis
terminal and chassis ground. Ω? ground.
Connector & terminal
(F27) No. 19 — Chassis ground:
 STEP CHECK YES NO
29.CHECK POWER SUPPLY TO MAIN FAN RELAY 2. Is the voltage Repair the power supply
1) Turn the ignition switch to ON. 10 V or line.
2) Measure the voltage between main fan relay 2 more?
terminal and chassis ground.
Connector & terminal
(F27) No. 20 (+) — Chassis ground (−):
30.CHECK MAIN FAN RELAY 2. Is the Replace the main fan relay
1) Turn the ignition switch to OFF. resistance 1 2.
2) Remove the main fan relay 2. MΩ or more?
3) Measure the resistance of main fan relay 2.
Terminals
(F27) No. 19 — (F27) No. 18:
31.CHECK MAIN FAN RELAY 2. Is the Replace the main fan relay
1) Connect the battery to terminals No. 20 and No. 22 resistance 2.
of the main fan relay 2. less than 1
2) Measure the resistance of main fan relay 2. Ω?
Terminal
(F27) No. 19 — (F27) No. 18:
COOLING(H4DOTC DIESEL) > Engine Coolant
REPLACEMENT

1. DRAINING OF ENGINE COOLANT

1. Lift up the vehicle.
2. Remove the under cover.
3. Remove the drain plug to drain engine coolant into container.
NOTE:
Remove the radiator cap so that engine coolant will drain faster.

4. Install the drain plug.

2. FILLING OF ENGINE COOLANT

1. Pour engine coolant into the radiator up to the filler neck position.
Recommended engine coolant:
Refer to “SPECIFICATION” for the recommended engine coolant.
Amount of engine coolant:
Refer to “SPECIFICATION” for the amount of engine coolant.
2. Open the air bleeder valve on the heater hose side.

3. If the engine coolant level drops, add engine coolant into radiator up to the filler neck position.
4. Close the air bleeder valve when engine coolant comes out of the air bleeder valve on the heater hose side.
5. Fill engine coolant into the reservoir tank up to “FULL” level.
6. Close the radiator cap and start the engine. Race 5 to 6 times at 3,000 rpm or less, then stop the engine.
(Complete this operation within 40 seconds.)
7. Wait for one minute after the engine stops, open the radiator cap. If the engine coolant level drops, open the air
bleeder valve on the heater hose side, and add engine coolant into the radiator up to the filler neck position.
8. Perform the procedures 6) and 7) again.
9. Attach the radiator cap and reservoir tank cap properly.
10. Start the engine and operate the heater at maximum hot position and the blower speed setting to “LO”.
11. Run the engine at 2,000 rpm or less until radiator fan starts and stops.
NOTE:
Be careful with the engine coolant temperature gauge to prevent overheating.
12. Stop the engine and wait until the engine coolant temperature lowers to 30°C (86°F) or less.
13. Open the radiator cap. If the engine coolant level drops, add engine coolant into radiator up to the filler neck
position and reservoir tank to the “FULL” level.
14. Attach the radiator cap and reservoir tank cap properly.
15. Set the heater setting to maximum hot position and the blower speed setting to “LO” and start the engine.
Perform racing at 2,500 rpm or less. If the flowing sound is heard from heater core, repeat the procedures from step
9).
COOLING(H4DOTC DIESEL) > Engine Coolant
ADJUSTMENT
CAUTION:
When using an equivalent engine coolant, follow the handling instructions for maintenance intervals, freezing
temperature and other items.

1. ADJUSTMENT PROCEDURES FOR SUBARU SUPER COOLANT CONCENTRATION

CAUTION:
To fully utilize the antifreeze and rustproof performance, use SUBARU super coolant in a range of 50 to 60%.
To adjust the concentration of SUBARU super coolant according to temperature, find the proper coolant concentration
from the table, and adjust the concentration of the coolant (concentrated type) with a dilution water to the proper value.
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)
Recommended engine coolant and dilution water:
Refer to “SPECIFICATION” for the recommended engine coolant and dilution water.
COOLING(H4DOTC DIESEL) > Water Pump
REMOVAL
1. Remove the collector cover.
2. Remove the V-belts.
3. Lift up the vehicle.
4. Remove the under cover.
5. Drain engine coolant completely.
6. Remove the water pump.
COOLING(H4DOTC DIESEL) > Water Pump
INSTALLATION
1. Install the water pump.
NOTE:
Use a new gasket.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)

2. Install the under cover.

3. Lower the vehicle.
4. Install the V-belts.
5. Fill engine coolant.
6. Install the collector cover.
COOLING(H4DOTC DIESEL) > Water Pump
INSPECTION
1. Check the water pump bearing for smooth rotation.
2. Check the water pump pulley for abnormalities.
3. Make sure the impeller is not abnormally deformed or damaged.
4. After water pump installation, check for engine coolant leaks or noise. If leaks or noise are noted, replace the
water pump assembly.
COOLING(H4DOTC DIESEL) > Thermostat
REMOVAL
1. Lift up the vehicle.
2. Remove the under cover.
3. Drain engine coolant completely.

4. Disconnect the radiator outlet hose from the radiator.

5. Remove the catalytic converter and DPF.

6. Remove the thermostat cover, radiator outlet hose, and thermostat.

7. Disconnect the radiator outlet hose from the thermostat cover.

COOLING(H4DOTC DIESEL) > Thermostat
INSTALLATION
1. Install the radiator outlet hose to the thermostat cover.
2. Install the thermostat and thermostat cover.
NOTE:
Install the thermostat with the arrow pointing upward.
Tightening torque:
16 N·m (1.6 kgf-m, 11.8 ft-lb)

3. Install the catalytic converter and DPF.

4. Connect the radiator outlet hose to the radiator.

5. Install the under cover.

6. Lower the vehicle.
7. Fill engine coolant.
COOLING(H4DOTC DIESEL) > Thermostat
INSPECTION
Replace the thermostat if the valve does not close completely at an ambient temperature or if the following test shows
unsatisfactory results.
• Inspection method
Immerse the thermostat and thermometer in water. Raise water temperature gradually, and measure the temperature
and valve lift when the valve begins to open and when the valve is fully opened. During the test, agitate the water for
even temperature distribution. The measured value should meet the specification.
NOTE:
• Leave the thermostat in the boiling water for five minutes or more before measuring valve lift.
• Hold the thermostat with a wire or the like to avoid contacting the container bottom.
Opening start temperature:
84 — 88°C (183 — 190°F)
Full open temperature:
93°C (199°F)
Total valve lift:
9.0 mm (0.354 in) or more

(A) Thermometer (B) Thermostat

COOLING(H4DOTC DIESEL) > Radiator Sub Fan and Fan Motor
REMOVAL
1. Disconnect the ground cable from the battery.
2. Remove the collector cover.
3. Lift up the vehicle.
4. Remove the under cover.
5. Disconnect the radiator sub fan motor connector.

6. Lower the vehicle.

7. Remove the air intake duct.

8. Remove the mounting bolts from the radiator sub fan motor assembly.

9. Remove the radiator sub fan motor assembly from the vehicle.
NOTE:
Pull the radiator sub fan assembly upwards from in between the radiator inlet hose (RH) and radiator.
(A) Radiator inlet hose RH
COOLING(H4DOTC DIESEL) > Radiator Sub Fan and Fan Motor
INSTALLATION
Install in the reverse order of removal.
Tightening torque:
7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
COOLING(H4DOTC DIESEL) > Radiator Sub Fan and Fan Motor
DISASSEMBLY
1. Remove the nut which holds the fan to the fan motor.

2. Remove the bolts which hold fan motor onto shroud.

3. Remove the fan motor connector and harness from the shroud.
COOLING(H4DOTC DIESEL) > Radiator Sub Fan and Fan Motor
ASSEMBLY
Assemble in the reverse order of disassembly.
Tightening torque:
5 N·m (0.5 kgf-m, 3.7 ft-lb)

Tightening torque:
3.4 N·m (0.3 kgf-m, 2.5 ft-lb)
COOLING(H4DOTC DIESEL) > Radiator Main Fan and Fan Motor
REMOVAL
1. Disconnect the ground cable from the battery.
2. Remove the collector cover.
3. Lift up the vehicle.
4. Remove the under cover.
5. Disconnect the connectors of the radiator main fan and sub fan motors.
• Radiator main fan connector

• Radiator sub fan connector

6. Lower the vehicle.

7. Remove the air intake duct.

8. Disconnect the overflow hose from the reservoir tank.

9. Remove the reservoir tank.
10. Remove the radiator sub fan motor.
11. Remove the mounting bolts from radiator main fan motor assembly.

12. Remove the radiator main fan motor assembly from vehicle.
NOTE:
Move the radiator main fan motor assembly to the sub fan motor assembly side, and lift upwards from
between the radiator inlet hoses (RH and LH).

(A) Radiator inlet hose RH

COOLING(H4DOTC DIESEL) > Radiator Main Fan and Fan Motor
INSTALLATION
Install in the reverse order of removal.
Tightening torque:
7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
COOLING(H4DOTC DIESEL) > Radiator Main Fan and Fan Motor
DISASSEMBLY
1. Remove the nut which holds the fan to the fan motor.

2. Remove the bolts which hold fan motor onto shroud.

3. Remove the fan motor connector and harness from the shroud.
COOLING(H4DOTC DIESEL) > Radiator Main Fan and Fan Motor
ASSEMBLY
Assemble in the reverse order of disassembly.
Tightening torque:
5 N·m (0.5 kgf-m, 3.7 ft-lb)

Tightening torque:
3.4 N·m (0.3 kgf-m, 2.5 ft-lb)
COOLING(H4DOTC DIESEL) > Radiator
REMOVAL
CAUTION:
The radiator is pressurized. Wait until engine cools down before working on the radiator.
1. Disconnect the ground cable from the battery.
2. Remove the collector cover.
3. Lift up the vehicle.
4. Remove the under cover.
5. Drain engine coolant completely.

6. Disconnect the connectors of the radiator main fan and sub fan motors.
• Radiator main fan connector

• Radiator sub fan connector

7. Disconnect the radiator outlet hose from thermostat cover.

8. Lower the vehicle.
9. Disconnect the over flow hose.
10. Remove the reservoir tank.
11. Remove the radiator sub fan and fan motor.
12. Remove the radiator main fan and fan motor.
13. Remove the hood stay holder.

14. Disconnect the radiator inlet hose (RH) from the radiator.

15. Remove the radiator upper brackets.

16. Lift the radiator up and away from vehicle.

COOLING(H4DOTC DIESEL) > Radiator
INSTALLATION
1. Attach the radiator lower cushion to the hole on the radiator lower bracket.

2. Install the radiator to vehicle.

NOTE:
Make pins on the lower side of radiator be fitted into the radiator lower cushions on body side.
3. Install the radiator upper brackets and tighten the bolts.
Tightening torque:
12 N·m (1.2 kgf-m, 8.9 ft-lb)

4. Connect the radiator inlet hoses (RH and LH).

5. Install the hood stay holder.

Tightening torque:
7.5 N·m (0.8 kgf-m, 5.5 ft-lb)
6. Install the radiator main fan and fan motor.
7. Install the radiator sub fan and fan motor.
8. Install the reservoir tank.
9. Connect the over flow hose.
10. Lift up the vehicle.
11. Connect the radiator outlet hose.

12. Connect the connectors to the radiator main fan and sub fan motors.
• Radiator main fan connector

• Radiator sub fan connector

13. Install the under cover.
14. Lower the vehicle.
15. Install the collector cover.
16. Connect the battery ground cable to the battery.
17. Fill engine coolant.
COOLING(H4DOTC DIESEL) > Radiator
INSPECTION
1. Remove the radiator cap, fill the radiator with engine coolant, and then install the tester to the installation position
of cap.
2. Apply a pressure of 122 kPa (1.2 kgf/cm2, 18 psi) to the radiator, and check the following items.
• Leakage from the radiator or its vicinity
• Leakage from the hose or its connections
CAUTION:
• Engine should be turned off.
• Wipe engine coolant from check points in advance.
• Be careful of the spurt of engine coolant when removing the tester.
• Be careful not to deform the filler neck of radiator when installing and removing the tester.
COOLING(H4DOTC DIESEL) > Radiator Cap
INSPECTION
1. Attach the radiator cap to tester.

2. Increase pressure until the tester gauge needle stops. Radiator cap is functioning properly if it holds the service
limit pressure for five to six seconds. If the valve opens under a pressure below the service limit value, replace the
radiator cap.
Radiator side
Standard:
93 — 123 kPa (0.95 — 1.25 kgf/cm2, 14 — 18 psi)
Service limit:
83 kPa (0.85 kgf/cm2, 12 psi)
CAUTION:
Be sure to remove foreign matter and rust from the cap in advance. Otherwise, results of pressure test will
be incorrect.
COOLING(H4DOTC DIESEL) > Reservoir Tank
REMOVAL
1. Remove the collector cover.
2. Disconnect the overflow hose from the reservoir tank.
3. Pull out the reservoir tank in the direction of the arrow while pushing the tab.
COOLING(H4DOTC DIESEL) > Engine Cooling System Trouble in General
INSPECTION
Trouble Possible cause Corrective action
Replenish engine coolant, inspect for leakage, and repair it if
a. Insufficient engine coolant
necessary.
b. Defective thermostat Replace.
c. Malfunction of water pump Replace.
d. Clogged engine coolant passage Clean.
e. Improper ignition timing Inspect and repair the engine control system.
f. Clogged or leaking radiator Clean, repair or replace.
g. Improper engine oil in engine Replace engine coolant. If defectiveness is not improved, check
coolant and repair the engine side parts.
Overheat
h. Air/fuel mixture ratio too lean Inspect and repair the engine control system.
i. Excessive back pressure in exhaust
Clean or replace.
system
j. Insufficient clearance between
Adjust or replace.
piston and cylinder
k. Slipping clutch Repair or replace.
l. Dragging brake Adjust.
Inspect the radiator fan relay, engine coolant temperature sensor
m. Defective radiator fan
or fan motor and replace them.
a. Ambient temperature extremely
Partly cover radiator front area.
Over-cooling low
b. Defective thermostat Replace.
a. Loosened or damaged connecting
Repair or replace.
units on hoses
b. Leakage from water pump Replace.
c. Leakage from water pipe Repair or replace.
d. Leakage around cylinder head
Engine Retighten cylinder head bolts or replace gasket.
gasket
coolant leaks
e. Damaged or cracked cylinder head
Repair or replace.
and cylinder block
f. Damaged or cracked thermostat
Repair or replace.
case
g. Leakage from radiator Repair or replace.
a. Defective radiator fan Replace.
b. Defective water pump bearing Replace water pump.
Noise
c. Mechanical water pump
Replace water pump.
malfunction