Subaru Car 1998-05

Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Remove the radiator undercover, if equipped.
  8.  
  9. Disconnect the radiator fan electrical connectors.
  10.  
  11. Disconnect the lower radiator hose from the radiator.
  12.  
  13. Disconnect the transmission cooler hoses from the radiator, if equipped.
  14.  
  15. Lower the vehicle.
  16.  
  17. Remove the air intake assembly.
  18.  
  19. Remove the overflow hose and reservoir tank.
  20.  
  21. Remove the accessory drive belt covers.
  22.  
  23. Disconnect the upper radiator hoses from the radiator.
  24.  
  25. Disconnect the coolant filler tank hose, if equipped with a turbo.
  26.  
  27. Remove the upper radiator mounting brackets.
  28.  
  29. Detach the power steering hose from the clip on the radiator.
  30.  
  31. Raise the radiator slightly, slide it to the left, and lift the radiator up and out of the vehicle.
  32.  

To install:

  1. If not already installed, attach radiator mounting cushions to the lower holes.
  2.  
  3. Install the radiator. Fit the pins at the bottom of the radiator into the mounting cushions.
  4.  
  5. Install the upper radiator mounting brackets and tighten to 9 ft. lbs. (12 Nm).
  6.  
  7. Attach the power steering hose to the radiator.
  8.  
  9. Connect the upper radiator hoses.
  10.  
  11. Connect the coolant filler tank hoses, if equipped with a turbo.
  12.  
  13. Install the reservoir tank and overflow hose.
  14.  
  15. Install the air intake assembly.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Connect the automatic transmission cooler hoses to the radiator, if equipped.
  20.  
  21. Connect the radiator fan motor electrical connectors.
  22.  
  23. Connect the lower radiator hose.
  24.  
  25. Install the radiator under cover, if equipped.
  26.  
  27. Install the engine undercover.
  28.  
  29. Lower the vehicle.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Fill the engine cooling system to the correct level.
  34.  
  35. Start the engine and check for leaks.
  36.  

1.8L Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.

    Click image to see an enlarged view

    Fig. Exploded view of a radiator and cooling fan assembly-1.8L engine

  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Disconnect the upper and lower hoses from the radiator.
  8.  
  9. Disconnect the cooling fan lead wire.
  10.  
  11. On automatic transaxle models, disconnect and cap the transaxle oil cooler lines.
  12.  
  13. Disconnect the thermoswitch electrical connector.
  14.  
  15. Remove the radiator mounting bracket screws.
  16.  
  17. Remove the radiator and the oil cooler hose, if equipped, from the vehicle as a unit.
  18.  
  19. Inspect the rubber cushion on the base of the radiator and replace if worn or cracked.
  20.  

To install:

  1. Install the radiator in the vehicle, making sure the rubber cushions align correctly with the indents in the lower support of the engine compartment.
  2.  
  3. Install the radiator mounting brackets and screws. Tighten the screws 24-48 inch lbs. (3-5 Nm).
  4.  
  5. The remainder of installation is the reverse of removal.
  6.  
  7. Refill the cooling system.
  8.  
  9. Start the vehicle and check for coolant leaks.
  10.  

2.5L Engine





Click image to see an enlarged view

Fig. Remove the radiator retainer bracket bolts . . .



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Fig. . . . and brackets from the radiator



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Fig. Loosen the radiator hose clamps, and disconnect the hoses from the radiator assembly



Click image to see an enlarged view

Fig. Disconnect the reservoir hose connection from the radiator



Click image to see an enlarged view

Fig. Unfasten the reservoir bracket's upper retainer bolt . . .



Click image to see an enlarged view

Fig. . . . and the lower retainer screw . . .



Click image to see an enlarged view

Fig. . . . then lift the reservoir assembly out of the engine compartment



Click image to see an enlarged view

Fig. With all the installation hardware removed, carefully lift out the radiator

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect and remove the battery.
  4.  
  5. Drain the coolant from the radiator into a suitable container.
  6.  
  7. Disconnect the upper and lower hoses from the radiator.
  8.  
  9. Remove the drive belt cover.
  10.  
  11. Remove the reservoir tank and overflow hose.
  12.  
  13. Disconnect the fan motor electrical connectors.
  14.  
  15. Remove the upper radiator brackets.
  16.  
  17. Lift the radiator slightly and slide it to the left.
  18.  
  19. If equipped with an automatic transaxle, disconnect the cooling lines from the radiator.
  20.  
  21. Lift the radiator from the engine compartment.
  22.  
  23. Installation is the reverse of removal. Secure the radiator brackets bolts to 9-17 ft. lbs. (12-22 Nm).
  24.  
  25. Fill and bleed the cooling system.
  26.  
  27. Install the battery.
  28.  

3.3L Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the battery cables, negative first and then the positive.
  4.  
  5. Remove the battery from the engine compartment.
  6.  
  7. Drain the cooling system into a suitable container.
  8.  
  9. Disconnect the outlet hose from the water pump.
  10.  
  11. Disconnect the transaxle cooler hose from the pipe, if equipped.
  12.  
  13. Disconnect the cooling fan electrical connectors.
  14.  
  15. Disconnect the coolant overflow hose from the radiator.
  16.  
  17. Remove the drive belt cover.
  18.  
  19. Disconnect the inlet hose from the thermostat housing.
  20.  
  21. Remove the upper radiator mounting brackets.
  22.  
  23. Remove the radiator from the vehicle.
  24.  
  25. Installation is the reverse of removal. Tighten all components to specifications.
  26.  
  27. Refill the cooling system.
  28.  
  29. Install the battery and connect the battery cables, positive cable followed by the negative cable.
  30.  
  31. Start the engine and check for leaks.
  32.  

 
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