Subaru Car 1998-05

Removal & Installation

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CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system into a suitable container to a level below the intake manifold.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. On some engines, disconnect the air intake duct and intake manifold hoses from the thermostat housing.
  8.  
  9. Loosen the hose clamp, and disconnect the upper radiator hose from the thermostat housing.
  10.  
  11. Remove the thermostat housing mounting bolts, then remove the housing and thermostat. Note the placement and direction of the thermostat for ease of installation.
    NOTE
    If the housing is difficult to remove, tap it lightly with a plastic-faced hammer.

  12.  
  13. Installation is the reverse of removal. Secure the thermostat housing mounting bolts to 4-9 ft. lbs. (6-12 Nm).
  14.  
  15. For non-turbo models, install the thermostat with the jiggle valve facing down.
  16.  
  17. For turbocharged models, install the thermostat with the jiggle valve at the 12 o'clock position.
  18.  
  19. Refill and bleed the cooling system.
  20.  
  21. Start the engine and bleed the cooling system and check for leaks.

    Click image to see an enlarged view

    Fig. Loosen the radiator draincock . . .



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    Fig. . . . and drain the coolant into a suitable container



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    Fig. Loosen and remove the thermostat housing retainer bolts



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    Fig. Detach the housing to reveal the thermostat and gasket



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    Fig. Remove the thermostat and gasket assembly



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    Fig. Loosen the bleeder screw on top of the radiator to bleed air from the cooling system

  22.  

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the engine undercover.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Loosen the hose clamp and disconnect the lower radiator hose from the thermostat cover.
  8.  
  9. Remove the thermostat cover and gasket, and pull out the thermostat.

    Click image to see an enlarged view

    Fig. Remove the thermostat cover, and pull out the thermostat-2.5L engine shown



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    Fig. Exploded view of the thermostat and related components-2.5L Turbo engine shown

  10.  

To install:

  1. Install the thermostat in the intake manifold.
    NOTE
    2.2L, 2.5L engines-The thermostat must be installed with the jiggle pin upward.


    NOTE
    2.5L Turbo engines-The thermostat must be install with the jiggle pin facing front.

  2.  
  3. Install the thermostat cover together with a new gasket.
  4.  
  5. Install the lower radiator hose to the thermostat cover and tighten the hose clamp.
  6.  
  7. Install the engine undercover.
  8.  
  9. Lower the vehicle.
  10.  
  11. Refill the engine cooling system to the correct level.
  12.  
  13. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Ensure the jiggle pin faces upward-2.2L and 2.5L Engines

  14.  

 
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