Subaru Coupes/Sedans/Wagons 1985-1996 Repair Guide

Radiator

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REMOVAL & INSTALLATION




CAUTION
When draining the 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 quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

1.2L Engine

See Figure 1

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Fig. Fig. 1: Radiator and cooling fan assembly-1.2L engine

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Disconnect the upper and lower hoses from the radiator.
  6.  
  7. Disconnect the cooling fan lead wire.
  8.  
  9. Disconnect the oil cooler hose from the pipe at the transaxle, if equipped.
  10.  
  11. Remove the radiator mounting bracket screws.
  12.  
  13. Remove the radiator and the oil cooler hose, if equipped, from the vehicle as a unit.
  14.  
  15. Inspect the rubber cushion on the base of the radiator and replace if worn or cracked.
  16.  

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 to 24-48 inch lbs. (3-5 Nm).
  4.  
  5. Connect the oil cooler hose to the pipe at the transaxle, if equipped.
  6.  
  7. Connect the cooling fan lead wire.
  8.  
  9. Connect the upper and lower radiator hoses.
  10.  
  11. Refill the cooling system.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the vehicle and check for coolant leaks.
  16.  

1.6L and 1.8L Engines

See Figure 2

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Fig. Fig. 2: Radiator and cooling fan assembly-1.6L and 1.8L engines

  1. Drain the cooling system into a suitable container.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the upper and lower hoses from the radiator.
  6.  
  7. On automatic transaxle models, disconnect and cap the transaxle oil cooler lines.
  8.  
  9. Disconnect the cooling fan motor electrical connector.
  10.  
  11. Disconnect the thermoswitch electrical connector.
  12.  
  13. Remove the two radiator mounting bolts.
  14.  
  15. Lift the radiator out of the radiator support.
  16.  

To install:
  1. Install the radiator mounting cushions onto the lower radiator pins.
  2.  
  3. Position the radiator in to the vehicle and install the two mounting bolts.
  4.  
  5. Connect the electrical connector to the thermoswitch.
  6.  
  7. Connect the electrical connector to the fan motor.
  8.  
  9. Connect the transaxle oil cooler lines to the radiator, if equipped.
  10.  
  11. Connect the upper and lower radiator hoses.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Fill and bleed the cooling system.
  16.  

2.2L and 2.5L Engines

See Figures 3, 4, 5, 6, 7, 8, 9, 10, 11 and 12

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Fig. Fig. 3: Radiator and cooling fan assembly-2.2L and 2.5L engines



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Fig. Fig. 4: Loosen and remove the drive belt cover-2.2L model shown



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Fig. Fig. 5: Remove the radiator retainer bracket bolts ...



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Fig. Fig. 6: ... and brackets from the radiator



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Fig. Fig. 7: Loosen the radiator hose clamps, and disconnect the hoses from the radiator assembly



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Fig. Fig. 8: Disconnect the reservoir hose connection from the radiator



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Fig. Fig. 9: Unfasten the reservoir bracket's upper retainer bolt ...



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Fig. Fig. 10: ... and the lower retainer screw ...



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Fig. Fig. 11: ... then lift the reservoir assembly out of the engine compartment



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Fig. Fig. 12: With all the installation hardware removed, carefully lift out the radiator

  1. Disconnect and remove the battery.
  2.  
  3. Drain the coolant from the radiator into a suitable container.
  4.  
  5. Disconnect the upper and lower hoses from the radiator.
  6.  
  7. Remove the drive belt cover.
  8.  
  9. Remove the reservoir tank and overflow hose.
  10.  
  11. Disconnect the fan motor electrical connectors.
  12.  
  13. Remove the upper radiator brackets.
  14.  
  15. Lift the radiator slightly and slide it to the left.
  16.  
  17. If equipped with an automatic transaxle, disconnect the cooling lines from the radiator.
  18.  
  19. Lift the radiator from the engine compartment.
  20.  

To install:
  1. Attach the radiator mounting cushions to the pins on the lower side of the radiator.
  2.  
  3. Fit the pins on the lower portion of the radiator into the holes on the radiator support.
  4.  
  5. If equipped, connect the transaxle cooling lines to the radiator.
  6.  
  7. Install the radiator brackets and tighten the bolts to 9-17 ft. lbs. (12-22 Nm).
  8.  
  9. Connect the fan motor electrical connectors.
  10.  
  11. Connect the inlet and outlet hoses to the radiator.
  12.  
  13. Install the reservoir tank and overflow hose.
  14.  
  15. Install the drive belt cover.
  16.  
  17. Fill and bleed the cooling system.
  18.  
  19. Install the battery.
  20.  

2.7L Engine

See Figure 13

Click image to see an enlarged view

Fig. Fig. 13: Radiator and cooling fan assembly-2.7L engine

  1. Drain the cooling system into a suitable container.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the upper and lower hoses from the radiator.
  6.  
  7. On automatic transaxle models, disconnect and cap the transaxle oil cooler lines.
  8.  
  9. Disconnect the cooling fan motor electrical connector.
  10.  
  11. Disconnect the thermoswitch electrical connector.
  12.  
  13. Remove the two radiator mounting bolts.
  14.  
  15. Lift the radiator out of the radiator support.
  16.  

To install:
  1. Install the radiator mounting cushions onto the lower radiator pins.
  2.  
  3. Position the radiator in to the vehicle and install the two mounting bolts. Tighten the bolts to 9-17 ft. lbs. (12-22 Nm)
  4.  
  5. Fasten the electrical connector to the thermoswitch.
  6.  
  7. Fasten the electrical connector to the fan motor.
  8.  
  9. If equipped, connect the transaxle oil cooler lines to the radiator.
  10.  
  11. Connect the upper and lower radiator hoses.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Start the engine and check for coolant leaks.
  18.  

3.3L Engine

See Figure 14

Click image to see an enlarged view

Fig. Fig. 14: Radiator and cooling fan assembly-3.3L engine

  1. Disconnect the battery cables, negative first and then the positive.
  2.  
  3. Remove the battery from the engine compartment.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. Disconnect the outlet hose from the water pump.
  8.  
  9. Disconnect the transaxle cooler hose from the pipe, if equipped.
  10.  
  11. Disconnect the cooling fan electrical connectors.
  12.  
  13. Disconnect the coolant overflow hose from the radiator.
  14.  
  15. Remove the drive belt cover.
  16.  
  17. Disconnect the inlet hose from the thermostat housing.
  18.  
  19. Remove the upper radiator mounting brackets.
  20.  
  21. Remove the radiator from the vehicle.
  22.  

To install:
  1. Install the radiator in the vehicle.
  2.  
  3. Install the upper radiator brackets.
  4.  
  5. Connect the inlet hose to the thermostat housing.
  6.  
  7. Install the belt cover.
  8.  
  9. Connect the coolant overflow hose to the radiator.
  10.  
  11. Fasten the electrical connector to the fan motor.
  12.  
  13. Connect the transaxle hose, if equipped.
  14.  
  15. Connect the outlet hose to the water pump.
  16.  
  17. Refill the cooling system.
  18.  
  19. Install the battery and connect the battery cables, positive cable followed by the negative cable.
  20.  
  21. Start the engine and check for leaks.
  22.  

 
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