Subaru BRZ 2013 · Service Manual Engine/hybrid system

Radiator ASSY (FA20)

Components Inspection Removal / installation

COOLING
RADIATOR ASSY (FA20)
EXPLODED VIEW
REMOVAL
1. Disconnection of the battery ground terminal (Refer to )
2. Removal of air cleaner case SUB-ASSY
(1) Move the hose clip and disconnect the ventilation hose NO. 2.
(2) Disconnect the connector from the intake air flow meter SUB-ASSY.
(3) Release the clamp and disconnect the wiring harness from the air cleaner cap.
(4) Loosen the two hose clamps and remove the air cleaner duct and air intake boot.
(5) Remove the three bolts and remove the air cleaner case SUB-ASSY.
3. Removal of front bumper cover (Refer to )
4. Removal of under cover front AL (Refer to )
5. Draining of coolant (SUBARU Super Coolant) (Refer to )
6. Radiator outlet hose disconnection (Refer to )
7. Radiator reservoir tank ASSY removal
(1) Remove the two bolts and remove the radiator reservoir tank ASSY.
8. Air cleaner duct removal
(1) Remove the two bolts and remove the air cleaner duct.
9. Radiator cover plate removal
(1) Release the six clips and remove the radiator cover plate.
10. Removal of water filler SUB-ASSY
(1) Disconnect the radiator cap hose.
(2) Move the two hose clamps and disconnect the radiator inlet hose and radiator hose NO. 1.
NOTE:
Since the hose has its proper installation position, mark the alignment mark before removing it.
(3) Remove the four bolts and remove the radiator cap stay.
11. Disconnection of hood lock ASSY (Refer to )
12. Radiator support SUB-ASSY removal
(1) Remove the two lower bolts of radiator support SUB-ASSY.
(2) Remove the four bolts and remove the radiator support SUB-ASSY.
13. Cooler condenser ASSY disconnection (when there is air conditioning)
(1) Remove the bolt.
(2) Remove the bolt.
(3) Remove the bolt.
(4) Remove the bolt A.
(5) Remove the bolt B and disconnect the cooler condenser ASSY from the radiator ASSY.
14. Removal of cooler thermistor (ambient sensor) bracket (without air conditioning)
(1) Remove the connector for the cooler thermistor (ambient sensor).
(2) Remove the bracket together with the cooler thermistor (ambient sensor).
15. Fan shroud removal (Refer to )
16. Radiator ASSY removal
(1) Remove the two bolts and remove the radiator support bracket RH.
(2) Remove the two bolts and remove the radiator support bracket LH.
(3) Disconnect the ambient sensor connector. (With air conditioning)
(4) Remove the radiator ASSY while lifting the radiator outlet hose.
CAUTION:
Insert a cardboard, blanket, etc. between the radiator ASSY and cooler condenser ASSY to protect the cooler condenser ASSY.
Captions in illustration
*1
 Cooler condenser ASSY
*2
 Cardboard or blanket
*3
 Radiator ASSY
(5) Remove the two radiator supports LWR.
INSTALLATION
1. Radiator gasket installation (for the lower side)
(1) Install a new radiator gasket.
2. Radiator gasket NO. 2 installation
(1) Install a new radiator gasket NO. 2.
3. Radiator gasket NO. 1 installation
(1) Install a new radiator gasket NO. 1.
5. Radiator inlet hose installation
(1) Align the marks marked when removing the hose and install the radiator inlet hose to the radiator cap stay with the hose clamp.
6. Radiator outlet hose installation
(1) Align the marks marked when removing the hose and install the radiator outlet hose to the radiator with the hose clamp.
7. Radiator hose NO. 1 installation
(1) Align the marks marked when removing the hose and install the radiator hose NO.1 to the radiator with the hose clamp.
8. Radiator ASSY installation
(1) Install the two radiator supports LWR.
(2) Install the radiator ASSY to the vehicle while lifting the radiator outlet hose.
CAUTION:
Place a cardboard, blanket, etc. on the cooler condenser ASSY to protect the cooler condenser ASSY.
(3) Connect the ambient sensor connector. (With air conditioning)
(4) Install the radiator support bracket RH with the two bolts.

Standard value:
Tightening torque=7.5N·m { 77kgf·cm} {5.5ft·lbf}
(5) Install the radiator support bracket LH with the two bolts.

Standard value:
Tightening torque=7.5N·m { 77kgf·cm} {5.5ft·lbf}
10. Installation of cooler thermistor (ambient sensor) bracket (Without air conditioning)
(1) Install the bracket together with the cooler thermistor (ambient sensor).
(2) Connect the connector for the cooler thermistor (ambient sensor).

Standard value:
Tightening torque=6.0N·m { 61kgf·cm} {4.4ft·lbf}
11. Cooler condenser ASSY connection (when there is air conditioning)
(1) Connect the cooler condenser ASSY to the radiator ASSY with the five bolts.

Standard value:
Tightening torque=6.0N·m { 61kgf·cm} {4.4ft·lbf}
12. Radiator support SUB-ASSY installation
(1) Install the radiator support SUB-ASSY with the six bolts.

Standard value:
Tightening torque=18N·m { 184kgf·cm} {13.3ft·lbf}
13. Hood lock ASSY connection (Refer to )
14. Water filler SUB-ASSY installation
(1) Install the water filler SUB-ASSY with the four bolts.

Standard value:
Tightening torque=7.5N·m { 77kgf·cm} {5.5ft·lbf}
(2) Align the marks marked when removing the hoses and install the radiator inlet hose and radiator hose NO.1 with the two hose clamps.
(3) Connect the radiator cap hose.
15. Radiator cover plate installation
(1) Install the radiator cover plate with the six clips.
16. Air cleaner duct installation
(1) Install the air cleaner duct with the two bolts.

Standard value:
Tightening torque=6.0N·m { 61kgf·cm} {4.4ft·lbf}
17. Radiator reservoir tank ASSY installation
(1) Install the radiator reservoir tank ASSY with the two bolts.

Standard value:
Tightening torque=7.5N·m { 77kgf·cm} {5.5ft·lbf}
18. Radiator outlet hose connection (Refer to )
19. Replenishing of coolant (SUBARU Super Coolant) (Refer to )
20. Leak check of coolant (SUBARU Super Coolant) (Refer to )
21. Under cover front AL installation (Refer to )
22. Installation of front bumper cover (Refer to )
23. Air cleaner case SUB-ASSY installation
(1) Install the air cleaner case SUB-ASSY with the three bolts.

Standard value:
Tightening torque=6.0N·m { 61kgf·cm} {4.4ft·lbf}
(2) Install the air cleaner duct and air cleaner intake boot with the two hose clamps.

Standard value:
Tightening torque=2.0N·m { 20kgf·cm} {1.5ft·lbf}
(3) Engage the clamp and install the wiring harness to the air cleaner cap.
(4) Connect the connector to the intake air flow meter SUB-ASSY.
(5) Connect the ventilation hose NO. 2 with the hose clip.
ON-VEHICLE INSPECTION
1. Radiator cap SUB-ASSY check
WARNING:
To avoid the risk of burn, do not remove the radiator cap SUB-ASSY when the engine and radiator are hot. The fluid and steam may blow out due to the pressure.
(1) Perform the visual check.
(a) When water scale or foreign matter is on the gaskets 1, 2 and 3, wash it with water.
NOTE:
Always perform the work by hands so as not to damage the gaskets 1, 2 and 3.
(b) Check the gaskets 1, 2 and 3 for deformation, cracks and expansion.
(c) Make sure that the gaskets 3 and 4 are not stuck.
(2) Perform the function check.
(a) Apply the engine coolant to the gaskets 2 and 3 before using the radiator cap tester.
Captions in illustration
*1
 Radiator cap tester
*2
 Radiator cap SUB-ASSY
*a
 30° or more
(b) Pump the cap tester several times and check the maximum pressure.
Pumping speed :  Pump once a second
CAUTION:
When using the cap tester, perform the check by tilting it 30° or more.
NOTE:
There is a case that the radiator cap SUB-ASSY cannot keep the maximum pressure, but it is not abnormal.
Standard value :  93 to 123 kPa {0.95 to 1.25 kgf/cm2, 14 to 18 psi}
Limit :  83 kPa {0.85 kgf/cm2, 12 psi}
NOTE:
·The valve opening pressure of a new radiator cap SUB-ASSY is 93 to 123 kPa {0.95 to 1.25 kgf/cm2, 14 to 18 psi}.
·If the maximum valve opening pressure does not exceed the limit value, replace the radiator cap SUB-ASSY.