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HOMESERVICE MANUALSSUBARU2004OUTBACK LIMITED, 4D SEDAN, EJ259REPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALCOOLING FANENGINE COOLING SYSTEM (H4SO)WATER PUMPINSTALLATION
2004 Subaru Outback Limited, 4D Sedan, EJ259

Water Pump: Installation

2004 Subaru Outback Limited, 4D Sedan, EJ259SECTION Installation
  1. Install water pump onto left-hand cylinder block.
    NOTE:
    • Replace gasket with a new one.
    • When installing water pump, tighten bolts in two stages in alphabetical sequence as shown in figure.
    1. Tightening torque: 
      1. First: 

        12 N.m (1.2 kgf-m, 8.7 ft-lb) 

      2. Second: 

        12 N.m (1.2 kgf-m, 8.7 ft-lb) 

    Fig 1: Installing Water Pump Bolts & Tightening Bolts In Alphabetical Sequence
    G00897459Courtesy of SUBARU OF AMERICA, INC.
  2. Install tensioner bracket.
    1. Tightening torque: 

      25 N.m (2.5 kgf-m, 18.1 ft-lb) 

    Fig 2: Installing Tensioner Bracket
    G00897460Courtesy of SUBARU OF AMERICA, INC.
  3. Install left-hand belt cover No. 2.
    1. Tightening torque: 

      5 N.m (0.5 kgf-m, 3.6 ft-lb) 

    Fig 3: Installing Left-Hand Belt Cover No. 2
    G00897461Courtesy of SUBARU OF AMERICA, INC.
  4. Install left-hand camshaft sprockets by using ST.

    ST 18231AA010 CAMSHAFT SPROCKET WRENCH

    NOTE: Camshaft sprocket wrench (499207100) is also available.
    1. Tightening torque: 

      78 N.m (8.0 kgf-m, 57.9 ft-lb) 

    Fig 4: Installing Left-Hand Camshaft Sprockets By Using ST
    G00897462Courtesy of SUBARU OF AMERICA, INC.
  5. Install belt idler No. 2.
    1. Tightening torque: 

      39 N.m (4.0 kgf-m, 28.9 ft-lb) 

    Fig 5: Installing Belt Idler No. 2
    G00897463Courtesy of SUBARU OF AMERICA, INC.
  6. Install automatic belt tension adjuster which tension rod is held with pin. Refer to AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER .
  7. Install timing belt. Refer to TIMING BELT .
  8. Install V-belts. Refer to INSTALLATION .
  9. Install radiator main fan and sub fan motor assemblies. Refer to INSTALLATION , Radiator Main Fan and Fan Motor and INSTALLATION , Radiator Sub Fan and Fan Motor.
  10. Install reservoir tank.
    Fig 6: Installing Reservoir Tank
    G00897464Courtesy of SUBARU OF AMERICA, INC.
  11. Connect overflow hose.
    Fig 7: Connecting Overflow Hose
    G00897465Courtesy of SUBARU OF AMERICA, INC.
  12. Install air intake duct.
    Fig 8: Installing Air Intake Duct
    G00897466Courtesy of SUBARU OF AMERICA, INC.
  13. Lift-up the vehicle.
  14. Connect radiator outlet hose and heater bypass hose to water pump.
    Fig 9: Connecting Radiator Outlet Hose & Heater Bypass Hose To Water Pump
    G00897467Courtesy of SUBARU OF AMERICA, INC.
  15. Connect connectors to radiator main fan (A) and sub fan (B) motors.
    Fig 10: Connecting Connectors To Radiator Main Fan & Sub Fan Motors
    G00897468Courtesy of SUBARU OF AMERICA, INC.
  16. Install under cover.
    Fig 11: Installing Under Cover
    G00897469Courtesy of SUBARU OF AMERICA, INC.
  17. Lower the vehicle.
  18. Connect battery ground cable.
    Fig 12: Connecting Battery Ground Cable
    G00897470Courtesy of SUBARU OF AMERICA, INC.
  19. Fill coolant. Refer to FILLING OF ENGINE COOLANT .
RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.