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Old 08-28-2007, 02:18 PM   #1
ZMANNH25rs
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Default 02 WRX Radiator issue...have a couple of ???

Car = 2002 WRX / Sedan

So apparently my radiator is leaking...a lot. The garage I was at said that when he called Subaru to quote the parts, the guy at the Subaru shop said the 02's WRX's had a TSB on the radiators and to install a new radiator you need to purchase a new set of hoses and some other parts as well as the new radiator.

My questions are, is their a TSB on the 02 WRX's ? Where can I get a copy of it. Also, will a stock 2003 or 2004 radiator fit in my WRX ? Lastly, besides the OEM part, is their another alternative that is close to the same price range ?

EDIT : One other question. If I buy a Koyo Radiator, will it also need to be re-routed in accordance with the TSB, or can the same old stock hoses be used in it's place ? Also, is this something that can be done on your own without a lift, or do you need a 'garage' to replace the radiator ?

TIA - JZ
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Last edited by ZMANNH25rs; 08-28-2007 at 02:43 PM.
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Old 08-28-2007, 04:27 PM   #2
wrxwhite
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Everything can be done from the top. There is a difference between an 02 and an 03. However the mounting is the same. If changing to an aluminum be prepared for some minor (?) mods.
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Old 08-28-2007, 04:42 PM   #3
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I went through the same ordeal a couple years ago. My 02 radiator basically busted at the stamped seams. I replaced the unit with the Koyo one, as it's about the same price as the dealer quoted factory piece, but way better. You can use the same stock hoses, however it is a tighter fit with the larger Koyo core. Make sure the upper radiator hose is not hitting the belts. I have two complaints with the Koyo. 1) The drain plug on the bottom is a plastic screw 2) You have to remove the subframe to gain access to the screw if you want to drain your coolant. Hope this helps.
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Old 08-28-2007, 04:42 PM   #4
5spdfrk
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I had the same problem. Mine left me stranded on the side of the road though. Instead of buying a used radiator or another one from Subaru (which is too much $$$) I bought a koyo off of ebay, got some samco hoses, a crucial racing thermostat and cap, and called it a day.
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Old 08-28-2007, 04:50 PM   #5
Kean
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.....in a nutshell, the radiators on '02's and early '03's didn't have a radiator cap on the radiator itself (only on the resevoir). The newer units have caps on them but will require a metal tube and two overflow hoses when replacing the old set up. I believe this is the TSB you were looking for (courtesy of ScoobyMods & DrD):

Quote:
NUMBER: 09-37-03
DATE: 07/15/03

APPLICABILITY: 2002-2003MY Impreza WRX

SUBJECT: New WRX Radiator

INTRODUCTION
If you are replacing the radiator in a WRX with a production date prior to September 2002 you will need to make a few changes. A radiator cap has been added to all new radiators being produced for this model, which requires you to add a new pipe and two hoses.

These items must be ordered and installed as a set when ordering the new radiator.

VEHICLES AFFECTED

STARTING VIN
SEDAN 2*507194
WAGON 2*806590

Production change: September, 2002.

PARTS INFORMATION

The new style radiator has a radiator cap that is incorporated into the top tank. The old style radiator did not have the radiator cap incorporated in the top.

Since the old style radiator was discontinued in production, the new style radiator must be substituted for it. In this situation you must install a new overflow pipe and overflow hose A & B as a set along with the new radiator.

MANUAL TRANSMISSION

RADIATOR 45111AE101
PIPE OVERFLOW 45175FE010
HOSE OVERFLOW B 45162FE010
HOSE OVERFLOW A 45162FE000


AUTOMATIC TRNASMISSION

RADIATOR 45111FE111
PIPE OVERFLOW 45175FE010
HOSE OVERFLOW B 45162FE010
HOSE OVERFLOW A 45162FE000

Install the parts as a set as shown.

CAUTION The new system is provided with two different caps, one on the radiator and one on the pressurized tank as shown in the above table. Accordingly, pay special attention not to mix up those caps. If they are switched, it could cause overheating which may lead to engine failure.
......I'm familiar with this issue since I've had to do the replacement as well.
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Old 08-28-2007, 06:02 PM   #6
ZMANNH25rs
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Quote:
Originally Posted by hoodscoob View Post
I went through the same ordeal a couple years ago. My 02 radiator basically busted at the stamped seams. I replaced the unit with the Koyo one, as it's about the same price as the dealer quoted factory piece, but way better. You can use the same stock hoses, however it is a tighter fit with the larger Koyo core. Make sure the upper radiator hose is not hitting the belts. I have two complaints with the Koyo. 1) The drain plug on the bottom is a plastic screw 2) You have to remove the subframe to gain access to the screw if you want to drain your coolant. Hope this helps.
Definitely helps...thanks !!! I think I am going with the Koyo one as well.

Quote:
Originally Posted by 5spdfrk View Post
I had the same problem. Mine left me stranded on the side of the road though. Instead of buying a used radiator or another one from Subaru (which is too much $$$) I bought a koyo off of ebay, got some samco hoses, a crucial racing thermostat and cap, and called it a day.
I was thinking of going the same way...I assume this has been running problem free for you ?

Quote:
Originally Posted by Kean View Post
.....in a nutshell, the radiators on '02's and early '03's didn't have a radiator cap on the radiator itself (only on the resevoir). The newer units have caps on them but will require a metal tube and two overflow hoses when replacing the old set up. I believe this is the TSB you were looking for (courtesy of ScoobyMods & DrD):



......I'm familiar with this issue since I've had to do the replacement as well.
AWESOME ! Thanks for teh TSB.

My questions with this, is the new Koyo radiators for the 02's have these changes made to it, to accomodate the change in where the radiator cap is ? Or does the newer Koyo models not need this change because they are not prone to leaking ? This part is confusing...
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Old 08-28-2007, 11:03 PM   #7
ralliharri
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Quote:
Originally Posted by hoodscoob View Post
I went through the same ordeal a couple years ago. My 02 radiator basically busted at the stamped seams. I replaced the unit with the Koyo one, as it's about the same price as the dealer quoted factory piece, but way better. You can use the same stock hoses, however it is a tighter fit with the larger Koyo core. Make sure the upper radiator hose is not hitting the belts. I have two complaints with the Koyo. 1) The drain plug on the bottom is a plastic screw 2) You have to remove the subframe to gain access to the screw if you want to drain your coolant. Hope this helps.

I had no problem reaching the drainplug on the radiator from the top, in fact it was even easier than w/ oem rad (just remove airintake). Oh, I left out the right side fan, figured with extra volume I dont need it. Most drainplugs on oem rads ARE plastic.
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Old 08-29-2007, 02:33 PM   #8
dwmoss_68
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Quote:
Originally Posted by ZMANNH25rs View Post
My questions with this, is the new Koyo radiators for the 02's have these changes made to it, to accomodate the change in where the radiator cap is ? Or does the newer Koyo models not need this change because they are not prone to leaking ? This part is confusing...
I believe Koyo makes both models for an 02 or the 03. I believe some have bought the 03 style (2 rad caps - 1 on koyo) and the additional plumbing needed. I went with the 02 style (1 rad cap - 0 on koyo) and have no complaints. You will need to shorten your hoses with the koyo being thicker then stock so they don't hit the fans.

good luck

dm

ps. my stock radiator cracked in similar locations to others...

here's a pic

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Old 08-29-2007, 02:44 PM   #9
5spdfrk
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Yeh, Koyo makes both designs '02 and '03. I went with the '02 design as well.
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Old 08-29-2007, 04:41 PM   #10
ZMANNH25rs
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thanks guys...now I need to find a place that sells stock hoses. Any ideas ? Either that or I guess I could buy some Samco hoses if I had to...
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Old 08-29-2007, 05:06 PM   #11
lawlerlaw
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samco should work
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Old 08-29-2007, 06:02 PM   #12
dwmoss_68
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Quote:
Originally Posted by ZMANNH25rs View Post
thanks guys...now I need to find a place that sells stock hoses. Any ideas ? Either that or I guess I could buy some Samco hoses if I had to...
stealer or online for the stock hoses, for the samco's you will need to trim them as well to account for the wider koyo

dm
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Old 08-30-2007, 02:35 AM   #13
dElKwOn
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^^ i 2nd the motion on trimming of the samco hoses w/ the install of a koyo radiator.i trimmed the top hose on just end that bolts into the block,the hose is a little cockeyed but no clearance problems.maybe a slight trim of both ends will yield a better result than just trimming only one end.

oh btw my stocker popped in the same area as everyone stocker!
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Old 08-30-2007, 09:37 PM   #14
5spdfrk
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I didn't have to trim the top or bottom samco hose, although I probably should have trimmed the bottom one. It was tight, but I made it fit.
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Old 10-11-2007, 12:57 AM   #15
BugeyePB Rex
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Just came accross this thread because my radiator recently cracked as well on the upper tank like the pic above. Does anyone know of where I can get a print out of the TSB? And are the newer radiator models any better? Any feedback is appreciated, I don't want to go through another cracked radiator, if so I'll buy a Koyo later on.
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Old 10-11-2007, 01:48 AM   #16
lettucemanatee
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i replaced my leaking 02's radiator with a speedmonkee/ron davis. installed a crucial t-stat at the same time. used new factory hoses with new clamps.


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