Subaru Forester Owners Forum banner
  • The "Garage" feature is for images of YOUR VEHICLE/S only - no blanks or other unrelated images please, thanks

2015 - Limited - Coolant leak apparently at "crossover" o-rings? [replaced O-rings] - SOLVED!

8.2K views 9 replies 5 participants last post by  Gary Brady  
#1 ·
Vehicle Details:
2015 2.5 limited, Fb25 with CVT
Friends,
Wife started noticing a coolant smell on our 2015(FB25,CVT,normally asperated, 75k miles city driving in fairly hot city) ) about a month or two ago ago. There is pooling of coolant on top forward part of engine. I cleaned it out, from thickness at bottom probably been leaking and evaporating a few months and it is intermittently leaking. Took a very close look with mirror and flashlight with pressure tester and it is 99.9% certainty at coolant crossover pipe mating to engine, seems compromised o-rings. Have not done chemical tests but no visible mud sign in oil, and no oil signs in radiator or overflow reservoir. So no obvious sings of zHG issue. For o-ring replacement, dealers want $1k, well regarded local independents want $800. Got a low estimate from an independent of $450, don't know whether to trust that lowball

anyone done this on 14-18?

I see there is a well done youtube for this job on 2013 impreza . Anyone know if:
1) there is any video or step by step write up for this on 14-18 foresters
2) if not if 2015 forester is going to have any differences from 13 imprezza?
3) If there are any things to watch out for? Bolts look awful corroded perhaps from slight continual leak, so i am going to PBlaster daily for a three days or so. any particular bolts prone to snapping?
4) and I am 99% sure this is o-rings, but is a pinhole leak in crossover pipe also possible at 75k/~nine years?
5) I have o-rings, plenum gaskets, throttle body gasket, fuel line tool, 2 gallons pre-diluted subaru blue. Anything else needed?
Thanks in Advance!
 
#8 ·
yes I looked at two of his, and an other. The one for the '13 Impreza looked more under the hood like my 15 forester than the video he did for the '15 outback. Perhaps because the forester 15s started being sold every early, in spring 14.
I did not see him replacing bolts, not with same pipe corrosion, so I mentioned those. Also I think this job is very different, much easier, if you can have a couple of minutes with a helper for midpoint removal.
 
#6 ·
OK Job finished. Took me three hours taking my time and being methodical making a list of everything I did so I could reverse my list on re-assembly. I think someone who has taken plenum/upper off before could do this in 90 minutes easy.
I had a pal come over for 15 minutes midway to help with removal of old o-rings and install of new ones. A pal to help really made a difference in having one person pull up and back on crossover from only partially removed harnesses and hoses while the other worked the pick to get baked-on o-ring out. I did not remove the 27mm egr fitting as although I had a 1 1/16 open end to do that, it was seriously rusted on and did not move with a large amount of pressure, and I was able to lift crossover just enough anyway.
When looking for info/parts, keep in mind the crossover pipe is also called water manifold, Water Pipe and Pipe CP Water.

Supplies/parts I used for 2015 CVT non-turbo 2.5:
PBlaster "catalyst."
Brake cleaner to clean dirt, copious pblaster and coolant from top of engine
A couple of good quality picks. I had a cheap set from amazon and they bent up and did nothing. I also had a craftsman pick that worked way way better.
Mid/light ftlb torque wrench
2 Gallons of subaru pre-mix
OEM o-rings
OEM plenum gaskets 14035aa570 for mine
OEM replacement (4) bolts for water manifold/crossover 6x25x18 part number 808206040 ($7 for four at parts counter)
Felpro throttlebody gasket

Also, in addition to crossover o-rings being current problem, a couple of the outlet/inlet pipes integrated to it were obscenely corroded for a nine year old vehicle. I think in my case the entire pipe is liable to fail at some point. Labor on getting crossover completely out and new one in is probably additional 60 mins. Part is $300 list but available oem from some online subaru dealerships for $203

Image


Also PCV valve is a bit easier to check and or replace at same time, BUT make sure you have new hose to that. My hose was utterly baked and not reusable. Autozone and advance auto did not have this in stock. In any case it was about $9 at dealer.
 
You have insufficient privileges to reply here.