Subaru Car 1998-05

Timing Belt, Cover, Sprockets, & Seal

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Removal & Installation



2.0L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the V-belt.
  6.  
  7. Remove the crankshaft pulley.
  8.  
  9. Remove the belt cover as follows:
    1. Crankshaft pulley.
    2.  
    3. Left hand belt cover.
    4.  
    5. Right hand belt cover.
    6.  
    7. Front hand belt cover.
    8.  

  10.  
  11. Remove the timing belt guides on models equipped with a manual transmission.
  12.  
  13. If the alignment marks that indicate rotation are faded, put new marks on the belt before removal as follows:
    1. Turn the crankshaft using crankshaft sprocket tool 499987500 and a breaker bar to align the crankshaft sprocket, left hand intake camshaft sprocket, left hand exhaust camshaft, right hand intake camshaft sprocket and right hand exhaust camshaft sprocket with the on the cover and cylinder block.
    2.  
    3. Using white paint such as white out, place alignment marks on the belts in relation to the sprockets.
    4.  

  14.  
  15. Remove the belt idler (A), illustrated in the accompanying illustration.
  16.  
  17. Remove the timing belt.
  18.  
  19. If necessary, remove belt idlers (B) and (C).
  20.  
  21. Remove the belt idler 2.
  22.  
  23. Remove the automatic belt tension adjuster assembly.
  24.  


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    Fig. Remove the left hand (A), right hand (B) and front (C) belt covers-2.0L engines



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    Fig. Location of the upper belt guide-2.0L engines



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    Fig. Location of the upper left belt guide-2.0L engines



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    Fig. Location of the lower right belt guide-2.0L engines



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    Fig. Location of the lower left belt guide-2.0L engines



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    Fig. Mark the upper belt-to-sprocket alignment-2.0L engines



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    Fig. Mark the lower belt-to-sprocket alignment-2.0L engines



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    Fig. Remove the belt idler (A)-2.0L engines


To install:

  1. To prepare the automatic belt tensioner for assembly, perform the following steps:
    1. Always use a vertical type pressing tool to move the adjuster rod down.
    2.  
    3. Do not use a lateral type vise.
    4.  
    5. Always push the adjuster rod vertically.
    6.  
    7. Make sure to slowly move the adjuster rod down applying a pressure of 66 lbs. (294 N).
    8.  
    9. Press in the push adjuster rod gradually taking more than 3 minutes.
    10.  
    11. Never allow the press pressure to exceed 2,205 lbs. (9,807 N).
    12.  
    13. Press the adjuster rod as far as the end surface of the cylinder. Do not press the rod into the cylinder as doing so may damage the cylinder.
    14.  
    15. Never release the press pressure until the stopper pin has been fully inserted.
    16.  

  2.  
  3. Attach the automatic belt tension adjuster assembly to the vertical pressing tool.
  4.  
  5. Move the adjuster rod down slowly using a pressure of 66 lbs. (294 N) until the rod is aligned with the stopper pin hole in the cylinder.
  6.  
  7. Insert a 0.08 inch (2mm) stopper pin or diameter Allen wrench into the stopper pin hole in the cylinder to retain the rod.
  8.  
  9. Install the adjuster assembly and tighten the retainers to 29 ft. lbs. (39 Nm).
  10.  
  11. Install belt idle 2 and tighten the retainers to 29 ft. lbs. (39 Nm).
  12.  
  13. Install the belt idler and tighten to 29 ft. lbs. (39 Nm).
  14.  
  15. Align the mark on the crankshaft sprocket with the mark on the oil pump.
  16.  
  17. Align the single line mark on the right hand exhaust camshaft sprocket with the notch on the belt cover.
  18.  
  19. Align the single line mark on the right hand intake camshaft with the notch on the belt cover. Make sure the double lines on the intake camshaft and exhaust sprockets are aligned as shown in the accompanying illustration.
  20.  
  21. Align the single line mark on the left hand exhaust camshaft sprocket with the notch on the belt cover by turning the sprocket counterclockwise (as viewed from the front of the engine).
  22.  
  23. Align the single line mark on the left hand intake camshaft sprocket with the notch on the belt cover by turning the sprocket counterclockwise (as viewed from the front of the engine). Make sure the double lines on the intake camshaft and exhaust sprockets are aligned as shown in the accompanying illustration.
  24.  


    Click image to see an enlarged view

    Fig. Attach the automatic belt tension adjuster assembly to the vertical pressing tool-2.0L engines



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    Fig. Insert a 0.08 inch (2mm) stopper pin or diameter Allen wrench into the stopper pin hole in the cylinder to retain the rod-2.0L engines



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    Fig. Install the adjuster assembly-2.0L engines



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    Fig. Align the mark on the crankshaft sprocket with the mark on the oil pump-2.0L engines



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    Fig. Align the single line mark on the right hand exhaust camshaft sprocket with the notch on the belt cover-2.0L engines



    Click image to see an enlarged view

    Fig. Align the single line mark on the right hand intake camshaft with the notch on the belt cover. Make sure the double lines on the intake camshaft and exhaust sprockets are aligned-2.0L engines



    Click image to see an enlarged view

    Fig. Align the single line mark on the left hand exhaust camshaft sprocket with the notch on the belt cover by turning the sprocket counterclockwise (as viewed from the front of the engine)-2.0L engines



    Click image to see an enlarged view

    Fig. Align the single line mark on the left hand intake camshaft sprocket with the notch on the belt cover by turning the sprocket counterclockwise (as viewed from the front of the engine). Make sure the double lines on the intake camshaft and exhaust sprockets are aligned-2.0L engines



NOTE
Make sure the camshaft and crankshaft sprockets are positioned correctly. The intake and exhaust camshafts on this engine can be rotated independently with the timing belt removed. By looking at the accompanying illustration it will show you that if the intake and exhaust valve are lift together the heads will hit each other and bend.


NOTE
When the timing belts are not installed, 4 camshafts are held at -zero lift- position, where all cams on the camshafts do not push the intake and exhaust valves down (under this condition all valves remain unlifted). When the camshafts are rotated to install the timing belts, # 2 intake and # 4 exhaust cam of the left hand camshafts are held to push their corresponding valves down. Under this condition these valves are held lifted. The right side camshafts are held in so that their cams do not push the valves down. The left hand camshafts must be rotated from the -zero lift- position to the position where the timing belt is to be installed at as small an angle as possible, in order to prevent mutual interference of intake and exhaust valve heads. Do not allow the camshafts to rotate in the direction illustrated as this causes both the intake and exhaust valves to lift off at the same time with will cause valve damage.

  1. When installing the belt, make sure to align the marks made during removal or if using a new belt, align the in alphabetical order as shown in the accompanying illustration.
  2.  


WARNING
Disengagement of more than 3 timing belt teeth may result in contact between the valve and piston. Always make sure the belts rotation is correct.



Click image to see an enlarged view

Fig. If the intake and exhaust valve are lift together the heads will hit each other and bend -2.0L engines



Click image to see an enlarged view

Fig. Do not allow the camshafts to rotate in the direction shown as this causes both the intake and exhaust valves to lift off at the same time with will cause valve damage-2.0L engines



Click image to see an enlarged view

Fig. Align the marks in alphabetical order as shown if using a new belt-2.0L engines

  1. Install the belt idlers and tighten to 29 ft. lbs. (39 Nm).
  2.  


WARNING
Make sure the marks on the belt and sprockets are properly aligned.

  1. Once the marks on the belt and sprockets are aligned, remove the stopper pin from the tensioner adjuster.
  2.  
  3. Install the timing belt guide on models with manual transmission. measure the clearance between the belt and guide. the clearance should be 0.019-0.059 inch (0.5-1.5mm) and tighten the retainers to 7 ft. lbs. (10 Nm).
  4.  
  5. Install the belt covers and tighten to 3.5 ft. lbs. (5 Nm).
  6.  
  7. Install the crankshaft pulley and tighten the bolt to 94 ft. lbs. (127 Nm).
  8.  
  9. Install the V-belt.
  10.  

 
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