Subaru Forester 1998-05

Timing Belt, Cover, Sprockets, & Seal

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Removal & Installation



DOHC Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the belt cover as follows:
    1. Remove the V-belt.
    2.  
    3. Crankshaft pulley.
    4.  
    5. Left hand belt cover.
    6.  
    7. Right hand belt cover.
    8.  
    9. Front belt cover.
    10.  

  6.  
  7. Remove the timing belt guides.
  8.  
  9. 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.  

  10.  
  11. Remove the belt idler (A), shown in the accompanying illustration.
  12.  
  13. Remove the timing belt.
  14.  
  15. If necessary, remove belt idlers (B) and (C).
  16.  
  17. Remove the belt idler 2.
  18.  
  19. Remove the automatic belt tension adjuster assembly.
  20.  


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    Fig. Location of the upper belt guide-DOHC engines



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    Fig. Location of the upper left belt guide-DOHC engines



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    Fig. Location of the lower right belt guide-DOHC engines



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    Fig. Location of the lower left belt guide-DOHC engines



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    Fig. Mark the upper belt-to-sprocket alignment-DOHC engines



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    Fig. Mark the lower belt-to-sprocket alignment-DOHC engines



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    Fig. Remove the belt idler (A)-DOHC 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.  


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



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    Fig. Install the adjuster assembly-DOHC engines



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



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    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-DOHC engines



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    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)-DOHC engines



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    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-DOHC 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 lifted 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.



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Fig. If the intake and exhaust valve are lifted together the heads will hit each other and bend -DOHC engines



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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-DOHC engines



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Fig. Align the marks in alphabetical order as shown if using a new belt-DOHC 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 guides. Measure the clearance between the belt and guide. the clearance should be 0.019-0.059 inch (0.5-1.5mm) and tighten the upper belt guide retainers to 7 ft. lbs. (10 Nm) and the remaining belt guides, tighten the retainers to 5 ft. lbs. (6.6 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 132 ft. lbs. (180 Nm).
  8.  
  9. Install the V-belt.
  10.  

SOHC Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  

When servicing the timing belt, note the following:

  1. The intake and exhaust camshafts can be rotated independently when the timing belt is removed. If the intake and exhaust valves are lifted off of their seats simultaneously, their heads will contact each other, possibly causing damage.
  2.  
  3. When the timing belt is removed, the camshafts are positioned so that none of the valves are lifted off of their seats, resulting in a -zero-lift- position.
  4.  
  5. The left-hand cylinder head camshafts must be rotated from the -zero-lift- position as little as possible when orienting it for timing belt installation, otherwise possible valve head interference may occur.
  6.  
  7. Never allow the camshafts to rotate in the direction shown in the accompanying illustration, which would cause both the intake and exhaust valves to lift simultaneously, causing interference.
  8.  



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Fig. Remove the timing belt guide on vehicles equipped with manual transmission-SOHC engine



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Fig. Before removing the timing belt, turn the crankshaft sprocket until all of the alignment marks are aligned as indicated-SOHC engine

  1. Remove all necessary components to gain access to the timing belt.
  2.  
  3. If equipped with manual transmissions, loosen the 2 timing belt guide mounting bolts, then separate the guide from the engine block.
  4.  
  5. If the directional arrow and alignment marks on the timing belt are faded, and the belt is to be reused, remark the belt with white paint or a grease pencil as follows:
    1. Using a Subaru tool No. ST-499987500 Crankshaft Socket, or equivalent, installed on the crankshaft sprocket, rotate the crankshaft until the crankshaft sprocket, left-hand exhaust camshaft sprocket, left-hand intake camshaft sprocket, right-hand intake camshaft sprocket and right-hand exhaust camshaft sprocket timing mark notches are aligned with the respective marks on the belt cover and engine block.
    2.  


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      Fig. If the original marks on the timing belt are worn or faded, make new alignment marks in the positions indicated-SOHC engine

    3. Make alignment and/or arrow marks on the timing belt in relation to the sprockets as indicated in the accompanying illustration.
    4.  



    Z1: 46.8 tooth length
     
    Z2: 43.7 tooth length
     

  6.  
  7. Loosen the center bolt from the timing belt idler pulley, then remove the idler pulley from the engine block.
  8.  


WARNING
After removing the timing belt, DO NOT rotate the camshafts. Damage to the valves may occur.

  1. Carefully remove the timing belt from all of the sprockets.
  2.  
  3. Remove the automatic belt tension adjuster assembly as follows:
    1. Remove the 2 timing belt idler pulleys, as indicated in the accompanying illustration.
    2.  
    3. Loosen the automatic tension adjuster assembly mounting bolts, then separate the adjuster assembly from the engine block.
    4.  

  4.  


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    Fig. It is necessary to remove the automatic adjuster assembly and reset the pushrod for timing belt installation-SOHC engine


To install:


WARNING
Do not allow oil, grease, or coolant to come in contact with the timing belt. If this occurs, quickly and thoroughly remove all traces of the compound. Also, never bend the timing belt sharply; the minimum bending radius is 2.36 in. (60mm).



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Fig. Never bend the timing belt into a radius tighter than 2.36 in./60mm (h), otherwise it will be damaged beyond-SOHC engine



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Fig. Use a vertical press to push the adjuster rod into its housing until it is flush with the assembly-s outer surface . . .



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Fig. . . . then insert a 0.08 in. (2mm) diameter pin or Allen wrench into the housing and rod holes to hold it in position-SOHC engine

  1. Inspect the camshaft and crankshaft sprocket teeth for abnormal or excessive wear or scratches. Ensure there is no free-play between the sprocket and the key. Inspect the crankshaft sprocket sensor notch for damage or contamination with debris or dirt.
  2.  


NOTE
When preparing the automatic tension adjuster assembly for installation, adhere to the following points:



Always use a vertical press, rather than a horizontal press or vise, to depress the adjuster assembly rod
 
Depress the adjuster rod in a vertical position ONLY
 
Depress the adjuster rod slowly (taking more than 3 minutes) with a force of 66 lbs. (30 kg)
 
Do not allow the press force to exceed 2205 lbs. (1000 kg)
 
Press the adjuster rod in as far as the end surface of the cylinder - do not press the rod into the cylinder, which may cause damage to the assembly
 
Do not release the press force from the rod until the stopper pin is completely inserted in the cylinder
 

  1. Prepare the automatic timing belt tension adjuster assembly for installation as follows:
    1. Position the adjuster assembly in a vertical press.
    2.  
    3. Slowly depress the adjuster rod with a force of 66 lbs. (30 kg) until the hole in the rod is aligned with the hole in the adjuster cylinder housing.
    4.  
    5. Insert a 0.08 in. (2mm) diameter stopper pin or Allen wrench through the hole in the cylinder housing and rod, then slowly release the press force from the adjuster rod.
    6.  

  2.  
  3. Install the adjuster assembly onto the engine block.
  4.  
  5. Install timing belt idler pulley No. 2 on the engine block. Tighten the bolts to 28 ft. lbs. (39 Nm).
  6.  
  7. Install the timing belt idler pulley No. 1 on the engine block. Tighten the bolts to 28 ft. lbs. (39 Nm).
  8.  
  9. If the camshaft and crankshaft timing marks are no longer aligned, perform the following:
    1. Position the crankshaft sprocket so that its mark is aligned with the mark on the oil pump cover on the engine block.
    2.  


      Click image to see an enlarged view

      Fig. Make sure the sprockets are aligned as shown-SOHC engine



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      Fig. After installing the timing belt, the alignment marks should be positioned as shown. If not, remove the belt and align the sprockets and reinstall the belt-SOHC engine

    3. Align the single line mark on the right-hand exhaust camshaft sprocket with the notch on the belt cover.
    4.  
    5. Rotate the right-hand intake camshaft so that the single line mark is aligned with the notch on the belt cover.
    6.  

  10.  


NOTE
At this point, the double line marks on both right-hand camshaft sprockets should be aligned.

  1. Turn the left-hand exhaust (lower) camshaft counterclockwise (as viewed from the front of the engine) until the single line mark is aligned with the notch on the belt cover.
  2.  
  3. Position the single line mark on the left-hand intake camshaft sprocket so that it is aligned with the notch on the belt cover. When rotating the camshaft, do so only in a clockwise direction (as viewed from the front of the engine).
  4.  


NOTE
At this point, the double line marks on both left-hand camshaft sprockets should be aligned.

  1. Ensure the timing marks are aligned as shown in the accompanying illustration. If they are not, repeat Substeps 12a through 12e until they are properly aligned.
  2.  

  1. Install the timing belt around the camshaft, crankshaft and idler pulleys so that the positioning marks on the timing belt are aligned with the marks on the sprockets as follows:
    1. Position the timing belt on the crankshaft sprocket so that the marks are aligned.
    2.  
    3. Route the belt down and under the left-hand, upper idler pulley, then up and around the left-hand intake camshaft sprocket, ensuring the camshaft sprocket mark is aligned with the mark on the belt.
    4.  
    5. Route the belt down and around the left-hand exhaust camshaft sprocket, making sure the marks are properly aligned, then up and over the first lower idler pulley and down and around the second lower idler pulley.
    6.  
    7. While holding the timing belt on the inner, left-hand, lower idler pulley, route the other side of the timing belt (from the crankshaft sprocket) down and under the right-hand upper idler pulley.
    8.  
    9. Route the timing belt up and around the right-hand intake camshaft sprocket so that the belt and sprocket marks are aligned.
    10.  
    11. Position the belt down and around the right-hand exhaust camshaft sprocket, ensuring the positioning marks are aligned.
    12.  

  2.  
  3. Install the right-hand lower idler pulley so that the timing belt is routed over the top side of it.
  4.  


NOTE
Once the belt is completely installed on all of the pulleys and sprockets, ensure that the positioning marks are still all aligned.

  1. After ensuring all of the marks are still aligned, use a pair of pliers to withdraw the stopper pin or Allen wrench from the adjuster assembly housing.
  2.  
  3. On models with manual transmissions, perform the following:
    1. Install the timing belt guide by temporarily tightening the mounting bolts.
    2.  
    3. Position the timing belt guide so that there is 0.019-0.059 in. (0.5-1.5mm) clearance between the timing belt and the belt guide.
    4.  


      Click image to see an enlarged view

      Fig. On models equipped with manual transmissions, ensure the timing belt-to-guide clearance (arrows) is correct before tightening the mounting bolts-SOHC engine



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      Fig. On models equipped with manual transmissions, use a feeler gauges to adjust the clearance between the timing belt and the belt guide-SOHC engine

    5. Tighten the guide mounting bolts securely, then double check the guide clearance.
    6.  

  4.  
  5. Install the timing belt covers and all remaining engine components.
  6.  

 
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