Subaru Forester 1998-05

Timing Belt & Sprockets

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Removal & Installation



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.

    Click image to see an enlarged view

    Fig. Remove the timing belt guide on vehicles equipped with manual transmission-1999-2004 SOHC engine shown



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    Fig. Before removing the timing belt, turn the crankshaft sprocket until all of the alignment marks are aligned as indicated-1999-2004 SOHC engine shown

  8.  

  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.

      Click image to see an enlarged view

      Fig. If the original marks on the timing belt are worn or faded, make new alignment marks in the positions indicated-1999-2004 SOHC engine shown

    2.  
    3. Make alignment and/or arrow marks on the timing belt in relation to the sprockets as indicated in the accompanying illustration.

      Z1: 46.8 tooth length
       
      Z2: 43.7 tooth length
       

    4.  

  6.  
  7. Loosen the center bolt from the timing belt idler pulley, then remove the idler pulley from the engine block.
    WARNING
    After removing the timing belt, DO NOT rotate the camshafts. Damage to the valves may occur.

  8.  
  9. Carefully remove the timing belt from all of the sprockets.

    Click image to see an enlarged view

    Fig. It is necessary to remove the automatic adjuster assembly and reset the pushrod for timing belt installation-1999-2004 SOHC engine shown

  10.  
  11. 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.  

  12.  

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-1999-2004 SOHC engine shown



Click image to see an enlarged view

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-1999-2004 SOHC engine shown

  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.
    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
     

  2.  
  3. 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.  

  4.  
  5. Install the adjuster assembly onto the engine block.
  6.  
  7. Install timing belt idler pulley No. 2 on the engine block. Tighten the bolts to 28 ft. lbs. (39 Nm).
  8.  
  9. Install the timing belt idler pulley No. 1 on the engine block. Tighten the bolts to 28 ft. lbs. (39 Nm).
  10.  
  11. 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.

      Click image to see an enlarged view

      Fig. Make sure the sprockets are aligned as shown-1999-2004 SOHC engine shown



      Click image to see an enlarged view

      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-1999-2004 SOHC engine shown

    2.  
    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.
      NOTE
      At this point, the double line marks on both right-hand camshaft sprockets should be aligned.

    6.  
    7. 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.
    8.  
    9. 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).
      NOTE
      At this point, the double line marks on both left-hand camshaft sprockets should be aligned.

    10.  
    11. Ensure the timing marks are aligned as shown in the accompanying illustration. If they are not, repeat Sub-steps 12a through 12e until they are properly aligned.
    12.  

  12.  
  13. 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.  

  14.  
  15. Install the right-hand lower idler pulley so that the timing belt is routed over the top side of it.
    NOTE
    Once the belt is completely installed on all of the pulleys and sprockets, ensure that the positioning marks are still all aligned.

  16.  
  17. 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.
  18.  
  19. 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.

      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-1999-2004 SOHC engine shown



      Click image to see an enlarged view

      Fig. On models equipped with manual transmissions, use a feeler gauges to adjust the clearance between the timing belt and the belt guide-1999-2004 SOHC engine shown

    4.  
    5. Tighten the guide mounting bolts securely, then double check the guide clearance.
    6.  

  20.  
  21. Install the timing belt covers and all remaining engine components.
  22.  

  1. Disconnect the negative battery cable.
  2.  
  3. To remove the front side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the front side belt.
  4.  
  5. To remove the rear side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the rear side belt. Remove the belt tensioner.
  6.  
  7. Remove the crankshaft pulley bolt.
  8.  
  9. Lock the crankshaft in place using tool ST499977100, or equivalent.
  10.  
  11. Remove the crankshaft pulley.
  12.  
  13. Remove the left side timing belt cover.
  14.  
  15. Remove the front timing belt cover.
  16.  
  17. If equipped with manual transmission, remove the timing belt guide.
    NOTE
    If the belt is going to be reused and the alignment mark on the belt is not readable, put a new mark on the belt to indicate the direction of rotation. Using tool ST499987500, turn the crankshaft to align the mark of the sprocket -A- to the cylinder mark notch -B-. Ensure that the right side cam sprocket mark -C-, cam cap and cylinder head matching surface -D- or left side cam sprocket mark -E-, timing belt cover notch -F- are properly aligned. Paint an alignment mark on the belt in relation to the crankshaft sprocket and camshaft sprockets. Z1 measurement is 46.8 teeth. Z2 measurement is 43.7 teeth.



    Click image to see an enlarged view

    Fig. Timing belt alignment-2005 SOHC engine



    Click image to see an enlarged view

    Fig. Timing belt Z1 and Z2 teeth measurement-2005 SOHC engine

  18.  
  19. Remove both the number two belt idlers. Remove the timing belt from the engine.
  20.  
  21. Remove the number one belt idler. Remove the automatic belt tension adjuster assembly.
  22.  

To install:

  1. Attach the automatic belt tension adjuster assembly to a vertical pressing tool.
    NOTE
    Always use a vertical type pressing tool to move the adjuster rod downward. Do not use a lateral type vise. Push the adjuster rod vertically. Press in the push adjuster rod gradually, which should take three minutes or more. Do not allow pressure to exceed 2,205 lb. force.

  2.  
  3. Slowly move the adjuster rod down until the adjuster rod is aligned with the stopper pin hole in the cylinder.
    NOTE
    Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.

  4.  
  5. Using a 0.08 inch stopper pin, insert it into the stopper pin hole in the cylinder. Secure the adjuster rod.
    NOTE
    Do not release the press pressure until the stopper pin is completely inserted in the hole.

  6.  
  7. Install the automatic belt tensioner assembly. Tighten the retaining bolt to 28.9 ft. lbs.
  8.  
  9. Install the belt idler number one. Tighten the retaining bolt to 28.9 ft. lbs.
  10.  
  11. Turn the number one and number two camshaft sprockets, using tool ST499207100 or tool ST18231AA010 and position the alignment marks -A- on each at the highest position.

    Click image to see an enlarged view

    Fig. Timing mark alignment position A-2005 SOHC engine



    Click image to see an enlarged view

    Fig. Timing mark alignment position B-2005 SOHC engine

  12.  
  13. While aligning the alignment mark -B- on the timing belt with mark -A- on the sprockets, position the timing belt properly.
  14.  
  15. Install both belt idler number two-s. Tighten the retaining bolt to 28.9 ft. lbs.

    Click image to see an enlarged view

    Fig. Belt idler number two locations-2005 SOHC engine

  16.  
  17. After checking to be sure the marks on the timing belt and the camshaft sprockets are aligned remove the stopper pin from the belt tension adjuster.
  18.  
  19. Install the timing belt guide, if equipped with manual transmission. Temporarily tighten the bolts. Check and adjust the clearance between the belt and the guide. It should be 0.039 +/- 0.020 inch. Tighten the bolts to 7.2 ft. lbs.
  20.  
  21. Continue the installation in the reverse order of the removal procedure.
  22.  

Turbo Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the collector cover.
  4.  
  5. To remove the front side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the front side belt.
  6.  
  7. To remove the rear side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the rear side belt. Remove the belt tensioner.
  8.  
  9. Remove the crankshaft pulley bolt.
  10.  
  11. Lock the crankshaft in place using tool ST499977100, or equivalent.
  12.  
  13. Remove the crankshaft pulley.
  14.  
  15. Remove the left side timing belt cover.
  16.  
  17. Remove the right side timing belt cover.
  18.  
  19. Remove the front timing belt cover.
  20.  
  21. Remove the timing belt guide, if equipped.
    NOTE
    If the belt is going to be reused and the alignment mark on the belt is not readable, put a new mark on the belt to indicate the direction of rotation. Using tool ST499987500, turn the crankshaft to align the mark on the crankshaft sprocket, intake camshaft sprocket (left), exhaust camshaft sprocket (left), intake camshaft sprocket (right), exhaust camshaft sprocket (right) with the notches of the timing belt cover and cylinder block. Paint an alignment mark on the belts in relation to the camshaft sprockets. Z1 measurement is 54.4 teeth. Z2 measurement is 51.0 teeth and Z3 measurement is 28.0 teeth.



    Click image to see an enlarged view

    Fig. Timing belt alignment-DOHC (Turbo) engine



    Click image to see an enlarged view

    Fig. Timing belt Z1, Z2 and Z3 teeth measurement- DOHC (Turbo) engine

  22.  
  23. Remove the belt idler belt -A-. Remove the timing belt.
  24.  
  25. Remove the belt idlers belt -B- and -C-.

    Click image to see an enlarged view

    Fig. Belt idler identification and location- DOHC (Turbo) engine

  26.  
  27. Remove the belt idler number two. Remove the automatic belt tension adjuster assembly.
  28.  

To install:

  1. Attach the automatic belt tension adjuster assembly to a vertical pressing tool.
    NOTE
    Always use a vertical type pressing tool to move the adjuster rod downward. Do not use a lateral type vise. Push the adjuster rod vertically. Press in the push adjuster rod gradually, which should take three minutes or more. Do not allow pressure to exceed 2,205 lb. force.

  2.  
  3. Slowly move the adjuster rod down until the adjuster rod is aligned with the stopper pin hole in the cylinder.
    NOTE
    Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.

  4.  
  5. Using a 0.08 inch stopper pin, insert it into the stopper pin hole in the cylinder. Secure the adjuster rod.
    NOTE
    Do not release the press pressure until the stopper pin is completely inserted in the hole.

  6.  
  7. Install the automatic belt tensioner assembly. Tighten the retaining bolt to 28.9 ft. lbs.
  8.  
  9. Install the belt idler number two. Tighten the retaining bolt to 28.9 ft. lbs.
  10.  
  11. Install the belt idlers. Tighten the retaining bolts to 28.9 ft. lbs.
  12.  
  13. Align the mark -A- on the crankshaft sprocket with the mark on the oil pump at the cylinder block.
  14.  
  15. Align the single line mark -A- on the right exhaust camshaft sprocket with the notch -B- on the timing belt cover.
  16.  
  17. Align single line mark -A- on the right intake camshaft sprocket with the notch -B- on the timing cover. Ensure that the double lines -C- on the intake and exhaust camshaft sprockets are aligned.
  18.  
  19. Align single line mark -A- on the left exhaust camshaft sprocket with the notch -B- on the timing cover by turning the sprocket counterclockwise as viewed from the front of the engine.
  20.  
  21. Align single line mark -A- on the left intake camshaft sprocket with the notch -B- on the timing cover, by turning the sprocket clockwise as viewed from the front of the engine. Ensure that the double lines -C- on the intake and exhaust camshaft sprockets are aligned.

    Click image to see an enlarged view

    Fig. Crankshaft sprocket mark A to oil pump cover alignment- DOHC (Turbo) engine



    Click image to see an enlarged view

    Fig. Right exhaust camshaft sprocket alignment mark A with timing belt cover B alignment mark- DOHC (Turbo) engine



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    Fig. Right intake camshaft sprocket alignment mark A with timing belt cover B alignment mark an double line C alignment mark- DOHC (Turbo) engine



    Click image to see an enlarged view

    Fig. Left exhaust camshaft sprocket alignment mark A with timing belt cover B alignment mark-2005- DOHC (Turbo) engine



    Click image to see an enlarged view

    Fig. Left intake camshaft sprocket alignment mark A with timing belt cover B alignment mark an double line C alignment mark- DOHC (Turbo) engine

  22.  
  23. Make sure that the camshaft and crankshaft sprockets are positioned properly.
    NOTE
    The intake and exhaust camshafts on this engine can be rotated independently with the timing belt removed. By looking at the 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, No. 2 intake and No. 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.

  24.  
  25. 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 illustration.
    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 lifted together the heads will hit each other and bend - DOHC (Turbo) engine



    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- DOHC (Turbo) engine

  26.  
  27. Install the timing belt.
    NOTE
    Align the alignment mark on the timing belt with marks on the sprocket in the order shown in the illustration. While aligning the timing marks, position the timing belt properly.



    Click image to see an enlarged view

    Fig. Timing belt alignment and installation sequence- DOHC (Turbo) engine

  28.  
  29. Install the belt idlers. Tighten the retaining bolts to 28.9 ft. lbs.
    NOTE
    Make sure that the marks on the timing belt and sprockets are aligned.

  30.  
  31. After checking to be sure the marks on the timing belt and the camshaft sprockets are aligned remove the stopper pin from the belt tension adjuster.
  32.  
  33. Install the timing belt guide, if equipped with manual transmission. Temporarily tighten the bolts. Check and adjust the clearance between the belt and the guide. It should be 0.039 +/- 0.020 inch. Tighten the guide bolts to specification, see illustration.
  34.  
  35. Continue the installation in the reverse order of the removal procedure.

    Click image to see an enlarged view

    Fig. Timing belt guide bolt location and tightening specification- DOHC (Turbo) engine

  36.  

 
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