SUBARU LEGACY 1999 Service Repair Manual

(1) Slowly press the adjuster rod down to the
end surface of the cylinder. Repeat this motion
2 or 3 times.
(2) With the adjuster rod moved all the way up,
apply a pressure of 294 N (30 kg, 66 lb) to it.
Check adjuster rod stiffness.
(3) If the adjuster rod is not stiff and moves
down, replace the automatic belt tension
adjuster assembly with a new one.
CAUTION:
IAlways use a vertical type pressing tool to
move the adjuster rod down.
IDo not use a lateral type vise.
IPush adjuster rod vertically.
IPress-in the push adjuster rod gradually tak-
ing more than three minutes.
IDo not allow press pressure to exceed 9,807
N (1,000 kg, 2,205 lb).
IPress the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
4) Measure the extension of rod beyond the body.
If it is not within specifications, replace with a new
one.
Rod extension: H
5.7
±0.5 mm (0.224±0.020 in)
H2M2381A
3. BELT TENSION PULLEY
1) Check mating surfaces of timing belt and con-
tact point of adjuster rod for abnormal wear or
scratches. Replace belt tension pulley if faulty.
2) Check belt tension pulley for smooth rotation.
Replace if noise or excessive play is noted.
3) Check belt tension pulley for grease leakage.
4. BELT IDLER
1) Check idler for smooth rotation. Replace if
noise or excessive play is noted.
2) Check outer contacting surfaces of idler pulley
for abnormal wear and scratches.
3) Check idler for grease leakage.
5. SPROCKET
1) Check sprocket teeth for abnormal wear and
scratches.
2) Make sure there is no free play between
sprocket and key.
3) Check crankshaft sprocket notch for sensor for
damage and contamination of foreign matter.
20
2-3b[W2B3]SERVICE PROCEDURE
2. Timing Belt

C: INSTALLATION
1. SPROCKET
H2M2404D
(1) Right-hand belt cover No. 2
(2) Left-hand belt cover No. 2
(3) Tensioner bracket
(4) Crankshaft sprocket
(5) Right-hand exhaust camshaft
sprocket(6) Right-hand intake camshaft
sprocket
(7) Left-hand exhaust camshaft
sprocket
(8) Left-hand intake camshaft
sprocketTightening torque: N´m (kg-m, ft-lb)
T1:
4.9±0.5 (0.5±0.05, 3.6±0.4)
T2:25±3 (2.5±0.3, 18.1±2.2)
T3:78±5 (8.0±0.5, 57.9±3.6)
1) Install right-hand belt cover No. 2.
B2M0738
2) Install left-hand belt cover No. 2.
S2M0415
3) Install tensioner bracket.
H2M2407
4) Install crankshaft sprocket.
S2M0414
21
[W2C1]2-3bSERVICE PROCEDURE
2. Timing Belt

5) Install right-hand exhaust camshaft sprocket.
To lock camshaft, use ST.
6) Install right-hand intake camshaft sprocket
using ST.
7) Install left-hand exhaust camshaft sprocket
using ST.
8) Install left-hand intake camshaft sprocket using
ST.
ST 499207300 CAMSHAFT SPROCKET
WRENCH
S2M0413A
2. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
H2M2400D
(1) Automatic belt tension adjuster
ASSY
(2) Belt idler No. 2(3) Belt idlerTightening torque: N´m (kg-m, ft-lb)
T1:
39±4 (4.0±0.4, 28.9±2.9)
22
2-3b[W2C2]SERVICE PROCEDURE
2. Timing Belt

1) Preparation for installation of automatic belt
tension adjuster assembly:
CAUTION:
IAlways use a vertical type pressing tool to
move the adjuster rod down.
IDo not use a lateral type vise.
IPush adjuster rod vertically.
IBe sure to slowly move the adjuster rod
down applying a pressure of 294 N (30 kg, 66
lb).
IPress-in the push adjuster rod gradually tak-
ing more than three minutes.
IDo not allow press pressure to exceed 9,807
N (1,000 kg, 2,205 lb).
IPress the adjuster rod as far as the end sur-
face of the cylinder. Do not press the adjuster
rod into the cylinder. Doing so may damage the
cylinder.
IDo not release press pressure until stopper
pin is completely inserted.
(1) Attach the automatic belt tension adjuster
assembly to the vertical pressing tool.
(2) Slowly move the adjuster rod down with a
pressure of 294 N (30 kg, 66 lb) until the
adjuster rod is aligned with the stopper pin hole
in the cylinder.
H2M2382
(3) Witha2mm(0.08 in) dia. stopper pin or a
2 mm (0.08 in) (nominal) dia. hex bar wrench
inserted into the stopper pin hole in the cylinder,
secure the adjuster rod.
H2M2383A
2) Install Automatic belt tension adjuster assem-
bly.
S2M0416
3) Install belt idler No. 2.
S2M0411
4) Install belt idler.
S2M0410
23
[W2C2]2-3bSERVICE PROCEDURE
2. Timing Belt

3. TIMING BELT
S2M0295B
(1) Timing belt
(2) Belt idler
(3) Timing belt guide (MT vehicles
only)(a) Alignment mark (Timing belt
side)
(b) Alignment mark (Sprocket side)Tightening torque: N´m (kg-m, ft-lb)
T1:
9.8±1.0 (1.0±0.1, 7.2±0.7)
T2:39±4 (4.0±0.4, 28.9±2.9)
1) Crankshaft and camshaft sprocket alignment.
(1) Align mark on crankshaft sprocket with
mark on the oil pump cover at cylinder block.
S2M0417A
(2) Align single line mark on right-hand exhaust
camshaft sprocket with notch on belt cover.
B2M0694A
(3) Align single line mark on right-hand exhaust
camshaft sprocket with notch on belt cover.
(Make sure double lines on intake camshaft and
exhaust camshaft sprockets are aligned.)
B2M0695A
24
2-3b[W2C3]SERVICE PROCEDURE
2. Timing Belt

(4) Align single line mark on left-hand exhaust
camshaft sprocket with notch on belt cover by
turning sprocket counter-clockwise (as viewed
from front of engine).
B2M0696A
(5) Align single line mark on left-hand intake
camshaft sprocket with notch on belt cover by
turning sprocket clockwise (as viewed from front
of engine).
Ensure double lines on intake and exhaust cam-
shaft sprockets are aligned.
B2M0697A
(6) Ensure camshaft and crankshaft sprockets are positioned as shown.
G2M0734
25
[W2C3]2-3bSERVICE PROCEDURE
2. Timing Belt

CAUTION:
IIntake and exhaust camshafts for this DOHC
engine can be independently rotated with tim-
ing belts removed. As can be seen from the
figure, if intake and exhaust valves are lifted
simultaneously, their heads will interfere with
each other, resulting in bent valves.
B2M1392A
IWhen timing belts are not installed, four
camshafts are held at the ªzero-liftº position,
where all cams on camshafts do not push
intake and exhaust valves down. (Under this
condition, all valves remain unlifted.)
IWhen camshafts are rotated to install timing
belts, #2 intake and #4 exhaust cam of left-hand
camshafts are held to push their correspond-
ing valves down. (Under this condition, these
valves are held lifted.) Right-side camshafts
are held so that their cams do not push valves
down.
ILeft-hand camshafts must be rotated from
the ªzero-liftº position to the position where
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.
IDo not allow camshafts to rotate in the direc-
tion shown in the figure as this causes both
intake and exhaust valves to lift
simultaneously, resulting in interference with
their heads.
B2M0698A
26
2-3b[W2C3]SERVICE PROCEDURE
2. Timing Belt

2) Installation of timing belt
S2M0418
Align alignment mark on timing belt with marks on sprockets in the alphabetical order shown in figure. While
aligning marks, position timing belt properly.
CAUTION:
IDisengagement of more than three timing belt teeth may result in interference between the valve
and piston.
IEnsure belt's rotating direction is correct.
S2M0296A
3) Install belt idler.
CAUTION:
Make sure that the marks on timing belt and
sprockets are aligned.
H2M2398
4) After ensuring that the marks on timing belt and
sprockets are aligned, remove stopper pin from
tensioner adjuster.
S2M0419
27
[W2C3]2-3bSERVICE PROCEDURE
2. Timing Belt

5) Install timing belt guide. (MT vehicles only)
(1) Temporarily tighten remaining bolts.
S2M0294
(2) Check and adjust clearance between timing
belt and timing belt guide.
Clearance:
1.0
±0.5 mm (0.039±0.020 in)
S2M0297
(3) Tighten remaining bolts.
H2M2416
4. CRANKSHAFT PULLEY AND BELT COVER
B2M1705D
(1) Front belt cover
(2) Right-hand belt cover No. 1
(3) Left-hand belt cover No. 1
(4) Crankshft pulley(5) Crankshaft pulley boltTightening torque: N´m (kg-m, ft-lb)
T1:
4.9±0.5 (0.5±0.05, 3.6±0.4)
T2:177±10 (18.0±1.0, 130±7)
28
2-3b[W2C4]SERVICE PROCEDURE
2. Timing Belt

1) Install front belt cover.
B2M0731
2) Install right-hand belt cover.
B2M0730
3) Install left-hand belt cover.
B2M0729
4) Install crankshaft pulley.
5) Tighten pulley bolt by using ST.
ST 499977100 CRANKSHAFT PULLEY
WRENCH
H2M2393A
6) Install V-belt, air conditioning compressor drive
belt tensioner and V-belt cover. [G2B0].>
CAUTION:
After installing V-belt, check and adjust V-belt
tension.
B2M1706
29
[W2C4]2-3bSERVICE PROCEDURE
2. Timing Belt