SUBARU LEGACY 1999 Service Manual PDF

3) Remove crankshaft sprocket.
B2M2600A
S2M0414A
4) Remove belt cover No. 2 (LH).
5) Remove belt cover No. 2 (RH).
CAUTION:
Do not damage or lose the seal rubber when
removing belt covers.
B2M2601
6) Remove tensioner bracket.
H2M2380
B: INSPECTION
1. TIMING BELT
1) Check timing belt teeth for breaks, cracks, and
wear. If any fault is found, replace belt.
2) Check the condition of back side of belt; if any
crack is found, replace belt.
CAUTION:
IBe careful not to let oil, grease or coolant
contact the belt. Remove quickly and thor-
oughly if this happens.
IDo not bend the belt sharply.
Bending radius: h
60 mm (2.36 in) or more
G2M0115
2. AUTOMATIC BELT TENSION
ADJUSTER
1) Visually check oil seals for leaks, and rod ends
for abnormal wear or scratches. If necessary,
replace faulty parts.
CAUTION:
Slight traces of oil at rod's oil seal does not
indicate a problem.
2) Check that the adjuster rod does not move
when a pressure of 294 N (30 kg, 66 lb) is applied
to it. This is to check adjuster rod stiffness.
3) If the adjuster rod is not stiff and moves freely
when applying 294 N (30 kg, 66 lb), check it using
the following procedures:
(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.
18
2-3a[W2B1]SERVICE PROCEDURE
2. Timing Belt

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 automatic belt tension adjuster
assembly if faulty.
2) Check tension pulley for smooth rotation.
Replace if noise or excessive play is noted.
3) Check tension pulley for grease leakage.
4. BELT IDLER
1) Check belt idler for smooth rotation. Replace if
noise or excessive play is noted.
2) Check belt outer contacting surfaces of idler
pulley for abnormal wear and scratches.
3) Check belt idler for grease leakage.
5. CAMSHAFT AND CRANKSHAFT
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.
C: INSTALLATION
1. CAMSHAFT AND CRANKSHAFT SPROCKET
B2M2598A
(1) Tensioner bracket
(2) Belt cover No. 2 (RH)
(3) Belt cover No. 2 (LH)
(4) Crankshaft sprocket(5) Camshaft sprocket No. 1
(6) Camshaft sprocket No. 2Tightening torque: N´m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:25±3 (2.5±0.3, 18.1±2.2)
T3:78±5 (8.0±0.5, 57.9±3.6)
19
[W2C1]2-3aSERVICE PROCEDURE
2. Timing Belt

1) Install tensioner bracket.
H2M2380
2) Install belt cover No. 2 (RH).
3) Install belt cover No. 2 (LH).
B2M2601
4) Install crankshaft sprocket.
B2M2600A
S2M0414A
5) Install camshaft sprocket No. 1. To lock
camshaft, use ST.
ST 499207400 CAMSHAFT SPROCKET
WRENCH
B2M2599A
6) Install camshaft sprocket No. 2. To lock
camshaft, use ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH
CAUTION:
Do not confuse left and right side camshaft
sprockets during installation. The camshaft
sprocket No. 2 is identified by a projection
used to monitor camshaft position sensor.
H2M2377A
20
2-3a[W2C1]SERVICE PROCEDURE
2. Timing Belt

2. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
B2M2595A
(1) Automatic belt tension adjuster
ASSY(2) Belt idler (No. 1)Tightening torque: N´m (kg-m, ft-lb)
T:
39±4 (4.0±0.4, 28.9±2.9)
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
21
[W2C2]2-3aSERVICE PROCEDURE
2. Timing Belt

(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.
H2M2384
3) Install belt idler (No. 1).
B2M2596
22
2-3a[W2C2]SERVICE PROCEDURE
2. Timing Belt

3. TIMING BELT
B2M2588A
(a) Alignment mark
(1) Timing belt
(2) Belt idler No. 2
(3) Belt idler (No. 2)(4) Timing belt guide (MT vehicles
only)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) Installation of timing belt
(1) Turn camshaft sprocket No. 2 using ST1,
and turn camshaft sprocket No. 1 using ST2 so
that their alignment marks come to top posi-
tions.
ST1 499207100 CAMSHAFT SPROCKET
WRENCH
ST2 499207400 CAMSHAFT SPROCKET
WRENCH
B2M2602A
(2) While aligning alignment mark on timing
belt with marks on sprockets, position timing
belt properly.
CAUTION:
Ensure belt's rotating direction is correct.
B2M2603A
23
[W2C3]2-3aSERVICE PROCEDURE
2. Timing Belt

2) Install belt idler No. 2.
3) Install belt idler (No. 2).
B2M2593
4) After ensuring that the marks on timing belt and
camshaft sprockets are aligned, remove stopper
pin from belt tensioner adjuster.
CAUTION:
After properly installing timing belt, remove
rocker cover and ensure that the valve lash
adjuster contains no air.
H2M2387A
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.
H2M2415
24
2-3a[W2C3]SERVICE PROCEDURE
2. Timing Belt

4. CRANKSHAFT PULLEY AND BELT COVER
B2M2583B
(1) Front belt cover
(2) Belt cover (LH)
(3) Crankshaft pulley
(4) Crankshaft pulley bolt(5) Rear side V-belt (With A/C
model)
(6) Front side V-beltTightening torque: N´m (kg-m, ft-lb)
T1:
5±1 (0.5±0.1, 3.6±0.7)
T2:127+10/þ5(13.0+1.0/þ0.5,
94+7.2/þ3.6)
1) Install front belt cover.
2) Install belt cover (LH).
B2M2587A
3) Install crankshaft pulley.
4) Install pulley bolt.
To lock crankshaft, use ST.
ST 499977000 CRANKSHAFT PULLEY
WRENCH
(1) Clean the crankshaft pulley thread using an
air gun.
(2) Apply engine oil to the crankshaft pulley bolt
seat and thread.
(3) Tighten the bolts temporarily with tightening
torque of 44 N´m (4.5 kg-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts.
Tightening torque:
127
±5 N´m (13.0±0.5 kg-m, 94.0±3.6 ft-lb)
B2M2586A
5) Confirm that the tightening angle of the crank-
shaft pulley bolt is 45 degrees or more. If not, con-
duct the following procedures (1) through (4).
25
[W2C4]2-3aSERVICE PROCEDURE
2. Timing Belt

(1) Replace the crankshaft pulley bolts and
clean them.
Crankshaft pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Tighten the bolts temporarily with tightening
torque of 44 N´m (4.5 kg-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts keeping
them in an angle between 45 degrees and 60
degrees.
CAUTION:
Conduct the tightening procedures by confirm-
ing the turning angle of the crankshaft pulley
bolt referring to the gauge indicated on the belt
cover.
6) Install A/C belt tensioner. (With A/C model)
B2M2585
7) Install A/C belt. (With A/C model)
B2M2584
3. Valve Rocker Assembly
A: REMOVAL
B2M2604A
(1) Rocker cover
(2) Intake valve rocker ASSY(3) Exhaust valve rocker ASSY
(4) Spark plug pipe gasket
26
2-3a[W3A0]SERVICE PROCEDURE
3. Valve Rocker Assembly

(1) Replace the crankshaft pulley bolts and
clean them.
Crankshaft pulley bolt:
12369AA011
(2) Clean the crankshaft thread using an air
gun.
(3) Tighten the bolts temporarily with tightening
torque of 44 N´m (4.5 kg-m, 33 ft-lb).
(4) Tighten the crankshaft pulley bolts keeping
them in an angle between 45 degrees and 60
degrees.
CAUTION:
Conduct the tightening procedures by confirm-
ing the turning angle of the crankshaft pulley
bolt referring to the gauge indicated on the belt
cover.
6) Install A/C belt tensioner. (With A/C model)
B2M2585
7) Install A/C belt. (With A/C model)
B2M2584
3. Valve Rocker Assembly
A: REMOVAL
B2M2604A
(1) Rocker cover
(2) Intake valve rocker ASSY(3) Exhaust valve rocker ASSY
(4) Spark plug pipe gasket
26
2-3a[W3A0]SERVICE PROCEDURE
3. Valve Rocker Assembly