1999 SUBARU LEGACY Service Repair Manual

2. Timing Belt
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT COVER
B2M1705C
(1) V-belt
(2) Crankshaft pulley bolt(3) Crankshaft pulley
(4) Left-hand belt cover No. 1(5) Right-hand belt cover No. 1
(6) Front belt cover
1) Remove V-belt cover, V-belt and air condition-
ing compressor drive belt tensioner. [G2B0].>
B2M1706
2) Remove pulley bolt. To lock crankshaft, use ST.
ST 499977100 CRANKSHAFT PULLEY
WRENCH
H2M2393A
3) Remove crankshaft pulley.
4) Remove left-hand belt cover.
B2M0729
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2-3b[W2A1]SERVICE PROCEDURE
2. Timing Belt

5) Remove right-hand belt cover.
B2M0730
6) Remove front belt cover.
B2M0731
2. TIMING BELT
S2M0295A
(1) Timing belt guide (MT vehicles
only)(2) Belt idler
(3) Timing belt(a) Alignment marks
G2M0713
15
[W2A2]2-3bSERVICE PROCEDURE
2. Timing Belt

1) Remove timing belt guide. (MT vehicles only)
S2M0294
2) If alignment mark and/or arrow mark (which
indicates rotation direction) on timing belt fade
away, put new marks before removing timing belt
as follows:
(1) Turn crankshaft using ST, and align align-
ment marks on crankshaft sprocket, left-hand
intake camshaft sprocket, left-hand exhaust
camshaft sprocket, right-hand intake camshaft
sprocket and right hand exhaust camshaft
sprocket with notches of belt cover and cylinder
block.
ST 499987500 CRANKSHAFT SOCKET
S2M0407A
(2) Using white paint, put alignment and/or
arrow marks on timing belts in relation to the
sprockets.
Z1: 54.5 tooth length
Z
2: 51 tooth length
Z
3: 28 tooth length
H2M2396A
S2M0408
B2M0689
3) Remove belt idler.
H2M2398
16
2-3b[W2A2]SERVICE PROCEDURE
2. Timing Belt

4) Remove timing belt.
CAUTION:
After timing belt has been removed, never
rotate intake and exhaust, camshaft sprocket.
If camshaft sprocket is rotated, the intake and
exhaust valve heads strike together and valve
stems are bent.
S2M0409
3. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY
H2M2400C
(1) Belt idler
(2) Belt idler No. 2(3) Automatic belt tension adjuster
ASSY
1) Remove belt idler.
S2M0410
2) Remove belt idler No. 2.
S2M0411
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[W2A3]2-3bSERVICE PROCEDURE
2. Timing Belt

3) Remove automatic belt tension adjuster assem-
bly.
S2M0412
4. SPROCKET
H2M2404C
(1) Left-hand intake camshaft
sprocket
(2) Left-hand exhaust camshaft
sprocket(3) Right-hand intake camshaft
sprocket
(4) Right-hand exhaust camshaft
sprocket(5) Crankshaft sprocket
(6) Tensioner bracket
(7) Left-hand belt cover No. 2
(8) Right-hand belt cover No. 2
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2-3b[W2A4]SERVICE PROCEDURE
2. Timing Belt

1) Remove left-hand intake camshaft sprocket.
2) Remove left-hand exhaust camshaft sprocket.
3) Remove right-hand intake camshaft sprocket.
4) Remove right-hand exhaust camshaft sprocket.
ST 499207300 CAMSHAFT SPROCKET
WRENCH
S2M0413A
5) Remove crankshaft sprocket.
S2M0414
6) Remove tensioner bracket.
H2M2407
7) Remove left-hand belt cover No. 2.
S2M0415
8) Remove right-hand belt cover No. 2.
B2M0738
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 automatic belt tension adjuster assembly.
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:
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[W2B2]2-3bSERVICE PROCEDURE
2. Timing Belt

(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.
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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
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[W2C1]2-3bSERVICE PROCEDURE
2. Timing Belt