1999 SUBARU LEGACY 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
18
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:
19
[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.
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