1999 SUBARU LEGACY 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

3. Camshaft
A: REMOVAL
1. RELATED PARTS
Remove timing belt, camshaft sprockets and related parts.

2. CAMSHAFT
S2M0298A
(1) Spark plug cord
(2) Rocker cover (LH)
(3) Rocker cover gasket (LH)(4) Intake camshaft cap (LH)
(5) Intake camshaft (LH)
(6) Exhaust camshaft cap (LH)(7) Exhaust camshaft (LH)
1) Remove camshaft position sensor (LH side
only).
2) Remove spark plug cord.
3) Remove rocker cover and gasket.4) Loosen intake camshaft cap bolts equally, a
little at a time in alphabetical sequence shown in
figure.
B2M1393B
5) Remove camshaft caps and intake camshaft.
30
2-3b[W3A1]SERVICE PROCEDURE
3. Camshaft

1) Camshaft installation
Apply engine oil to cylinder head at camshaft bear-
ing location before installing camshaft. Install cam-
shaft so that rocker arm is close to or in contact
with ªbase circleº of cam lobe.
CAUTION:
IWhen camshafts are positioned as shown in
figure, camshafts need to be rotated at a mini-
mum to align with timing belt during installa-
tion.
IRight-hand camshaft need not be rotated
when set at position shown in figure.
Left-hand intake camshaft: Rotate 80É clock-
wise.
Left-hand exhaust camshaft: Rotate 45É
counter-clockwise.
B2M1200A
2) Camshaft cap installation
(1) Apply fluid packing sparingly to cap mating
surface.
CAUTION:
Do not apply fluid packing excessively. Failure
to do so may cause excess packing to come
out and flow toward oil seal, resulting in oil
leaks.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0752
(2) Apply engine oil to cap bearing surface and
install cap on camshaft as shown by identifica-
tion mark.
(3) Gradually tighten cap in at least two stages
in alphabetical sequence shown in figure, and
then tighten to specified torque.
B2M1395B
(4) Similarly, tighten cap on exhaust side.
After tightening cap, ensure camshaft rotates
only slightly while holding it at ªbaseº circle.
34
2-3b[W3C1]SERVICE PROCEDURE
3. Camshaft

3) Camshaft oil seal installation
Apply grease to new oil seal lips and press onto
front end of camshaft by using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499587100 OIL SEAL INSTALLER
ST2 499597000 OIL SEAL GUIDE
G2M0754
4) Rocker cover installation
(1) Install gasket on rocker cover.
Install peripheral gasket and ignition coil gasket.
(2) Apply fluid packing to four front open edges
of peripheral gasket.
Fluid packing:
THREE BOND 1215 or equivalent
S2M0300A
(3) Install rocker cover on cylinder head.
Ensure gasket is properly positioned during
installation.
5) Install ignition coil.
6) Install cam angle sensor.
7) Similarly, install parts on right-hand side.
2. RELATED PARTS
Install timing belt, camshaft sprockets and related
parts.

35
[W3C2]2-3bSERVICE PROCEDURE
3. Camshaft

4. Cylinder Head
A: REMOVAL
1. RELATED PARTS
1) Remove V-belt.
2) Remove generator, air conditioner compressor
and brackets.
3) Remove hoses and tubes from cylinder block.
4) Disconnect each connector and/or remove con-
nector bracket.5) Remove intake manifold assembly and gasket.
6) Remove camshaft position sensor.
7) Remove timing belt, camshaft sprockets and
related parts.

8) Remove rocker cover, camshafts and related
parts.

2. CYLINDER HEAD
S2M0421A
(1) Bolt
(2) Cylinder head bolt(3) Cylinder head
(4) Cylinder head gasket
1) Remove oil level gauge guide attaching bolt
(LH side only).
36
2-3b[W4A1]SERVICE PROCEDURE
4. Cylinder Head