1999 SUBARU LEGACY Service Repair Manual

1. General Precautions
A: GENERAL PRECAUTIONS
1) Before disassembling engine, place it on ST3.
ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817000 ENGINE STAND
B2M2582A
2) All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pis-
tons and bearings.
3) Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
4) Be careful not to let oil, grease or coolant con-
tact the timing belt, clutch disc and flywheel.
5) All removed parts, if to be reused, should be
reinstalled in the original positions and directions.
6) All removed parts, if to be reused, should be
reinstalled in the original positions and directions.
7) Bolts, nuts and washers should be replaced
with new ones as required.
8) Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
12
2-3a[W1A0]SERVICE PROCEDURE
1. General Precautions

2. Timing Belt
A: REMOVAL
1. CRANKSHAFT PULLEY AND BELT COVER
B2M2583A
(1) Front side V-belt
(2) Rear side V-belt (With A/C
model)(3) Crankshaft pulley bolt
(4) Crankshaft Pulley
(5) Belt cover (LH)(6) Front belt cover
1) Remove A/C belt. (With A/C model)
B2M2584
2) Remove A/C belt tensioner. (With A/C model)
B2M2585
3) Remove crankshaft pulley bolt. To lock
crankshaft, use ST.
ST 499977000 CRANKSHAFT PULLEY
WRENCH
B2M2586A
4) Remove crankshaft pulley.
13
[W2A1]2-3aSERVICE PROCEDURE
2. Timing Belt

5) Remove belt cover (LH).
6) Remove front belt cover.
B2M2587A
2. TIMING BELT
B2M2588B
(a) Alignment mark
(1) Timing belt guide (MT vehicles
only)(2) Belt idler (No. 2)
(3) Belt idler No. 2
(4) Timing belt
1) Remove timing belt guide. (MT vehicles only)
S2M0294
14
2-3a[W2A2]SERVICE PROCEDURE
2. Timing Belt

2) If alignment mark (a) and/or arrow mark (which
indicates rotation direction) on timing belt fade
away, put new marks before removing timing belt
as shown in figure:
B2M2589A
(1) Turn crankshaft using ST, and align align-
ment marks (c) on crankshaft sprocket, and left
side camshaft sprocket with notch (c) of belt
cover, and align the right side camshaft
sprocket with notch (c) on the mating surface of
camshaft cap and cylinder head.
ST 499987500 CRANKSHAFT SOCKET
B2M2590A
(2) Using white paint, put alignment and/or
arrow marks on timing belts in relation to the
sprockets.
B2M2591
Specified data:
Z
1: 44 tooth length
Z
2: 40.5 tooth
B2M2592A
3) Remove belt idler (No. 2).
4) Remove belt idler No. 2.
B2M2593
5) Remove timing belt.
B2M2594
15
[W2A2]2-3aSERVICE PROCEDURE
2. Timing Belt

3. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY
B2M2595B
(1) Belt idler (No. 1)
(2) Automatic belt tension adjuster
ASSY
1) Remove belt idler (No. 1).
B2M2596
2) Remove automatic belt tension adjuster assem-
bly.
H2M2375
16
2-3a[W2A3]SERVICE PROCEDURE
2. Timing Belt

4. CAMSHAFT AND CRANKSHAFT SPROCKET
B2M2598B
(1) Camshaft sprocket No. 2
(2) Camshaft sprocket No. 1
(3) Crankshaft sprocket (California
spec. vehicles)(4) Belt cover No. 2 (LH)
(5) Belt cover No. 2 (RH)
(6) Tensioner bracket
1) Remove camshaft sprocket No. 2. To lock
camshaft, use ST.
ST 499207100 CAMSHAFT SPROCKET
WRENCH
H2M2377A
2) Remove camshaft sprocket No. 1. To lock
camshaft, use ST.
ST 499207400 CAMSHAFT SPROCKET
WRENCH
B2M2599A
17
[W2A4]2-3aSERVICE PROCEDURE
2. Timing Belt

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.
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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)
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[W2C1]2-3aSERVICE PROCEDURE
2. Timing Belt