Timing Belt Assembly: Installation

AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER
1. Preparation for installation of automatic belt tension adjuster assembly:
  CAUTION:
  - Always use a vertical type pressing tool to move the adjuster rod down.
  - Do not use a lateral type vise.
  - Push the adjuster rod vertically.
  - Press-in the push adjuster rod gradually taking more than 3 minutes.
  - Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb).
  - Press the adjuster rod as far as the end surface of cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.
  - Do not release the 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 kgf, 66 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder.
    
    Fig 1: Aligning Adjuster Rod With Stopper Pin Hole In Cylinder
    Courtesy of SUBARU OF AMERICA, INC.
  3. With a 2 mm (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.
    
    Fig 2: Inserting Hex Bar Wrench Into Stopper Pin Hole In Cylinder
    Courtesy of SUBARU OF AMERICA, INC.
2. Install the automatic belt tension adjuster assembly.
  1. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
  Fig 3: Installing Automatic Belt Tension Adjuster Assembly
  Courtesy of SUBARU OF AMERICA, INC.
3. Install the belt idler No. 2.
  1. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
  Fig 4: Installing Belt Idler No 2
  Courtesy of SUBARU OF AMERICA, INC.
4. Install the belt idler.
  1. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
  Fig 5: Installing Belt Idler
  Courtesy of SUBARU OF AMERICA, INC.
TIMING BELT
1. Preparation for installation of automatic belt tension adjuster assembly. < Ref. to INSPECTION . >
2. Crankshaft and cam sprocket alignment.
3. Align mark (A) on the crank sprocket with mark on the oil pump cover at cylinder block.
  
  Fig 6: Aligning Mark On Crank Sprocket With Mark On Oil Pump Cover At Cylinder Block
  Courtesy of SUBARU OF AMERICA, INC.
4. Align single line mark (A) on the exhaust cam sprocket (RH) with notch (B) on timing belt cover.
5. Align single line mark (A) on the intake cam sprocket (RH) with notch (B) on timing belt cover.
  (Make sure double lines (C) on intake camshaft and exhaust cam sprockets are aligned.)
  
  Fig 7: Aligning Single Line Mark On Exhaust Cam Sprocket (RH) With Notch On Timing Belt Cover
  Courtesy of SUBARU OF AMERICA, INC.
6. Align single line mark (A) on exhaust cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket counterclockwise (as viewed from front of engine).
  
  Fig 8: Aligning Single Line Mark On Intake Cam Sprocket (RH) With Notch On Timing Belt Cover
  Courtesy of SUBARU OF AMERICA, INC.
7. Align the single line mark (A) on intake cam sprocket (LH) with notch (B) on timing belt cover by turning the sprocket clockwise (as viewed from front of engine).
8. Ensure the double lines (C) on intake and exhaust cam sprockets are aligned.
  
  Fig 9: Aligning Single Line Mark On Exhaust Cam Sprocket (LH) With Notch On Timing Belt Cover
  Courtesy of SUBARU OF AMERICA, INC.
  
  Fig 10: Aligning Single Line Mark On Intake Cam Sprocket (LH) With Notch On Timing Belt Cover
  Courtesy of SUBARU OF AMERICA, INC.
9. Ensure the camshaft and crank sprockets are positioned properly.
  CAUTION:
  - Intake and exhaust camshafts for this DOHC engine can be independently rotated with the timing belts removed. As can be seen from the figure, if the intake and exhaust valves are lifted simultaneously, their heads will interfere with each other, resulting in bent valves.
    
    Fig 11: Identifying Intake And Exhaust Camshaft Position
    Courtesy of SUBARU OF AMERICA, INC.
  - When the timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts do not push the intake and exhaust valves down. (Under this condition, all valves remain unlifted.)
  - When the camshafts are rotated to install the timing belts, #2 intake and #4 exhaust cam of camshafts (LH) are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Camshafts (RH) are held so that their cams do not push valves down.
  - Camshafts (LH) must be rotated from the "zero-lift" position to the position where the 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.
  - Do not allow the camshafts to rotate in the direction shown in the figure as this causes both intake and exhaust valves to lift simultaneously, resulting in interference with their heads.
    
    Fig 12: Identifying Camshaft Rotation Direction
    Courtesy of SUBARU OF AMERICA, INC.
10. Installation of timing belt:
  Align the alignment mark on timing belt with marks on sprockets in alphabetical order shown in the figure. While aligning marks, position the timing belt properly.
  CAUTION:
  - Disengagement of more than three timing belt teeth may result in interference between the valve and piston.
  - Ensure the belt's rotating direction is correct.
  Fig 13: Identifying Timing Belt Tooth Length
  Courtesy of SUBARU OF AMERICA, INC.
11. Install the belt idlers.
  1. Tightening torque: 39 N.m (4.0 kgf-m, 28.9 ft-lb)
  NOTE: Make sure that the marks on the timing belt and sprockets are aligned.
  
  Fig 14: Aligning Marks On Timing Belt And Sprockets
  Courtesy of SUBARU OF AMERICA, INC.
12. After ensuring that the marks on the timing belt and sprockets are aligned, remove the stopper pin from tensioner adjuster.
13. Install the timing belt guide.
  1. Temporarily tighten the bolts.
  2. Check and adjust the clearance between timing belt and timing belt guide.
    1. Clearance: 1.0+/-0.5 mm (0.039+/-0.020 in)
    Fig 15: Installing Timing Belt Guide (1 Of 4)
    Courtesy of SUBARU OF AMERICA, INC.
    
    Fig 16: Installing Timing Belt Guide (2 Of 4)
    Courtesy of SUBARU OF AMERICA, INC.
    
    Fig 17: Installing Timing Belt Guide (3 Of 4)
    Courtesy of SUBARU OF AMERICA, INC.
    
    Fig 18: Installing Timing Belt Guide (4 Of 4)
    Courtesy of SUBARU OF AMERICA, INC.
  3. Tighten the bolts.
    1. Tightening torque: 10 N.m (1.0 kgf-m, 7.2 ft-lb)
    Fig 19: Tightening Timing Belt Guide Bolts (1 Of 4)
    Courtesy of SUBARU OF AMERICA, INC.
    1. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
    Fig 20: Tightening Timing Belt Guide Bolts (2 Of 4)
    Courtesy of SUBARU OF AMERICA, INC.
    1. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
    Fig 21: Tightening Timing Belt Guide Bolts (3 Of 4)
    Courtesy of SUBARU OF AMERICA, INC.
    1. Tightening torque: 6.4 N.m (0.65 kgf-m, 4.7 ft-lb)
    Fig 22: Tightening Timing Belt Guide Bolts (4 Of 4)
    Courtesy of SUBARU OF AMERICA, INC.
14. Install the timing belt cover. < Ref. to INSTALLATION . >
15. Install the crank pulley. < Ref. to INSTALLATION . >
16. Install the V-belt. < Ref. to INSTALLATION . >