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Removal & Installation

SUBARU MODELS

1.8L Engine
  1. Remove all necessary components for access to the timing belt covers, then remove the covers.
  2. Loosen the timing belt tensioner mounting bolts 1⁄2 turn and slacken the timing belt. Tighten the mounting bolts.
  3. Mark the rotating direction of the No. 1 timing belt, then remove the belt.
  4. Perform the same procedure for the No. 2 timing belt. Remove the crankshaft sprockets.
  5. Remove both tensioners together with the tensioner springs.
  6. Remove the belt idler. Remove the camshaft sprockets.
  7. Remove the No. 2 belt covers.

    To install:

  8. Inspect the timing belt for breaks, cracks and wear. Replace as required.
  9. Check the belt tensioner and idler for smooth rotation. Replace if noisy or excessive play is noticed.
  10. Install the driver's side belt cover seal No. 3 to the cylinder block.
  11. Install the driver's side belt cover seal, driver's side belt cover seal No. 4, and belt cover mount to the right rear belt cover, then install the assembly on the cylinder block. Tighten to 34 ft. lbs. (45 Nm).
  12. Install the driver's side belt cover seal No. 2 and belt cover mounts to driver's side belt cover No. 2, then install to the cylinder head and camshaft case. Tighten to 34 ft. lbs. (45 Nm).
  13. Install the passenger's side belt cover seal, belt cover seal No. 2 and belt cover mounts to the passenger's side belt cover No. 2, then install to the cylinder head and camshaft case. Tighten to 34 ft. lbs. (45 Nm).
  14. Install the camshaft sprockets to the right and left camshafts. Tighten the bolts gradually in 2-3 steps to 67 ft. lbs. (91 Nm).
  15. Attach the tensioner spring to the tensioner, then install to the right side of the cylinder block. Tighten the bolts temporarily by hand.
  16. Attach the tensioner spring to the bolt, tighten the right side bolt, then loosen it 1⁄2 turn.
  17. Push down the tensioner until it stops, then temporarily tighten the left bolt.
  18. Install the left side tensioner in the same manner.
  19. Install the belt idler to the cylinder block using care not to turn the seal. Tighten to 29-35 ft. lbs. (39-47 Nm).
  20. Install the sprockets on the crankshaft. Install the crankshaft pulley and tighten the bolt temporarily.
  21. Align the center of the three lines scribed on the flywheel with the timing mark on the flywheel housing.
  22. Align the timing mark on the driver's side camshaft sprocket with the notch on the belt cover.
  23. Attach timing belt No. 2 to the crankshaft sprocket No. 2, oil pump sprocket, belt idler, and camshaft sprocket in that order. Avoid downward slackening of the belt.
  24. Loosen tensioner No. 2 lower bolt 1⁄2 turn to apply tension. Push timing belt by hand to ensure smooth movement of tensioner.
  25. Apply 25 ft. lbs. (new belt) or 18 ft. lbs. (used belt) torque to the camshaft sprocket in counterclockwise direction. While applying torque tighten tensioner No. 2 lower bolt temporarily, then tighten upper bolt temporarily.
  26. Tighten the lower bolt, then the upper bolt to 13-15 ft. lbs. (17-20 Nm) in that order.
  27. Check that the flywheel timing mark and drivers side camshaft sprocket marks are in their proper positions.
  28. Turn the crankshaft one turn clockwise from the position where timing belt No. 2 was installed, and align the center of the three lines on the flywheel with the timing mark on the flywheel housing.
  29. Align the timing mark on the passenger's side camshaft sprocket with the notch in the belt cover.
  30. Attach the timing belt to the crankshaft sprocket and camshaft sprocket, avoiding slackening of the belt on the upper side.
  31. Loosen the tensioner 1⁄2 turn to apply tension to the belt. Push the belt by hand to ensure smooth operation.
  32. Apply 25 ft. lbs. (34 Nm) for new belts or 18 ft. lbs. (24 Nm) for used belts, tighten to the camshaft sprocket in counterclockwise direction. While applying torque, tighten the tensioner left bolt temporarily, then tighten right bolt temporarily.
  33. Tighten the left bolt, then the right bolt to 13-15 ft. lbs. (17-20 Nm) in that order.
  34. Check that the flywheel timing mark and drivers side camshaft sprocket marks are in their proper positions.
  35. Remove the crankshaft pulley.
  36. Install the right front belt cover seals and belt cover plug. Install the belt covers to the cylinder block.
  37. On turbo-charged engines, install the belt cover plate.
  38. Install the crankshaft pulley and tighten to 66-79 ft. lbs. (89-107 Nm).
  39. Install the water pump pulley and tighten to 67 ft. lbs. (91 Nm). Install the pulley cover, oil level guide and gauge and oil pressure switch connector.
  40. Install and properly tension the accessory drive belt.

    Fig. 1: Timing belt components and alignment mark locations-Subaru 1.8L and 2.2L engines

2.2L Engine

The engine uses a single cam belt drive system with a serpentine type belt. The left side of the engine uses a hydraulic cam belt tensioner, which is self-adjusting.

NOTE: It is recommended that the timing belt be replaced at least every 60,000 miles (96,618 km).

  1. Disconnect the negative battery cable.
  2. Position the No. 1 piston to Top Dead Center (TDC) of its compression stroke.
  3. Remove the engine drive belts.
  4. Remove the timing belt covers.
  5. Align the camshaft sprockets so each sprocket notch aligns with the cam cover notches. Align the crankshaft sprocket top tooth notch, located at the rear of the tooth, with the notch on the crank angle sensor boss. Mark the three alignment points as well as the direction of cam belt rotation.
  6. Loosen the tensioner adjusting bolts. Remove the bottom three idlers, the cam belt and the cam belt tensioner. The cam sprockets can, then be removed with a modified camshaft sprocket wrench tool.
  7. Remove the sprockets, if necessary. Note the reference sensor at the rear of the left cam sprocket.

    To install:

  8. Install the sprockets, if removed and tighten the retaining bolts to 47-54 ft. lbs. (64-74 Nm).
  9. Install the crankshaft sprocket and the non-adjustable right side idler. Do not install the tensioner idler at this time.
  10. Compress the hydraulic tensioner in a vise slowly and temporarily secure the plunger with a pin or suitable Allen wrench. Install the tensioner and the pulley with the adjustable idler pulley. Temporarily tighten the tensioner while the tensioner is pushed to the right.
  11. Align the crankshaft sprocket notch on the rear sprocket tooth with the crank angle sensor boss. This places the sprocket notch in the 12 o'clock position.
  12. Align the camshaft sprockets with the notches in the cam rear belt cover. This places the sprocket notch in the 12 o'clock position for each camshaft.
  13. Install the timing belt with the directional mark and alignment marks properly positioned (if the belt is reused).
  14. Loosen the tensioner retaining bolts and slide the tensioner to the left. Tighten the mounting bolts.
  15. After verifying the timing marks are correct, remove the stopper pin from the tensioner.
  16. Verify the correctness of the timing by noting that the notches on the 2 cam pulleys and the notch on the crankshaft pulley all point to the 12 o'clock position when the belt is properly installed.
  17. Complete the engine component assembly by installing the cam belt covers, the crankshaft pulley bolt and pulley and the remaining components.
  18. Connect the negative battery cable.
2.5L Engine

The engine uses a single cam belt drive system with a serpentine type belt. The left side of the engine uses a hydraulic cam belt tensioner, which is self-adjusting.

NOTE: It is recommended that the timing belt be replaced at least every 60,000 miles (96,618 km).

  1. Remove all necessary components for access to the left, right and center timing belt covers, then remove the covers.
  2. Align the camshaft sprockets so each sprocket notch aligns with the rear cover notches. Align the crankshaft sprocket top tooth notch, located at the rear of the tooth with the notch. The crankshaft notch will be at 12 o'clock and the keyway will be at 6 o'clock.

    NOTE: Mark the sprocket alignment points as well as the direction of cam belt rotation for reinstallation purposes if the belt is to be reused.

  3. Loosen the tensioner adjusting bolts.
  4. Remove the lower timing belt idler.
  5. Remove the timing belt from the pulleys.

    WARNING
    After the timing belt is removed, DO NOT rotate the camshaft sprockets or the crankshaft. Severe internal damage will result from the valve and/or piston contact.

  6. Remove the timing belt tensioner and the timing belt tension adjuster.

    Fig. 2: Timing belt routing, showing the alignment marks-Subaru 2.5L engine

    To install:

    NOTE: Inspect the timing belt and tensioner for wear or damage and replace as necessary.

  7. Inspect the timing belt tensioner as follows:
    1. When compressing the pushrod of the tensioner with a force of 33 lbs. (147 N), the tensioner should not sink.
    2. When compressing the pushrod of the tensioner with a force of 33-110 lbs. (147-490 N), the tensioner should not sink within 8.5 seconds.
    3. Measure the extension of the rod beyond the body of the tensioner for a length of 0.606-0.646 in. (15.4-16.4mm). If not within specifications, replace the tensioner.

      NOTE: Check the idler sprockets for smooth operation. Replace as necessary.

  8. Using a press, compress the tensioner gradually, taking three minutes or more, and insert a 0.059 in. (1.5mm) pin to secure the rod.
  9. Install the tensioner and the pulley with the adjustable idler pulley. Temporarily tighten the tensioner while the tensioner is pushed to the right.
  10. Align the crankshaft sprocket notch on the rear sprocket tooth with the crank angle sensor boss. This places the sprocket notch in the 12 o'clock position and the key way at the 6 o'clock position.
  11. Align the camshaft sprockets with the notches in the cam rear belt cover. This places the sprocket notch in the 12 o'clock position for each camshaft.
  12. Install the timing belt in a clockwise direction starting at the crankshaft with the directional mark and alignment marks properly positioned (if the belt was reused).
  13. Install the lower timing belt idler and tighten the mounting bolt to 29 ft. lbs. (39 Nm).

    WARNING
    Be sure all the timing marks are properly aligned.

  14. Loosen the tensioner retaining bolts and slide the tensioner to the left. Tighten the mounting bolts to 18 ft. lbs. (25 Nm).
  15. After verifying the timing marks are correct, remove the stopper pin from the tensioner and recheck the timing marks.
  16. Install the center, right, then the center timing belt covers. Tighten the bolts to 44 inch lbs. (5 Nm).
  17. Install the remaining components in the reverse order of the removal procedure. When installing the crankshaft sprocket, be sure to tighten the mounting bolt to 94 ft. lbs. (127 Nm).
3.3L Engine
  1. Disconnect the negative battery cable.
  2. Remove the timing belt covers.
  3. Matchmark the timing belt to the sprocket, cover and block marks as follows:
    1. Turn the crankshaft to align the timing marks on the crankshaft sprocket with the mark on the block.
    2. With the crankshaft marks aligned be sure the left and right camshaft sprocket marks are aligned with marks on the timing covers.
    3. If all the marks align, use white paint to mark the direction of rotation of the belt as well as mark the spots on the belt where it crosses over the timing marks on the pulleys.
  4. Loosen the belt tensioner bolts.
  5. Remove belt idler pulley No. 1.
  6. Remove belt idler pulley No. 2.
  7. Remove the timing belt.
  8. Remove the tensioner pulley bolt and remove the tensioner pulley.
  9. Remove the two bolts and the tensioner assembly.

    Fig. 3: To ensure proper installation of the timing belt, be sure the proper number of belt teeth are between each sprockets, as indicated-Subaru 3.3L engine

    To install:

  10. Insert a 0.059 in. (1.5mm) diameter stopper pin into place while pushing the tension adjuster rod into the tensioner body.
  11. Install the tensioner and tighten the bolts to 18 ft. lbs. (24 Nm), while the tensioner is pushed all the way to the right.
  12. Install the tensioner pulley and mounting bolt. DO NOT tighten the idler pulley bolt completely.
  13. Be sure the crankshaft and both camshaft sprockets are still aligned with their respective timing marks.
  14. Install the timing belt onto the sprockets with the direction of rotation arrow in the correct direction and the timing marks on the belt align with the marks on the sprockets.
  15. Install No. 1 and 2 idler pulleys and tighten the mounting bolts to 29 ft. lbs. (39 Nm).
  16. Loosen the tensioner pulley bolt and the tensioner assembly mounting bolts. Slide the tensioner assembly all the way to the left and tighten the bolts to 18 ft. lbs. (24 Nm).
  17. Check again that all the timing marks are still in alignment. If they are remove the stopper pin from the tensioner assembly.
  18. Install the timing belt covers.
  19. Connect the negative battery cable.

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