Subaru Legacy (2005 year). Manual — part 276

ME(H4DOTC)-47

MECHANICAL

Timing Belt

(2) Using white paint, put alignment and/or ar-
row marks on the timing belts in relation to the
cam sprockets.

Z

1

: 54.5 tooth length

Z

2

: 51 tooth length

Z

3

: 28 tooth length

6) Remove the belt idler (A).

7) Remove the timing belt.

CAUTION:
After the timing belt has been removed, never
rotate the intake and exhaust cam sprocket. If
the cam sprocket is rotated, the intake and ex-
haust valve heads strike together and valve
stems are bent.

2. BELT IDLER AND AUTOMATIC BELT
TENSION ADJUSTER ASSEMBLY

1) Remove the belt idlers (B) and (C).

2) Remove the belt idler No. 2.

3) Remove the automatic belt tension adjuster as-
sembly.

ME-00070

ME-00071

ME-00072

Z

3

Z

1

Z

2

Z

3

ME-00073

(A)

(B)

(C)

ME-00074

(A)

(B)

(C)

ME-00075

ME-00076

ME(H4DOTC)-48

MECHANICAL

Timing Belt

B: INSTALLATION

1. AUTOMATIC BELT TENSION ADJUST-
ER ASSEMBLY AND BELT IDLER

1) Preparation for installation of automatic belt ten-
sion 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 tak-
ing more than three minutes.
• Do not allow press pressure to exceed 9,807
N (1,000 kgf, 2,205 lbf).
• Press the adjuster rod as far as to the end
surface of cylinder. Do not press the adjuster
rod into cylinder. Doing so may damage the cyl-
inder.
• Do not release the press pressure before
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 lbf) or more until
the adjuster rod is aligned with the stopper pin
hole in the cylinder.

(3) With a 2 mm (0.08 in) dia. stopper pin or a 2
mm (nominal) dia. hex wrench inserted into the
stopper pin hole in cylinder, secure the adjuster
rod.

2) Install the automatic belt tension adjuster as-
sembly.

Tightening torque:

39 N

⋅

m (4.0 kgf-m, 28.8 ft-lb)

3) Install the belt idler No. 2.

Tightening torque:

39 N

⋅

m (4.0 kgf-m, 28.8 ft-lb)

4) Install the belt idlers.

Tightening torque:

39 N

⋅

m (4.0 kgf-m, 28.8 ft-lb)

ME-00077

ME-00078

ME-00079

ME-00075

ME-00080

ME(H4DOTC)-49

MECHANICAL

Timing Belt

2. TIMING BELT

1) Preparation for installation of automatic belt ten-
sion adjuster assembly <Ref. to ME(H4DOTC)-48,
AUTOMATIC BELT TENSION ADJUSTER AS-
SEMBLY AND BELT IDLER, INSTALLATION,
Timing Belt.>
2) Crankshaft and cam sprocket alignment

(1) Align the mark (A) on crank sprocket with
the mark on oil pump cover at cylinder block.

(2) Align single line mark (A) on the exhaust
cam sprocket (RH) with the notch (B) on timing
belt cover.

(3) Align single line mark (A) on the intake cam
sprocket (RH) with the notch (B) on timing belt
cover. (Ensure double lines (C) on intake and
exhaust cam sprockets are aligned.)

(4) 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).

(5) Align 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). Ensure double lines (C) on
intake and exhaust cam sprockets are aligned.

(A)

ME-00081

ME-00082

(A)

(B)

ME-00083

(B)

(C)

(A)

ME-00084

(B)

(A)

ME-00085

(A)

(B)

(C)

ME(H4DOTC)-50

MECHANICAL

Timing Belt

(6) Ensure that the cam sprocket 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.

• When the timing belts are not installed, four
camshafts are held at the “zero-lift” position,
none of cam on the camshafts push the intake
and exhaust valves down. (Under this condi-
tion, 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 corre-
sponding 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 “ze-
ro-lift” position to the position where the timing
belt is to be installed with the smallest possible
angle, in order to prevent mutual interference of
intake and exhaust valve heads.

• Do not allow the camshafts to rotate in the di-
rection shown in the figure of upper one. Doing
this cause both the intake and exhaust valves
to lift simultaneously, resulting in interference
with their heads.

(A) Intake camshaft

(B) Exhaust camshaft

ME-00086

(A)

(B)

(A) Revolving direction

(B) Timing belt installation position

(A)

(A)

(A)

(A)

(B)

(B)

ME-00314