how to remove Timing Belt and Sprockets on 2003 Subaru Outback?

Removal & Installation

1.8L Engine

Fig. Flywheel stopper tool installed-1.8L engine with manual transaxle

Fig. Driveplate stopper tool installed-1.8L engine with automatic transaxle

Fig. Aligning the marks on the flywheel with the marks on the flywheel cover-1.8L engine

Fig. Driver side timing belt (No. 2) and No. 2 tensioner-1.8L engine

Fig. Passenger side timing belt (No. 1) and No. 1 tensioner-1.8L engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect the negative battery cable.
3. Remove the timing belt covers following the recommended procedure.
4. Loosen the tensioner mounting bolts on the number 1 cylinder by 1/2 turn.
5. Rotate the tensioner to the fully retracted position and tighten the mounting bolts.
6. Mark the direction of the belt and remove the belt from the engine.
7. Loosen the tensioner mounting bolts on the number 2 cylinder by 1/2 turn.
8. Rotate the tensioner using a tensioner wrench, to the fully retracted position and tighten the mounting bolts.
9. Mark the direction of the belt and remove the belt from the engine.
10. Remove the crankshaft pulley.
11. Remove the timing belt after marking the direction of rotation.
12. Remove the outer crankshaft sprocket.
13. Remove the tensioner mounting bolts and remove the tensioners and spring on the number 2 tensioner.
14. Remove the idler pulley mounting bolt and remove the idler.
15. Remove the camshaft sprockets using tool 49920700, or an equivalent camshaft sprocket wrench.

To install:

1. Install the camshaft sprockets using tool 49920700, or an equivalent camshaft sprocket wrench to hold the camshaft in place while tightening the camshaft sprocket bolts to 7 ft. lbs. (10 Nm).
2. To install the tensioners, perform the following:
   1. Attach the tensioner spring to the tensioner, then install the assembly on the cylinder block. Tighten the bolts by hand.
   2. Attach the tensioner spring to the bolt. Tighten the bolt then loosen 1/2 turn.
   3. Push the tensioner into the fully retracted position and tighten the mounting bolts.

   
   
3. Install the timing belt idler pulley and tighten the mounting bolt to 32 ft. lbs. (43 Nm).
4. Install the timing belt.
5. Install the crankshaft sprockets.
6. Install the crankshaft pulley and tighten the mounting bolt temporarily.
7. Line up the center of the three lines scribed on the flywheel with the timing mark on the flywheel housing.
8. Align the timing mark on the left side camshaft sprocket with the notch in the belt cover.
9. Attach timing belt No. 2 to the crankshaft sprocket No. 2, oil pump sprocket, belt idler and camshaft sprocket in that order, avoiding downward slackening of the belt.
10. Loosen tensioner No. 2 mounting bolts by 1/2 turn and let the tensioner contact the belt.
11. Push on the belt by hand to ensure smooth tensioner operation.
12. Apply torque to the camshaft sprocket in the counterclockwise direction using a belt tension wrench. While applying the torque tighten the tensioner mounting bolts temporarily.
    
    
    Tighten the slide bolt to 14 ft. lbs. (18 Nm).

    Tighten the pivot bolt to 14 ft. lbs. (18 Nm).
    
    
13. Verify the timing marks are still in alignment.
14. Rotate the crankshaft one full turn and line up the center of the three lines on the flywheel with the housing mark.
15. Align the right side camshaft sprocket timing mark with the notch in the cover.
16. Attach the timing belt to the crankshaft sprocket and camshaft sprocket. Avoid slackening the belt on the upper side.
17. Loosen the tensioner mounting bolts 1/2 turn and allow the tensioner to contact the belt.
18. Push on the belt by hand to ensure smooth tensioner operation.
19. Apply torque to the camshaft sprocket in the counterclockwise direction using a belt tension wrench. While applying the torque tighten the tensioner mounting bolts temporarily.
    
    
    Tighten the slide bolt to 14 ft. lbs. (18 Nm).

    Tighten the pivot bolt to 14 ft. lbs. (18 Nm).
    
    
20. Verify the timing marks are still in alignment.
21. Remove the crankshaft pulley.
22. Install the timing belt covers.
23. Install the crankshaft pulley.
24. Connect the negative battery cable.

3.3L Engine

Fig. Timing belt routing and alignment marks-3.3L engine

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect the negative battery cable.
3. Remove the timing belt covers.
4. 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 make sure the left and right camshaft sprocket marks are lined up with marks on the timing covers.
   3. If all the marks are in line, 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.

   
   
5. Loosen the belt tensioner bolts.
6. Remove belt idler pulley No. 1., idler pulley No. 2 and timing belt.
7. Remove the tensioner pulley bolt and extract the tensioner pulley.
8. Remove the two bolts and the tensioner assembly.
9. Remove the left side camshaft mounting bolt. To keep the camshaft from turning use camshaft sprocket wrench 499207100 or equivalent. Remove the sprocket.
10. Remove the right side camshaft mounting bolt. To keep the camshaft from turning use camshaft sprocket wrench 499207100 or equivalent. Remove the sprocket.
11. Remove the crankshaft sprocket.

To install:

1. Install the crankshaft sprocket.
2. Install the right side camshaft sprocket and mounting bolt. Tighten the mounting bolt to 29 ft. lbs. (39 Nm).
3. Install the left side camshaft sprocket and mounting bolt. Tighten the mounting bolt to 29 ft. lbs. (39 Nm).
4. Insert a 0.059 inch (1.5mm) diameter stopper pin into place while pushing the tension adjuster rod into the tensioner body.
5. Install the tensioner and tighten the bolts to 18 ft. lbs. (24 Nm), while the tensioner is pushed all the way to the right.
6. Install the tensioner pulley and mounting bolt. DO NOT tighten the idler pulley bolt completely.
7. Make sure the crankshaft and both camshaft sprockets are still lined up with their respective timing marks.
8. Install the timing belt onto the sprockets with the direction of rotation arrow in the correct direction and the timing marks on the belt in line with the marks on the sprockets.
9. Install the number 1 and 2 idler pulleys and tighten the mounting bolts to 29 ft. lbs. (39 Nm).
10. 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).
11. Check again that all the timing marks are still in alignment. If they are remove the stopper pin from the tensioner assembly.
12. Install the timing belt covers.
13. Connect the negative battery cable.

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