How to remove timing belt on 2003 Subaru Outback DOHC ENGINE?

Timing Belt

Removal & Installation

2.5L Engine
DOHC Engine

1. Disconnect the negative battery cable.
2. Remove the collector cover.
3. To remove the front side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the front side belt.
4. To remove the rear side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the rear side belt. Remove the belt tensioner.
5. Remove the crankshaft pulley bolt.
6. Lock the crankshaft in place using tool ST499977100, or equivalent.
7. Remove the crankshaft pulley.
8. Remove the left side timing belt cover.
9. Remove the right side timing belt cover.
10. Remove the front timing belt cover.
11. Remove the timing belt guide, if equipped.
    
    NOTE

    If the belt is going to be reused and the alignment mark on the belt is not readable, put a new mark on the belt to indicate the direction of rotation. Using tool ST499987500, turn the crankshaft to align the mark on the crankshaft sprocket, intake camshaft sprocket (left), exhaust camshaft sprocket (left), intake camshaft sprocket (right), exhaust camshaft sprocket (right) with the notches of the timing belt cover and cylinder block. Paint an alignment mark on the belts in relation to the camshaft sprockets. Z1 measurement is 54.4 teeth. Z2 measurement is 51.0 teeth and Z3 measurement is 28.0 teeth.
    
    
    
    
    

    

    Fig. Timing belt alignment-2005 2.5L DOHC engine

    
    
    
    

    

    Fig. Timing belt Z1, Z2 and Z3 teeth measurement-2005 2.5L DOHC engine

12. Remove the belt idler belt -A-. Remove the timing belt.
13. Remove the belt idlers belt -B- and -C-.
    
    
    

    

    Fig. Belt idler identification and location-2005 2.5L DOHC engine

14. Remove the belt idler number two. Remove the automatic belt tension adjuster assembly.

To install:

1. Attach the automatic belt tension adjuster assembly to a vertical pressing tool.
   
   NOTE

   Always use a vertical type pressing tool to move the adjuster rod downward. Do not use a lateral type vise. Push the adjuster rod vertically. Press in the push adjuster rod gradually, which should take three minutes or more. Do not allow pressure to exceed 2,205 lb. force.
   
   
2. Slowly move the adjuster rod down until the adjuster rod is aligned with the stopper pin hole in the cylinder.
   
   NOTE

   Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.
   
   
3. Using a 0.08 inch stopper pin, insert it into the stopper pin hole in the cylinder. Secure the adjuster rod.
   
   NOTE

   Do not release the press pressure until the stopper pin is completely inserted in the hole.
   
   
4. Install the automatic belt tensioner assembly. Tighten the retaining bolt to 28.9 ft. lbs.
5. Install the belt idler number two. Tighten the retaining bolt to 28.9 ft. lbs.
6. Install the belt idlers. Tighten the retaining bolts to 28.9 ft. lbs.
7. Align the mark -A- on the crankshaft sprocket with the mark on the oil pump at the cylinder block. Align the single line mark -A- on the right exhaust camshaft sprocket with the notch -B- on the timing belt cover.
8. Align single line mark -A- on the right intake camshaft sprocket with the notch -B- on the timing cover. Ensure that the double lines -C- on the intake and exhaust camshaft sprockets are aligned.
9. Align single line mark -A- on the left exhaust camshaft sprocket with the notch -B- on the timing cover by turning the sprocket counterclockwise as viewed from the front of the engine.
10. Align single line mark -A- on the left intake camshaft sprocket with the notch -B- on the timing cover, by turning the sprocket clockwise as viewed from the front of the engine. Ensure that the double lines -C- on the intake and exhaust camshaft sprockets are aligned.
    
    
    

    

    Fig. Crankshaft sprocket mark A to oil pump cover alignment-2005 2.5L DOHC engine

    
    
    
    

    

    Fig. Right exhaust camshaft sprocket alignment mark A with timing belt cover B alignment mark-2005 2.5L DOHC engine

    
    
    
    

    

    Fig. Right intake camshaft sprocket alignment mark A with timing belt cover B alignment mark an double line C alignment mark-2005 2.5L DOHC engine

    
    
    
    

    

    Fig. Left exhaust camshaft sprocket alignment mark A with timing belt cover B alignment mark-2005 2.5L DOHC engine

    
    
    
    

    

    Fig. Left intake camshaft sprocket alignment mark A with timing belt cover B alignment mark an double line C alignment mark-2005 2.5L DOHC engine

11. Make sure that the camshaft and crankshaft sprockets are positioned properly.
    
    NOTE

    The intake and exhaust camshafts on this engine can be rotated independently with the timing belt removed. By looking at the illustration it will show you that if the intake and exhaust valve are lift together the heads will hit each other and bend.
    
    
    
    NOTE

    When the timing belts are not installed, 4 camshafts are held at -zero lift- position, where all cams on the 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, No. 2 intake and No. 4 exhaust cam of the left hand camshafts are held to push their corresponding valves down. Under this condition these valves are held lifted. The right side camshafts are held in so that their cams do not push the valves down. The left hand camshafts 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 illustrated as this causes both the intake and exhaust valves to lift off at the same time with will cause valve damage.
    
    
12. When installing the belt, make sure to align the marks made during removal or if using a new belt, align the in alphabetical order as shown in the illustration.
    
    WARNING

    Disengagement of more than 3 timing belt teeth may result in contact between the valve and piston. Always make sure the belts rotation is correct.
    
    
    
    
    

    

    Fig. If the intake and exhaust valve are lift together the heads will hit each other and bend -2.0L engine and 2005 2.5L DOHC engine

    
    
    
    

    

    Fig. Do not allow the camshafts to rotate in the direction shown as this causes both the intake and exhaust valves to lift off at the same time with will cause valve damage-2.0L engine and 2005 2.5L DOHC engine

13. Install the timing belt.
    
    NOTE

    Align the alignment mark on the timing belt with marks on the sprocket in the order shown in the illustration. While aligning the timing marks, position the timing belt properly.
    
    
    
    
    

    

    Fig. Timing belt alignment and installation sequence-2005 2.5L DOHC engine

14. Install the belt idlers. Tighten the retaining bolts to 28.9 ft. lbs.
    
    NOTE

    Make sure that the marks on the timing belt and sprockets are aligned.
    
    
15. After checking to be sure the marks on the timing belt and the camshaft sprockets are aligned remove the stopper pin from the belt tension adjuster.
16. Install the timing belt guide, if equipped with manual transmission. Temporarily tighten the bolts. Check and adjust the clearance between the belt and the guide. It should be 0.039 +/- 0.020 inch. Tighten the guide bolts to specification, see illustration.
17. Continue the installation in the reverse order of the removal procedure.
    
    
    

    

    Fig. Timing belt guide bolt location and tightening specification-2005 2.5L DOHC engine

SOHC Engine

1. Disconnect the negative battery cable.
2. To remove the front side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the front side belt.
3. To remove the rear side V belt, remove the belt covers. Loosen the lock bolt. Loosen the slider bolt. Remove the rear side belt. Remove the belt tensioner.
4. Remove the crankshaft pulley bolt.
5. Lock the crankshaft in place using tool ST499977100, or equivalent.
6. Remove the crankshaft pulley.
7. Remove the left side timing belt cover.
8. Remove the front timing belt cover.
9. If equipped with manual transmission, remove the timing belt guide.
   
   NOTE

   If the belt is going to be reused and the alignment mark on the belt is not readable, put a new mark on the belt to indicate the direction of rotation. Using tool ST499987500, turn the crankshaft to align the mark of the sprocket -A- to the cylinder mark notch -B-. Ensure that the right side cam sprocket mark -C-, cam cap and cylinder head matching surface -D- or left side cam sprocket mark -E-, timing belt cover notch -F- are properly aligned. Paint an alignment mark on the belt in relation to the crankshaft sprocket and camshaft sprockets. Z1 measurement is 46.8 teeth. Z2 measurement is 43.7 teeth.
   
   
   
   
   

   

   Fig. Timing belt alignment-2005 2.5L SOHC engine

   
   
   
   

   

   Fig. Timing belt Z1 and Z2 teeth measurement-2005 2.5L SOHC engine

10. Remove both the number two belt idlers. Remove the timing belt from the engine.
11. Remove the number one belt idler. Remove the automatic belt tension adjuster assembly.

To install:

1. Attach the automatic belt tension adjuster assembly to a vertical pressing tool.
   
   NOTE

   Always use a vertical type pressing tool to move the adjuster rod downward. Do not use a lateral type vise. Push the adjuster rod vertically. Press in the push adjuster rod gradually, which should take three minutes or more. Do not allow pressure to exceed 2,205 lb. force.
   
   
2. Slowly move the adjuster rod down until the adjuster rod is aligned with the stopper pin hole in the cylinder.
   
   NOTE

   Press the adjuster rod as far as the end surface of the cylinder. Do not press the adjuster rod into the cylinder. Doing so may damage the cylinder.
   
   
3. Using a 0.08 inch stopper pin, insert it into the stopper pin hole in the cylinder. Secure the adjuster rod.
   
   NOTE

   Do not release the press pressure until the stopper pin is completely inserted in the hole.
   
   
4. Install the automatic belt tensioner assembly. Tighten the retaining bolt to 28.9 ft. lbs.
5. Install the belt idler number one. Tighten the retaining bolt to 28.9 ft. lbs.
6. Turn the number one and number two camshaft sprockets, using tool ST499207100 or tool ST18231AA010 and position the alignment marks -A- on each at the highest position.
   
   
   

   

   Fig. Timing mark alignment position A-2005 2.5L SOHC engine

   
   
   
   

   

   Fig. Timing mark alignment position B-2005 2.5L SOHC engine

7. While aligning the alignment mark -B- on the timing belt with mark -A- on the sprockets, position the timing belt properly.
8. Install both belt idler number two-s. Tighten the retaining bolt to 28.9 ft. lbs.
   
   
   

   

   Fig. Belt idler number two locations-2005 2.5L SOHC engine

9. After checking to be sure the marks on the timing belt and the camshaft sprockets are aligned remove the stopper pin from the belt tension adjuster.
10. Install the timing belt guide, if equipped with manual transmission. Temporarily tighten the bolts. Check and adjust the clearance between the belt and the guide. It should be 0.039 +/- 0.020 inch. Tighten the bolts to 7.2 ft. lbs.
11. Continue the installation in the reverse order of the removal procedure.

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. 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:

1. Insert a 0.059 in. (1.5mm) diameter stopper pin into place while pushing the tension adjuster rod into the tensioner body.
2. Install the tensioner and tighten the bolts to 18 ft. lbs. (24 Nm), while the tensioner is pushed all the way to the right.
3. Install the tensioner pulley and mounting bolt. DO NOT tighten the idler pulley bolt completely.
4. Be sure the crankshaft and both camshaft sprockets are still aligned with their respective timing marks.
5. 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.
6. Install No. 1 and 2 idler pulleys and tighten the mounting bolts to 29 ft. lbs. (39 Nm).
7. 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).
8. Check again that all the timing marks are still in alignment. If they are remove the stopper pin from the tensioner assembly.
9. Install the timing belt covers.
10. Connect the negative battery cable.

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