Wednesday, October 5, 2011

General information about timing belt for 2003 Subaru Outback?

Timing Belt


1) GENERAL INFORMATION.
2) INSPECTION.
3) REMOVAL & INSTALLATION.

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General Information



Timing belts are typically only used on overhead camshaft engines. Timing belts are used to synchronize the crankshaft with the camshaft, similar to a timing chain on an overhead valve (pushrod) engine. Unlike a timing belt, a timing chain will normally last the life of the engine without needing service or replacement. Timing belts use raised teeth to mesh with sprockets to operate the valvetrain of an overhead camshaft engine.

Whenever a vehicle with an unknown service history comes into your repair facility or is recently purchased, here are some points that should be asked to help prevent costly engine damage:



Does the owner know if, or when the belt was replaced-
If the vehicle purchased is used, or the condition and mileage of the last timing belt replacement are unknown, it is recommended to inspect, replace or at least inform the owner that the vehicle is equipped with a timing belt.
Note the mileage of the vehicle. The average replacement interval for a timing belt is approximately 60,000 miles (96,000 km).

Interference Engines

Engines, chain-or belt-driven, can be classified as either free-running or interference, depending on what would happen if the piston-to-valve timing were disrupted. A free-running engine is designed with enough clearance between the pistons and valves to allow the crankshaft to rotate (pistons still moving) while the camshaft stays in one position (several valves fully open). If this condition occurs normally, no internal engine damage will result. In an interference engine, there is not enough clearance between the pistons and valves to allow the crankshaft to turn without the camshaft being in time.

An interference engine can suffer extensive internal damage if a timing belt fails. The piston design does not allow clearance for the valve to be fully open and the piston to be at the top of its stroke. If the belt fails, the piston will collide with the valve and will bend or break the valve, damage the piston, and/or bend a connecting rod. When this type of failure occurs, the engine will need to be replaced or disassembled for further internal inspection; either choice costing many times that of replacing the timing belt.

Inspection




NOTE
For manufacturers recommended service interval, refer to the maintenance interval chart located in this manual.

The average replacement interval for a timing belt is approximately 60,000 miles (96,000km). If, however, the timing belt is inspected earlier or more frequently than suggested, and shows signs of wear or defects, the belt should be replaced at that time.


WARNING
Never allow antifreeze, oil or solvents to come into with a timing belt. If this occurs immediately wash the solution from the timing belt. Also, never excessive bend or twist the timing belt; this can damage the belt so that its lifetime is severely shortened.



Click image to see an enlarged view

Fig. Never bend or twist a timing belt excessively, and do not allow solvents, antifreeze, gasoline, acid or oil to come into contact with the belt

Inspect both sides of the timing belt. Replace the belt with a new one if any of the following conditions exist:



Hardening of the rubber-back side is glossy without resilience and leaves no indentation when pressed with a fingernail
Cracks on the rubber backing
Cracks or peeling of the canvas backing
Cracks on rib root
Cracks on belt sides
Missing teeth or chunks of teeth
Abnormal wear of belt sides-the sides are normal if they are sharp, as if cut by a knife

If none of these conditions exist, the belt does not need replacement unless it is at the recommended interval. The belt MUST be replaced at the recommended interval.


WARNING
On interference engines, it is very important to replace the timing belt at the recommended intervals, otherwise expensive engine damage will likely result if the belt fails.



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Fig. Broken tooth may be due to a damaged pulley



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Fig. Back surface worn or cracked from a possible overheated engine or interference with the belt cover



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Fig. Side wear from improper installation



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Fig. Worn teeth from excessive belt tension, camshaft or distributor not turning properly, or fluid leaking on the belt

Removal & Installation




NOTE
The radio may have a coded theft protection circuit. Obtain the code before disconnecting the battery, removing the radio fuse, or removing the radio.


CAUTION
Timing belt maintenance is extremely important. All Hyundai models use interference-type non-freewheeling engines. Should the timing belt break in these engines, the valves in the cylinder head will come in contact with the pistons, causing major engine damage. The recommended replacement interval for timing belts is 60,000 miles.


CAUTION
On models with an air bag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work.

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:

  1. Inspect the timing belt for breaks, cracks and wear. Replace as required.
  2. Check the belt tensioner and idler for smooth rotation. Replace if noisy or excessive play is noticed.
  3. Install the driver-s side belt cover seal No. 3 to the cylinder block.
  4. 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).
  5. 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).
  6. 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).
  7. Install the camshaft sprockets to the right and left camshafts. Tighten the bolts gradually in 2-3 steps to 67 ft. lbs. (91 Nm).
  8. Attach the tensioner spring to the tensioner, then install to the right side of the cylinder block. Tighten the bolts temporarily by hand.
  9. Attach the tensioner spring to the bolt, tighten the right side bolt, then loosen it 1 / 2 turn.
  10. Push down the tensioner until it stops, then temporarily tighten the left bolt.
  11. Install the left side tensioner in the same manner.
  12. Install the belt idler to the cylinder block using care not to turn the seal. Tighten to 29-35 ft. lbs. (39-47 Nm).
  13. Install the sprockets on the crankshaft. Install the crankshaft pulley and tighten the bolt temporarily.
  14. Align the center of the three lines scribed on the flywheel with the timing mark on the flywheel housing.
  15. Align the timing mark on the driver-s side camshaft sprocket with the notch on the belt cover.
  16. 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.
  17. Loosen tensioner No. 2 lower bolt 1 / 2 turn to apply tension. Push timing belt by hand to ensure smooth movement of tensioner.
  18. 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.
  19. Tighten the lower bolt, then the upper bolt to 13-15 ft. lbs. (17-20 Nm) in that order.
  20. Check that the flywheel timing mark and drivers side camshaft sprocket marks are in their proper positions.
  21. 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.
  22. Align the timing mark on the passenger-s side camshaft sprocket with the notch in the belt cover.
  23. Attach the timing belt to the crankshaft sprocket and camshaft sprocket, avoiding slackening of the belt on the upper side.
  24. Loosen the tensioner 1 / 2 turn to apply tension to the belt. Push the belt by hand to ensure smooth operation.
  25. 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.
  26. Tighten the left bolt, then the right 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. Remove the crankshaft pulley.
  29. Install the right front belt cover seals and belt cover plug. Install the belt covers to the cylinder block.
  30. On turbo-charged engines, install the belt cover plate.
  31. Install the crankshaft pulley and tighten to 66-79 ft. lbs. (89-107 Nm).
  32. 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.
  33. Install and properly tension the accessory drive belt.

    Click image to see an enlarged view

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


2.0L Engine
  1. Disconnect the negative battery cable.
  2. Remove the V-belt.
  3. Remove the crankshaft pulley.
  4. Remove the belt cover as follows:
    1. Crankshaft pulley.
    2. Left hand belt cover.
    3. Right hand belt cover.
    4. Front hand belt cover.

      Click image to see an enlarged view

      Fig. Remove the left hand (A), right hand (B) and front (C) belt covers-2.0L engine


  5. Remove the timing belt guides on vehicles equipped with a manual transmission.
  6. If the alignment marks that indicate rotation are faded, put new marks on the belt before removal as follows:
    1. Turn the crankshaft using crankshaft sprocket tool 499987500 and a breaker bar to align the crankshaft sprocket, left hand intake camshaft sprocket, left hand exhaust camshaft, right hand intake camshaft sprocket and right hand exhaust camshaft sprocket with the on the cover and cylinder block.
    2. Using white paint such as white out, place alignment marks on the belts in relation to the sprockets.

  7. Remove the belt idler (A), illustrated in the accompanying illustration.
  8. Remove the timing belt.
  9. If necessary, remove belt idlers (B) and (C).
  10. Remove the belt idler 2.
  11. Remove the automatic belt tension adjuster assembly.

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    Fig. Location of the upper belt guide-2.0L engine



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    Fig. Location of the upper left belt guide-2.0L engine



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    Fig. Location of the lower right belt guide-2.0L engine



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    Fig. Location of the lower left belt guide-2.0L engine



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    Fig. Mark the upper belt-to-sprocket alignment-2.0L engine



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    Fig. Mark the lower belt-to-sprocket alignment-2.0L engine



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    Fig. Remove the belt idler (A)-2.0L engine


To install:

  1. To prepare the automatic belt tensioner for assembly, perform the following steps:
    1. Always use a vertical type pressing tool to move the adjuster rod down.
    2. Do not use a lateral type vise.
    3. Always push the adjuster rod vertically.
    4. Make sure to slowly move the adjuster rod down applying a pressure of 66 lbs. (294 N).
    5. Press in the push adjuster rod gradually taking more than 3 minutes.
    6. Never allow the press pressure to exceed 2,205 lbs. (9,807 N).
    7. Press the adjuster rod as far as the end surface of the cylinder. Do not press the rod into the cylinder as doing so may damage the cylinder.
    8. Never release the press pressure until the stopper pin has been fully inserted.

  2. Attach the automatic belt tension adjuster assembly to the vertical pressing tool.
  3. Move the adjuster rod down slowly using a pressure of 66 lbs. (294 N) until the rod is aligned with the stopper pin hole in the cylinder.
  4. Insert a 0.08 inch (2mm) stopper pin or diameter Allen wrench into the stopper pin hole in the cylinder to retain the rod.
  5. Install the adjuster assembly and tighten the retainers to 29 ft. lbs. (39 Nm).
  6. Install belt idle 2 and tighten the retainers to 29 ft. lbs. (39 Nm).
  7. Install the belt idler and tighten to 29 ft. lbs. (39 Nm).
  8. Align the mark on the crankshaft sprocket with the mark on the oil pump.
  9. Align the single line mark on the right hand exhaust camshaft sprocket with the notch on the belt cover.
  10. Align the single line mark on the right hand intake camshaft with the notch on the belt cover. Make sure the double lines on the intake camshaft and exhaust sprockets are aligned as shown in the accompanying illustration.
  11. Align the single line mark on the left hand exhaust camshaft sprocket with the notch on the belt cover by turning the sprocket counterclockwise (as viewed from the front of the engine).
  12. Align the single line mark on the left hand intake camshaft sprocket with the notch on the belt cover by turning the sprocket counterclockwise (as viewed from the front of the engine). Make sure the double lines on the intake camshaft and exhaust sprockets are aligned as shown in the accompanying illustration.
    NOTE
    Make sure the camshaft and crankshaft sprockets are positioned correctly. 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.



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    Fig. Attach the automatic belt tension adjuster assembly to the vertical pressing tool-2.0L engine



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    Fig. Insert a 0.08 inch (2mm) stopper pin or diameter Allen wrench into the stopper pin hole in the cylinder to retain the rod-2.0L engine



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    Fig. Install the adjuster assembly-2.0L engine



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    Fig. Align the mark on the crankshaft sprocket with the mark on the oil pump-2.0L engine



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    Fig. Align the single line mark on the right hand exhaust camshaft sprocket with the notch on the belt cover-2.0L engine



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    Fig. Align the single line mark on the right hand intake camshaft with the notch on the belt cover. Make sure the double lines on the intake camshaft and exhaust sprockets are aligned-2.0L engine



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    Fig. Align the single line mark on the left hand exhaust camshaft sprocket with the notch on the belt cover by turning the sprocket counterclockwise (as viewed from the front of the engine)-2.0L engine



    Click image to see an enlarged view

    Fig. Align the single line mark on the left hand intake camshaft sprocket with the notch on the belt cover by turning the sprocket counterclockwise (as viewed from the front of the engine). Make sure the double lines on the intake camshaft and exhaust sprockets are aligned-2.0L engine

  13. 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.



    Click image to see an enlarged view

    Fig. Align the marks in alphabetical order as shown if using a new belt-2.0L engine

  14. Install the belt idlers and tighten to 29 ft. lbs. (39 Nm).
    WARNING
    Make sure the marks on the belt and sprockets are properly aligned.

  15. Once the marks on the belt and sprockets are aligned, remove the stopper pin from the tensioner adjuster.
  16. Install the timing belt guide on vehicles with manual transmission. Measure the clearance between the belt and guide. the clearance should be 0.019-0.059 inch (0.5-1.5mm) and tighten the retainers to 7 ft. lbs. (10 Nm).
  17. Install the belt covers and tighten to 3.5 ft. lbs. (5 Nm).
  18. Install the crankshaft pulley and tighten the bolt to 94 ft. lbs. (127 Nm).
  19. Install the V-belt.

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