2001 СУБАРУ ФОРЕСТЕР. Руководство по обслуживанию

TIMING BELT ASSEMBLY

Mechanical

2. BELT IDLER AND AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY

1) Remove belt idler (B) and (C).

Z1: 54.5 tooth length Z₂: 51 tooth length Z₃: 28 tooth length

2) Remove belt idler No. 2.

6) Remove belt idler (A).

3) Remove automatic belt tension adjuster assembly.

7) Remove timing belt.

CAUTION:

After timing belt has been removed, never rotate intake and exhaust, camshaft sprocket. If camshaft sprocket is rotated, the intake and exhaust valve heads strike together and valve stems are bent.

B: INSTALLATION

S183099A11

1. AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER

S183099A1101

1) Preparation for installation of automatic belt tension adjuster assembly:

CAUTION:

• Always use a vertical type pressing tool to move the adjuster rod down.

• Do not use a lateral type vise.

• Push adjuster rod vertically.

ME(DOHC TURBO)-49

TIMING BELT ASSEMBLY

Mechanical

• Be sure to slowly move the adjuster rod down applying a pressure of 294 N (30 kgf, 66 lb).

• Press-in the push adjuster rod gradually taking more than three minutes.

• Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb).

• 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.

• Do not release press pressure until 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 lb) until the adjuster rod is aligned with the stopper pin hole in the cylinder.

2) Install automatic belt tension adjuster assembly.

Tightening torque:

39 Nm (4.0 kgf-m, 28.9 ft-lb)

3) Install belt idler No. 2.

Tightening torque:

39 Nm (4.0 kgf-m, 28.9 ft-lb)

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

4) Install belt idler.

Tightening torque:

39 Nm (4.0 kgf-m, 28.9 ft-lb)

2. TIMING BELT

S183099A1102

1) Preparation for installation of automatic belt tension adjuster assembly. <Ref. to ME(DOHC TURBO)-49, AUTOMATIC BELT TENSION ADJUSTER ASSEMBLY AND BELT IDLER, INSTALLATION, Timing Belt Assembly.>

2) Crankshaft and camshaft sprocket alignment.

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TIMING BELT ASSEMBLY

Mechanical

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

(4) Align single line mark (A) on left-hand exhaust camshaft sprocket with notch (B) on belt cover by turning sprocket counterclockwise (as viewed from front of engine).

(2) Align single line mark (A) on right-hand exhaust camshaft sprocket with notch (B) on belt cover.

(5) Align single line mark (A) on left-hand intake camshaft sprocket with notch (B) on belt cover by turning sprocket clockwise (as viewed from front of engine).

Ensure double lines (C) on intake and exhaust camshaft sprockets are aligned.

(3) Align single line mark (A) on right-hand

intake camshaft sprocket with notch (B) on belt

cover.

(Make sure double lines (C) on intake camshaft

and exhaust camshaft sprockets are aligned.)

(6) Ensure camshaft and crankshaft sprockets are positioned properly.

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TIMING BELT ASSEMBLY

Mechanical

CAUTION:

• Intake and exhaust camshafts for this DOHC engine can be independently rotated with timing belts removed. As can be seen from the figure, if intake and exhaust valves are lifted simultaneously, their heads will interfere with each other, resulting in bent valves.

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 camshafts to rotate in the direction shown in the figure as this causes both intake and exhaust valves to lift simultaneously, resulting in interference with their heads.

(A) Intake camshaft

(B) Exhaust camshaft

• When timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts do not push intake and exhaust valves down. (Under this condition, all valves remain unlifted.)

• When camshafts are rotated to install timing belts, #2 intake and #4 exhaust cam of left-hand camshafts are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Right-side camshafts are held so that their cams do not push valves down.

• Left-hand camshafts must be rotated from the "zero-lift" position to the position where

3) Installation of timing belt

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TIMING BELT ASSEMBLY

Mechanical

Align alignment mark on timing belt with marks on sprockets in the alphabetical order shown in figure. While aligning marks, position timing belt properly.

CAUTION:

• Disengagement of more than three timing belt teeth may result in interference between the valve and piston.

• Ensure belt's rotating direction is correct.

4) Install belt idlers.

Tightening torque:

39 Nm (4.0 kgf-m, 28.9 ft-lb)

CAUTION:

Make sure that the marks on timing belt and

sprockets are aligned.

Clearance:

1.0±0.5 mm (0.039±0.020 in)

5) After ensuring that the marks on timing belt and sprockets are aligned, remove stopper pin from tensioner adjuster.

6) Install timing belt guide. (MT vehicle only)

(1) Temporarily tighten remaining bolts.

(2) Check and adjust clearance between timing belt and timing belt guide.

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TIMING BELT ASSEMBLY

Mechanical

(3) Tighten remaining bolts.

Tightening torque:

9.8 Nm (1.0 kgf-m, 7.2 ft-lb)

7) Install belt cover. <Ref. to ME(DOHC TURBO)-47, INSTALLATION, Belt Cover.>

8) Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.>

9) Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>

C: INSPECTION

S183099A10

1. TIMING BELT

S183099A1001

1) Check timing belt teeth for breaks, cracks, and wear. If any fault is found, replace belt.

2) Check the condition of back side of belt; if any crack is found, replace belt.

CAUTION:

• Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens.

• Do not bend the belt sharply.

Bending radius: h

60 mm (2.36 in) or more

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TIMING BELT ASSEMBLY

Mechanical

2. AUTOMATIC BELT TENSION

ADJUSTER S183099A1002

1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace automatic belt tension adjuster assembly.

CAUTION:

Slight traces of oil at rod's oil seal does not

indicate a problem.

2) Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lb) is applied to it. This is to check adjuster rod stiffness.

3) If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lb), check it using the following procedures:

(1) Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times.

(2) With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it. Check adjuster rod stiffness.

(3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one.

CAUTION:

• Always use a vertical type pressing tool to move the adjuster rod down.

• Do not use a lateral type vise.

• Push adjuster rod vertically.

• Press-in the push adjuster rod gradually taking more than three minutes.

• Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb).

• 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.

4) Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one.

Rod extension: H

5.7±0.5 mm (0.224±0.020 in)

3. BELT TENSION PULLEY

S183099A1003

1) Check mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace belt tension pulley if faulty.

2) Check belt tension pulley for smooth rotation. Replace if noise or excessive play is noted.

3) Check belt tension pulley for grease leakage.

4. BELT IDLER

S183099A1004

1) Check idler for smooth rotation. Replace if noise or excessive play is noted.

2) Check outer contacting surfaces of idler pulley for abnormal wear and scratches.

3) Check idler for grease leakage.

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TIMING BELT ASSEMBLY

Mechanical

15. Timing Belt Assembly		S183099
A: REMOVAL	S183099A18

1. TIMING BELT	S183099A1801
1) Remove V-belt. <Ref. to ME(DOHC TURBO)-44, REMOVAL, V-belt.> 2) Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.> 3) Remove belt cover. <Ref. to ME(DOHC TURBO)-47, REMOVAL, Belt Cover.> 4) Remove timing belt guides. (MT vehicle only)
			5) If alignment mark and/or arrow mark (which indicates rotation direction) on timing belt fade away, put new marks before removing timing belt as follows: (1) Turn crankshaft using ST, and align alignment marks on crankshaft sprocket, left-hand intake camshaft sprocket, left-hand exhaust camshaft sprocket, right-hand intake camshaft sprocket and right hand exhaust camshaft sprocket with notches of belt cover and cylinder block. ST 499987500 CRANKSHAFT SOCKET


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


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	TIMING BELT ASSEMBLY

	Mechanical

	CAUTION: • Intake and exhaust camshafts for this DOHC engine can be independently rotated with timing belts removed. As can be seen from the figure, if intake and exhaust valves are lifted simultaneously, their heads will interfere with each other, resulting in bent valves.	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 camshafts to rotate in the direction shown in the figure as this causes both intake and exhaust valves to lift simultaneously, resulting in interference with their heads.


	(A) Intake camshaft (B) Exhaust camshaft • When timing belts are not installed, four camshafts are held at the "zero-lift" position, where all cams on camshafts do not push intake and exhaust valves down. (Under this condition, all valves remain unlifted.) • When camshafts are rotated to install timing belts, #2 intake and #4 exhaust cam of left-hand camshafts are held to push their corresponding valves down. (Under this condition, these valves are held lifted.) Right-side camshafts are held so that their cams do not push valves down. • Left-hand camshafts must be rotated from the "zero-lift" position to the position where
		3) Installation of timing belt


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TIMING BELT ASSEMBLY

Mechanical



(3) Tighten remaining bolts. *Tightening torque:* *9.8 Nm (1.0 kgf-m, 7.2 ft-lb)*	7) Install belt cover. <Ref. to ME(DOHC TURBO)-47, INSTALLATION, Belt Cover.> 8) Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.> 9) Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>

	C: INSPECTION		S183099A10
	1. TIMING BELT	S183099A1001
	1) Check timing belt teeth for breaks, cracks, and wear. If any fault is found, replace belt. 2) Check the condition of back side of belt; if any crack is found, replace belt. CAUTION: • Be careful not to let oil, grease or coolant contact the belt. Remove quickly and thoroughly if this happens. • Do not bend the belt sharply. *Bending radius: h* *60 mm (2.36 in) or more*


ME(DOHC TURBO)-54



TIMING BELT ASSEMBLY

Mechanical

2. AUTOMATIC BELT TENSION ADJUSTER S183099A1002 1) Visually check oil seals for leaks, and rod ends for abnormal wear or scratches. If necessary, replace automatic belt tension adjuster assembly. CAUTION: Slight traces of oil at rod's oil seal does not indicate a problem. 2) Check that the adjuster rod does not move when a pressure of 294 N (30 kgf, 66 lb) is applied to it. This is to check adjuster rod stiffness. 3) If the adjuster rod is not stiff and moves freely when applying 294 N (30 kgf, 66 lb), check it using the following procedures: (1) Slowly press the adjuster rod down to the end surface of the cylinder. Repeat this motion 2 or 3 times. (2) With the adjuster rod moved all the way up, apply a pressure of 294 N (30 kgf, 66 lb) to it. Check adjuster rod stiffness. (3) If the adjuster rod is not stiff and moves down, replace the automatic belt tension adjuster assembly with a new one. CAUTION: • Always use a vertical type pressing tool to move the adjuster rod down. • Do not use a lateral type vise. • Push adjuster rod vertically. • Press-in the push adjuster rod gradually taking more than three minutes. • Do not allow press pressure to exceed 9,807 N (1,000 kgf, 2,205 lb). • 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. 4) Measure the extension of rod beyond the body. If it is not within specifications, replace with a new one. *Rod extension:* H 5.7±0.5 mm (0.224±0.020 in)	3. BELT TENSION PULLEY		S183099A1003
	1) Check mating surfaces of timing belt and contact point of adjuster rod for abnormal wear or scratches. Replace belt tension pulley if faulty. 2) Check belt tension pulley for smooth rotation. Replace if noise or excessive play is noted. 3) Check belt tension pulley for grease leakage.
	4. BELT IDLER	S183099A1004
	1) Check idler for smooth rotation. Replace if noise or excessive play is noted. 2) Check outer contacting surfaces of idler pulley for abnormal wear and scratches. 3) Check idler for grease leakage.



ME(DOHC TURBO)-55