Special Tools, Engine Disassembly, Cambelt, EGR or ASV Pipes & Rocker Cover Removal Information

SPECIAL TOOLS NEEDED:

QUANTITY PART NUMBER DESCRIPTION

1 X9971AA100 Valve Spring and Seal Tool Kit
1 499207000 Camshaft Sprocket Wrench
1 499437000 Belt Tensioner Tool

STEP 1) Disassembly of the engine components.

^ Remove the battery.
^ Remove the spare tire.
^ Unbolt the alternator and loosen the air conditioner pulser.
^ Remove the belts.
^ With the wires attached move the alternator out of the way.
^ Remove the canister hoses from the guide.
^ With the hoses attached move the canister out of the way.
^ Remove the lower engine compartment skirts.
^ Unbolt the engine cooling fan and shroud assembly. Disconnect the wiring and remove it.
^ Remove the oil filler pipe.
^ Remove the bolt holding the power steering lines to the right hand cam case, if the vehicle is equipped with power steering.
^ Remove the ground wires attached to the cooling system pipe and remove bolt holding the pipe to the left hand cam case.
^ Remove the spark plugs.
^ Remove the distributor cap.
^ Mark the vacuum lines to the distributor and remove them.
^ With the electrical wires attached move the distributor out of the way.

FIGURE 1:

STEP 2) Cambelt Removal.

Unbolt and remove the right and left outer cambelt covers. Using the 1986 Subaru Service Manual section 2-3 as a guide, align the center line of the three lines scribed on the flywheel and check the alignment of the camshaft sprocket timing mark and belt cover notch (See Figure 1). Whichever, side is aligned remove that cambelt from the sprocket. The right side cambelt can be loosened by pushing down on the tensioner pulley, while loosening the tensioner bolts. The left side cambelt can be loosened by pushing down on the top of the cambelt, while loosening the tensioner bolts. Then rotate the engine crankshaft 360~ clockwise being careful not to damage the cambelt that is off the sprocket. Check the alignment and remove the other cambelt according to the instructions given above. (See Figure 1).

NOTE: The tensioner wrench 499007000 should not be used because of clearance problems.

NOTE: Do not remove the cambelts from the engine.
STEP 3) Cambelt sprocket and inner cover removal

Unbolt and remove both cambelt sprockets by holding the sprocket with tool number 499207000. Then unbolt and remove both inner cambelt covers.

NOTE: When removing the right side inner cambelt cover, there is a bolt located behind the tensioner pulley.

FIGURE 2:

STEP 4) Moving the EGR or ASV pipes, and rocker cover removal

Unbolt the EGR pipe on turbo vehicles or the ASV pipes (right and left) on non-turbo vehicles. Without damaging the pipe or pipes move them down 1/2". This will allow more room when removing the cam cases. (See Figure 2). Next detach both right and left breather hoses and unbolt and remove the rocker covers.