Join Date: Dec 2009
Location: Salt Lake City, UT
Car Year: 2004
Car Model: Forester XT
Caution on Dayco Timing Belt Kit
I just changed the timing belt and associated idlers and pulleys on my new to me 2004 XT and ran into a bit of a problem.
First the kit I am referring to was purchased from Advance Auto and is Dayco part number 95328K1. I can't post a link since I don't have 15 posts, maybe when I get to that number I'll edit with the link.
Now on to the story. The smallest idler pulley that came in the kit appeared to be exactly the same as the one that was coming off, so I bolted it right up and torqued it down. Then came that dreaded feeling when turning the bolt suddenly becomes a lot easier than it ought to be. The bolt had broken off right where the threads end and was flush with the engine surface. After a few nights of drilling and hammering to get it off, we attempted a bolt extractor to pull out the broken bolt. While doing this we only succeeded in cracking the mounting tab in half. After a few minutes of near panic trying to figure out how much it would cost to get it machined and put back to a usable state, I realized the piece that this particular hole in is actually removable, so for the low price of $36 I had replaced all the broken bits in this area.
Then when I went to put the idler on the new bracket I realized that the unthreaded portion of the bolt was sticking out past the end of the idler. The bolt had run in to the unthreaded portion, but because the idler wasn't tight to the engine surface, I had kept tightening it. With no way to go in any further, the bolt had snapped.
Upon further inspection I noticed that the bearing inside the idler was recessed further than the one in the original idler. Since I was on a deadline to drive this car from NY to UT, I didn't have time to get a replacement so I added a spacer under the bolt head and everything torqued down just fine without any trouble.
So be on the lookout if using this kit, or any other, make sure that everything is exactly the same as the piece coming off. It will save a lot of headache and panic.
<tl;dr> Idler bearing was recessed too far, snapped the bolt and had to replace bolt and tensioner bracket.