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Autopapyrus · Subaru Forester SH 2.0 EJ204 (2011)
https://autopapyrus.com/guides/subaru/forester/alternator-belt-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Subaru Forester SH 2.0 EJ204 (2011): Alternator Belt Replacement

The Subaru Forester SH with the 2.0 EJ204 engine uses a two-belt drive layout: a separate alternator belt (5PK690) and an A/C belt (4PK805). The alternator belt drives the alternator and the power steering pump. Belt tension is adjusted manually by moving the alternator on its bracket. The procedure is simple and requires no special tools.

Difficulty: Easy Time: 15–20 minutes Steps: 10 Tools: 10 mm box-end wrench, 14 mm open-end wrench, flat-head screwdriver

Part

  • 🔩 Subaru 809218440 or 809218470 (5PK690, length 690 mm, 5 ribs). Aftermarket equivalents: Continental 5PK690, Gates 5PK690, Dayco 5PK690
There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes and 9 more. See manuals →

Step by step

10 steps
  1. Open the hood and let the engine cool down. Remove the plastic protective cover on the right side of the engine: remove the one 10 mm bolt on the left, undo the 10 mm nut on the right, and lift the cover off the stud.
  2. Loosen the upper alternator locking bolt (14 mm) by 1–2 turns. Do not remove it completely.
  3. Loosen the lower adjusting bolt (14 mm) by 2–4 cm. The alternator will now swing freely on the upper bolt, which acts as a pivot.
  4. Push the alternator down toward the cylinder block to release the belt tension. Take the old belt off the alternator pulley, the crankshaft pulley and the idler pulley.
  5. Fit the new 5PK690 belt onto the pulleys in the same order (crankshaft, alternator, idler pulley). Make sure the belt is seated in the pulley grooves and is not twisted.
  6. Pull the alternator away from the engine block (up and outward) to tension the belt. When you press on the belt with your thumb midway between the pulleys, the deflection should be 5–7 mm. It is better to leave the belt slightly loose than to overtighten it.
  7. While holding the alternator in this position, tighten the lower adjusting bolt (14 mm) to 20–25 N·m (15–18 lb-ft).
  8. Tighten the upper locking bolt (14 mm) to 35–40 N·m (26–30 lb-ft).
  9. Check the belt tension again: deflection should be 5–7 mm. Start the engine, let it idle for 1 minute, and shut it off. Recheck the tension and readjust if necessary.
  10. Reinstall the plastic cover and tighten the bolt and nut.

Common mistakes and warnings

  • Do not overtighten the belt. Excessive tension damages the alternator bearing, the power steering pump bearing and the A/C compressor clutch. Do not turn the adjusting bolt all the way to its end stop, as this can damage the threads in the bracket. If the belt slips or squeals on a cold start after installation, increase the tension slightly, by 1–2 mm.