Saturday, July 18, 2015

Subaru and the Plastic AC Idler Pulley

"That's odd, the ac just stopped working.."

This may be something you run into if you own a 2.5L powered Subaru.  For a number of years, Fuji Heavy Industries decided to use a plastic idler pulley for the ac belt.  This will seem all nice and fine for a good while, but the minute is begins to emit the tiniest chirp you'd better be shopping for a replacement part.  I didn't know about this little gem of a part and it's propensity for failing in spectacular fashion, so I just oiled it and let it ride.  Don't do that!



A replacement pulley that is actually made of metal can be purchased at just about any parts store.  If you have a Saab 9-2x Linear though, it won't show that it fits, so just search as if you own a 2004 Forester with the 2.5L.  The pulley from AutoZone is Duralast #231029 for $39, and the belt is Duralast #353K4 for about $9.  

If you put this off long enough and the pulley fails like mine did, you will also need the Dorman #917-124 Idler Pulley Adjuster Bolt Kit for under $30 with shipping.  Order this part from Amazon as soon as you see that it has failed/melted to everything.  Most parts stores won't have it and won't know how to order it.  The plastic melts to the parts in the kit and just generally makes a mess of things.  In my case, the belt ate into other parts after the pulley failed.  I consider myself lucky though, because sometimes this pulley fails and pushes back into the timing belt cover, clips the belt, and ruins the engine.

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