donkijote Posted July 8, 2005 Share Posted July 8, 2005 I have 94 RHD Subaru legacy L (2.2L) station wagon and its water pump went out recently. Since this vehicle had some oil leak problem, I decided to replace the oil seals (for camshafts and crankshaft) and vave cover gaskets along with the water pump. I've got the genuine Subaru parts and got it all installed, but now my Subaru is not starting up obviously for something I screwed up along the way. I used a compression gauge to locate the TDC for cylinder #1, but I am not so sure about the camshaft pulleys' position, although they're all aligned with the timing belt mark. It is supposedly at 44 and 40.5 tooth width, but I just could not align one of it to 40.5 tooth width (it is currently at 39.5) point. My questions are: 1. Suppose your timing belt is snapped off and you are installing a brand-new timing belt from a scratch, how would you align the camshaft pulleys precisely in relation to the TDC position for cylinder #1? Does anyone have a detailed installation procedure for 2.2L SOHC Legacy? 2. Do you use any special tool to align the right side of camshaft pulley at 40.5 tooth mark? It currently has a NAPA brand timing belt that I am planning to re-use and it seems to be one tooth short. It has 216 tooth in total and I was curious as to how many teeth are there in a genuine Subaru timing belt. Any advices would be greatly appreciated! Many thanks in advance! Quote Link to comment Share on other sites More sharing options...
ferret Posted July 8, 2005 Share Posted July 8, 2005 Great URL for you...it's a .PDF also you can save and print http://endwrench.com/images/pdfs/TBeltEWWin05.pdf Quote Link to comment Share on other sites More sharing options...
donkijote Posted July 8, 2005 Author Share Posted July 8, 2005 This PDF document is much better than my Haynes repair manual. I will give it another try! Great URL for you...it's a .PDF also you can save and printhttp://endwrench.com/images/pdfs/TBeltEWWin05.pdf Suppose that the timing belt was snapped off...how would you align the camshaft pulleys accurately? Isn't this just a matter of turning the intake side clockwise and the outtake side counter-clockwise, and align it to the mark? When I took the timing belt off, crankshaft was at the mark, but both cam pulleys were at 10 O'clock position. And the tooth width was at 43 and 41.5 mark, and the Subaru was starting up all right then. During my last attempt, cams and crank were all aligned, but the timing belt was at 44 and 39.5 mark(1 tooth short here), and Subaru was not starting up. Can anyone explain to me why? Many thanks! Quote Link to comment Share on other sites More sharing options...
BigMattyD Posted July 8, 2005 Share Posted July 8, 2005 I would think that you could just turn the camshaft sprockets by hand until the timing mark (the small radial hash mark on the edge of the sprocket, not the arrow) lines up with the timing mark on the belt cover (12 o'clock). When I changed my belt, I had to rotate them by hand a bit because one of them moved out of place while I was working. I just kept turning it in the same direction till it lined up again. I think the crankshaft is the only thing you have to be worried about. I may be wrong, but I think it is possible to have the timing mark in the right position, but for the crankshaft to be a full rotation off. That is, at the bottom of the stroke for cyl.1 vs. TDC? I am sure someone smarter than me can verify or dispute this. matt Quote Link to comment Share on other sites More sharing options...
TheBigJ Posted July 8, 2005 Share Posted July 8, 2005 I would think that being off by one tooth would not cause the car to not start. I think it should still start but not run very well - although I haven't verified this. There are many other things that can prevent the car from starting. When I did this, I was confounded that my car was not starting either. Fortunately for both of us the 2.2L is non interference so you couldn't have bent any valves or done any other damage. Pull out a spark plug, ground the body, and see if it's sparking. Mine wasn't. Turned out to be the crank position sensor which is mounted in the top of the oil pump. I forgot to put it back in and this prevents the car from starting. I think the cam sensors can cause this to happen as well. The timing belt I got from NAPA had marks on it at the appropriate number of teeth for installation. If you are removing the belt, look for these, they can help with the installation quite a bit. But don't expect them to line up after you turn the engine around with the belt installed. Quote Link to comment Share on other sites More sharing options...
donkijote Posted July 8, 2005 Author Share Posted July 8, 2005 I've followed the pdf document that ferret sent to me and I was able to align it to the timing belt alignment marks at 44 and 40.5 tooth width. Put'em all back together, but it still does not start up! I opened up oil pump housing to replace its O-ring inside, so as TheBigJ said, I had to remove crankshaft pos sensor, but it was re-installed. As for the camshaft sensor, I did not touch it. How do I check if the crank pos sensor is good? I also disconnected the electrical harness for the ignition coil, but it was reconnected. I removed the spark plug from cylinder #1 and smelled gas. Therefore, it is safe to assume that there was no spark. The crank pos sensor could be the culprit, but it is most likely to have something to do with the camshaft position(s). Ignition timing is just a way way off, therefore no spark or it just misses the right window completely. What I am still curious about is as to how to adjust the camshafts relative to the cylinder#1 TDC? When I brought the cylinder#1 at TDC and opened up the whole unit, both cam pulleys were at 10 O'clock position My Subaru was running good before its water pump went out, so the whole thing is a big mystery. Many thanks to everyone and hopefully I will get this Subaru start up soon. Any advices or helpful tips are still greatly appreciated. Many thanks in advance! This PDF document is much better than my Haynes repair manual.I will give it another try! Suppose that the timing belt was snapped off...how would you align the camshaft pulleys accurately? Isn't this just a matter of turning the intake side clockwise and the outtake side counter-clockwise, and align it to the mark? When I took the timing belt off, crankshaft was at the mark, but both cam pulleys were at 10 O'clock position. And the tooth width was at 43 and 41.5 mark, and the Subaru was starting up all right then. During my last attempt, cams and crank were all aligned, but the timing belt was at 44 and 39.5 mark(1 tooth short here), and Subaru was not starting up. Can anyone explain to me why? Many thanks! Quote Link to comment Share on other sites More sharing options...
Legacy777 Posted July 9, 2005 Share Posted July 9, 2005 You don't need to align anything for TDC. You align the marks on the cams and crank to the marks on the cover and oil pump. Are you sure you're using the correct mark on the crank gear. Don't use the arrrow on the front of the gear. Use the mark on the back of the one tab. Here's pics of my timing belt job http://www.main.experiencetherave.com:8080/subaru/images/timingbelt/ Factory manual scans for the timing belt job http://www.main.experiencetherave.com:8080/subaru_manual_scans/FSM_Scans/Timing_belt1.jpg http://www.main.experiencetherave.com:8080/subaru_manual_scans/FSM_Scans/Timing_belt2.jpg http://www.main.experiencetherave.com:8080/subaru_manual_scans/FSM_Scans/Timing_belt3.jpg http://www.main.experiencetherave.com:8080/subaru_manual_scans/FSM_Scans/Timing_belt4.jpg http://www.main.experiencetherave.com:8080/subaru_manual_scans/FSM_Scans/Timing_belt5.jpg http://www.main.experiencetherave.com:8080/subaru_manual_scans/FSM_Scans/Timing_belt6.jpg http://www.main.experiencetherave.com:8080/subaru_manual_scans/FSM_Scans/Timing_belt7.jpg http://www.main.experiencetherave.com:8080/subaru_manual_scans/FSM_Scans/Timing_belt8.jpg Quote Link to comment Share on other sites More sharing options...
donkijote Posted July 11, 2005 Author Share Posted July 11, 2005 Thanks everyone for your patience and help! I have finally got my Subaru started up this morning! Previously I aligned the timing belt mark to the crankshaft arrow (not sure what the purpose of this small arrow is, but it obviously confused me as the alignment mark), but after re-aligning the belt precisely to the mark at 44 and 40.5 tooth width, it just started right up at the first try. I have learned an invaluable lesson this time and hopefully I would be able to help out someone in a similar situation. Many thanks again! Quote Link to comment Share on other sites More sharing options...
The Dude Posted July 11, 2005 Share Posted July 11, 2005 .....You engine probably would be full of bent valves and maybe a couple of damaged pistons. You might have needed a new engine. But since your 2.2L engine is an older non-interference type all you suffered was a little inconvenience. Of course, your engine doesn't have the 0.5% HP boost that comes along with an interference engine. What do think, was worth it to have an engine with an imperceptably smaller amount of HP to avoid a $3,0000 or more repair bill? BTW, ALL current Subaru engines are INTERFERENCE engines, so don't count on being so lucky with your next Suby. Quote Link to comment Share on other sites More sharing options...
BigMattyD Posted July 11, 2005 Share Posted July 11, 2005 I had a feeling you were using the wrong timing marks either on the crankshaft or camshaft pulleys... I am glad you got the problem straightened out. Matt Quote Link to comment Share on other sites More sharing options...
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