DoughtCom Posted September 29, 2003 Share Posted September 29, 2003 Well... I won't go through the history of this damn car, but I'll just state the current problem, since that's the one I need to fix My crank pully is screwed. The one that runs the serpentine belt. It whobbles, which I've gone through this before due to bastard mechanics not doing their job correctly. Not using "lock tight", so said the past mechanic which obviously didn't follow his own advice . Anyway the key that holds it in place, I'm assuming because that was the last problem, has worn a bigger notch so now it has a lot of free play. I don't really know what the inside (the timing belt area) looks like since I've never taken it apart. But does this mean the main crank gear for the timing belt could be messed up too? Since I think the key goes into that as well, meaning that possibly the notch could be messed up on that too. If so this leads me to the next question..... how hard is it to change the timing belt on a DOHC EJ25 with an auto tensioner (which I believe I have?) I'm assuming it's not easy. But at this point I'm not throwing ANY more money into this bastard of a car.... and my haynes manual makes it seem doable by a person like me. Anyway.... any suggestions on fixing it would be awesome. Thanks in advance guys. Quote Link to comment Share on other sites More sharing options...
P K Posted September 29, 2003 Share Posted September 29, 2003 Sorry to hear. This is a common problem I am learning. My 2.2 did same. To fix, I removed the pulley, timing belt (radiator, etc) to see the worn key and very large slot it is supposed to be in. The crank gear wobbled too - argh. Removed it, then I put a new key in the slot and held it in its correct position with vise grips. I then used a MIG welder to fill the area around the key. Regular torch would be too hot I think, so the MIG was the ticket. I then filed away the excess to re-create the ideal slot. (took quite a good time to file though) I had to buy a new pulley since the old was too damaged. Put everything back on with new timing belt, and she runs perfect... over 2000 miles since. Not an easy fix, especially if you dont have the welder, but it is done right. Good luck. Quote Link to comment Share on other sites More sharing options...
DoughtCom Posted September 29, 2003 Author Share Posted September 29, 2003 So this could have messed up my timing? or the timing gear... that's what I was afraid of . I'm going to start ripping it apart tomorrow, so hopefully I'll see what the damage is. Quote Link to comment Share on other sites More sharing options...
Caboobaroo Posted September 29, 2003 Share Posted September 29, 2003 dude, that sucks major:banghead: Quote Link to comment Share on other sites More sharing options...
Lorryb Posted September 29, 2003 Share Posted September 29, 2003 On the EJ22 the key secures both the crank pulley and the crank Timing belt gear. It sounds like others have had success with rebuilding the keyway by welding. That may be your only course of action. When my pulley got loose and wobbled, it caused the tbelt to skip, throwing out the timing. I had to replace the key, the pulley and the gear, the pulley keyway was worn and I broke a crank sensor tab off the gear. I was lucky though the keyway on the crank was ok. Good luck. Quote Link to comment Share on other sites More sharing options...
cookie Posted September 29, 2003 Share Posted September 29, 2003 but when my 85 Mercedes spun the front crank pulley because of insufficent torque on the bolt, (I took the bolt out by hand and it should have been over 200 ft lbs) I fixed it by running the motor for short periods and using it like a lathe. I put various cutting tools from files to emery paper on the shaft exactly as if I was turning on a lathe. Be careful. If you did not have metal transfer this step would not be necessary. When I had it down to the correct diameter by measuring it with a mike I made a custom key to fill the slot. I could not weld it up as all I have is an oxy acetelene outfit at home. That would get the area too hot and kill the temper of the forged steel crank. The key I made just fit the enlarged slot and was two widths. The bottom section was larger to compensate for the wear, and the upper part that fit inside the crank damper was the stock size. To keep the timeing correct required very careful measurement and a lot of fileing on the custom key. Quote Link to comment Share on other sites More sharing options...
ShawnW Posted September 29, 2003 Share Posted September 29, 2003 I would try to get a used engine or have yours rebuilt by CCR. http://www.ccrengines.com Quote Link to comment Share on other sites More sharing options...
MorganM Posted September 29, 2003 Share Posted September 29, 2003 Hey I have that EJ22 main crank pulley and key thats in good shape if you want it. I dont know if it will swap onty an EJ25? Dont worry about any money for it; if it was actually worth something I would have sold it by now I dont have the timing gears however. If your timing gears are funked up you'll have to figure out something else. I'm sure a metal shop can weld up what you need done but trouble would be explaining to them exactly what you need. Maybe what happend was the last 2 guys who "fixed" this problem used the old crank gears with the messed up key slot and that is whats cuasing just enough initial play to start wearing out your new pulley and key? Just a thoguht on why it keeps happening. Why do you have to change the timing belt? Cant just loosen the tensioner pully enough to let you slip off the crank gear? If it does indeed have to come off besure to set the engine by hand exactly where all the marks are lined up. That will make installing the new one SOO much easier. Quote Link to comment Share on other sites More sharing options...
theotherskip Posted September 29, 2003 Share Posted September 29, 2003 changing the timing belt is not that difficult. i thought it would be much more difficult, but it wasn't that bad. one of the most difficult parts is removing the crank pulley bolt, but that won't be a problem in you case. you can see what is in store at my head gasket site . it has lots of pictures of doing the head gasket, and you have to do a timing belt change to get the heads off. it also has how to compress the tensioner by hand. it can at least give you some idea of what you would be in for if you try it yourself. if i recall correctly, the crank sprocket had it's own key built in...correct? Quote Link to comment Share on other sites More sharing options...
DoughtCom Posted September 30, 2003 Author Share Posted September 30, 2003 Well.... I took off the harmonic balancer to find that the F#@$ing bolt wasn't even on tight!!! I just used my damn hands to undo the bolt. Now that I have it out and on my desk I can see where part of it (like the key wasn't all the way in) has been dug away (lack of a better term). So hopefully I can just replace that and make sure the damn thing is on tight this time. I couldn't see the gear yet, the sun went down and I have no light in my apartment garage (yet). So I'll have to look at that tomorrow . Morgan, sorry I haven't been able to call you lately, life has been crappy (I did infact get dry socket on my right side). If that does fit my car, I would gladly pay you 45 for it, that's much I found it for online. Not sure if it will be the same size and whatnot though. Anyone else know? Anyway hopefully I can just replace this and all will be good. I'm selling it shortly after and relying on my GL-10 this winter, tired of this damn car. Quote Link to comment Share on other sites More sharing options...
MorganM Posted October 6, 2003 Share Posted October 6, 2003 Get that pulley swaped in yet? No worries on money for that thing. Someone needed it years ago and they fell through on the deal so it was just wasting space. Let me know if you need a hand. Peace Quote Link to comment Share on other sites More sharing options...
DoughtCom Posted October 6, 2003 Author Share Posted October 6, 2003 Hey I got it in, the key was in good enough shape that I just needed to put the new pulley on.... I'll hook you up somehow don't worry, I'm strapped for cash now (as always) but I always pay my debts. It seems to run pretty good now... now just to sell it . Now all I have to do is keep my job!! (I hate the technology market). I'll start posting here again soon, just been working on a site for my work on all my spare time. Learning C# as I go. Peace! Quote Link to comment Share on other sites More sharing options...
MorganM Posted October 7, 2003 Share Posted October 7, 2003 Awsome! Glad to hear it swaped in and she is up and running. Compensation? Come install my 4WD dual range tranny for me j/k Quote Link to comment Share on other sites More sharing options...
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