OK Experts – I’ve got a problem that has me baffled. This is going to be a long explanation, and I’m sorry for that, but I’d rather give too much explanation and possibly a red herring than too little info.

I recently undertook the task of replacing all the gaskets and seals in my EA82 (1993 Loyale, 5-speed manual). When it came time to replace the rear main seal I removed the flywheel, and much to my horror, discovered that there are no assembly reference marks to reinstall it. Unfortunately, the USMB was down during that time (due to the hackers), and I couldn’t find any other source of reliable information. So I used my intuition, turned the crank until the #1 (front right) cylinder was at TDC, and installed the flywheel with the zero degree mark lined up with the timing reference mark. I then proceeded with the rest of the engine reseal, installing the timing belt and the distributor per the instructions in my Haynes, Chilton and USMB repair guides. Now the problem.

It starts and runs, but when I go to time it, I don’t see the timing marks. What I do see is the three timing-belt marks. I have triple checked to verify that my timing light is attached to the #1 spark plug wire. This doesn’t make any sense to me. Since the timing belts and distributor were installed with reference to the flywheel marks, the engine shouldn’t even be running if I installed the flywheel incorrectly. Anybody have any thought – or better yet, the solution?

Firstly, the flywheel is most likely right. As it is almost impossible to bolt it on incorrectly using all 8 bolts. The reason you didn;'t see any marks for orientation is that the bolt holes are the marks. They aren't in a perfectly spaced circle. A few are closer and a few are further and it is impossible to install all 8 bolts in any other possition.

 

So what we have here, is simple timing problem. This sentence is the key to the answer:

 

"Since the timing belts and distributor were installed with reference to the flywheel marks, the engine shouldn’t even be running if I installed the flywheel incorrectly. "

 

You seem to know that the 3 marks are for timing belts. However the above sentence indicates that you used the numbered degree marks for setting up the belts. Re-do the belts to be lined up/down with the 3 marks, then reinstall the disty aligned with Zero degree mark.

If that still results in bad running let us know I might have a hunch.

Gloyale:

 

Sorry if I mislead you there. When I installed the timing belts, I did use the three timing belt marks, not the TDC marks.

 

Carmanos: What's your hunch?

 

Thanks guys! (or gals!)

You are supposed to install the drivers belt first with the whole(marK) pointing up and the first slot on the flywheel. Then you rotate it so the drivers side whole is pointing down and the passengers is pointing up then attach the passenger belt. If the engine is timed this way it should be ok. I heard rumors the Haynes was wrong. Anyways my hunch is: If you did do it this way and it runs, just runs crappy pull the conector of the front sensor on the throttle body. Have to find a pic of what Im talking about. If its corroded slightly scrape it with a small screwdriver and apply some conector/socket protector from Autozone($1 packets) then connect and disconnect the conector several times quickly so all the corrosion on the conector gets worn off. Be gentle but this should help allot. I though I had a timing problem after instaling both belt with a friend. It ran but acted like it was going to stall or off a tooth. Called a local guru he came over did this with some WD-40 in and out motion blew out the excess and it was like night and day

Thanks for the suggestion. Actually, I installed the timing belts using the instructions found right here on USMB. There is a really good detailed set with nice, clear color pictures.

 

I'll try cleaning the TPS connector per your suggestion. Thanks again.