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Old 06-24-2005, 08:44 PM   #1
Soon2BturbodRS
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Unhappy Engine problems - Need help ASAP!

So I started my car up today and there was a horrid noise from underhood. I pop it real quick and take a look... The crankshaft pulley bolt (the big 22mm one holding the pully onto the end of the crank) is loose, the pulley wobbling, and the accessory belt (power steering and alternator) is off.

The car has 126,869mi and this is the second time this has happened. The first time (121,702mi), everything came out okay, I put everything back together, torqued the bolt on and everything, and it was fine. This time, the pulley wouldn't go back on quite right.

After further investigation, it was obvious that the key on the crank has melted out of shape (pictures accompany description):


btw, the key is supposed to have 90-degree angles, not rolly-polly edges...

So, I called up the local Subie dealership (Lithia Subaru, Oregon City, OR) and they said there are two possible things they can do but both depend on how bad it is:
1. Re-work the crank and the key (~$550)
2. The car might need a new motor (~$3000-4000)

Can any of you tell me if the key is too mis-shaped to be fixed?? I want to get an opinion before I have it towed into the dealership because... If it needs a new engine, I don't know what to do. As much as I want to drop in a WRX motor I do not have the extra money for that... So if it needs a new engine, it's gotta go.

So what do you guys have to say? What should I do??

Thanks
-Ben
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Last edited by Soon2BturbodRS; 06-25-2005 at 04:40 PM.
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Old 06-24-2005, 09:14 PM   #2
munkis
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The woodruff key apears to e damaged, its removable. If you search for wooderuff key, I posted the part number for the ej crank in another thread, someone who had a similar problem.

Jay
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Old 06-24-2005, 09:35 PM   #3
Soon2BturbodRS
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Thank you!
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Old 06-24-2005, 10:14 PM   #4
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Quote:
Originally Posted by Soon2BturbodRS
Thank you!
Unless you're going to build it yourself, a new crank will probably cost you more than a "new" motor.
You should be able to find one of those engines for the $500 you would spend to have them "rework" the crank.
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Old 06-25-2005, 10:07 AM   #5
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holy smokes

what does the pulley look like??
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Old 06-25-2005, 12:17 PM   #6
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I would get a new key and pully, see if you can get that to wrok for a while. Then start saving money for a new motor.
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Old 06-25-2005, 02:34 PM   #7
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The pulley looks fine (to me but what do i know lol). I will post pics asap
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Old 06-25-2005, 02:48 PM   #8
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Front of the pulley
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Old 06-25-2005, 02:49 PM   #9
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Old 06-25-2005, 02:49 PM   #10
Soon2BturbodRS
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Closer look at the keyhole
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Old 06-25-2005, 03:31 PM   #11
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WHOA, thatís broken! The key slot should go the whole distance of contact. I got a cheap pulley on e-bay for 24 bucks plus shipping. Its light weight, but also under driven, and requires shorter belts i think. That might get you started.

Some time next week i will have a spare 1.8L motor, research if you can use any of it. Atleast you should be able to use the crank pulley.

Next time Turn youíre motor off the FIRST time you hear a bad noise. No doubt that thing was noisy.

Like i said before, start saving up for a new motor, or a get a creadit card.

Last edited by RS_to_WRX_swap; 06-25-2005 at 03:36 PM.
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Old 06-25-2005, 04:03 PM   #12
Patrick Olsen
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Quote:
Originally Posted by Soon2BturbodRS
So, I called up the local Subie dealership (Lithia Subaru, Oregon City, OR) and they said there are two possible things they can do but both depend on how bad it is:
1. Re-work the crank and the key (~$550)
2. The car might need a new motor (~$3000-4000)
Your photobucket pics aren't working for me, so I can't tell anything about the key and crank.

However, if it comes to replacing the motor, you should be able to find an engine to salvage for way less than $3-4k. I could be wrong, but I think the Pac Norwest is much like New England (where I used to live) with lots of Subarus rolling around. That means lots of Subarus in salvage yards, waiting for you to come get their engine.

Good luck!
Pat Olsen
'97 Legacy 2.5GT sedan
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Old 06-25-2005, 05:24 PM   #13
Soon2BturbodRS
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Thanks everyone...

Well... At a closer look, the end of the crank is not looking very good
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Old 06-25-2005, 06:08 PM   #14
Soon2BturbodRS
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So right now, I figure a temporary (2000-5000mi) fix would include:

Brand new crank pulley (Perrin or Mr.Josh lightened?)
New crank sprocket
New crank pulley bolt (the 22mm one)

and since the covers and bolts are old and wisconsinated (aka rusted bolts, worn covers), I bought new timing belt cover bolts that are due to arrive soon.

Thanks in advance for any help
-Ben
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