UPDATE:new xt, tensioner pulley striped bolts

[rpholz]

so i recently picked up a 89 XT GL full time all wheel drive, n/a, auto 30,000 original miles. (same car from classified section, "89 XT JAX FL")

 

:banana:and so my XT collection grows!

 

 

anywhoo. my question is the tensioner pulley for the driver side T-belt has both bolts stripped out, and i can't tell if the threads came out or a heli-coil, now what are my options for this? re-helicoil it? or thread for bigger bolt.

 

and we won't get into the hack job of some one re-wiring the injectors:mad:

i don't even understand what they were trying to accomplish

Edited May 23, 2010 by rpholz

[idosubaru]

I've fixed this before. The easiest method is to just get a longer bolt of the same thread and pitch. Pretty sure those are 8x1.25 threads - maybe 10x1.25. Just take the original bolt with you to any hardware store, lowes, home depot and get one a bit longer. Typically the holes are drilled and tapped deeper than the original bolts they use. I have a tap and die set so I usually chase the threads in the block really good...maybe even making them deeper if they're not cut to the bottom. And then chase the bolt I'm using too to make sure they're good and smooth. A dab of oil to make it thread in nice and smooth. If the bolt is too long just use a washer or too as spacers under the head.

 

If that doesn't work you can helicoil it too. It's really not that hard, just get a cheap-o right angle drill attachment. It's really easy - aluminum is easy to drill and the way those timing tensioners are set up it's cake to get to work right.

[murph]

30,000 original miles are you sure about that ? wow , that is cool ! Maybe the wrong bolt was re-installed on the tensioner ? just a fuzz too small ? I personally have not had much luck with heli-coils , but a bigger bolt may not fit in the pulley ..... taking shots in the dark here . good luck , all the best , Murph

[rpholz]

yea, i was thinking of just running the next size up tap to cut new threads and drive a bolt in there, and as far as drilling goes Comcast is nice enough to issue me a 18v dewalt hammer drill so i think i got enough grunt to drill the it out, i just really dont want to go that route cause if it messes up then i got to go even bigger. so i think i shall tap it, and call it a day.

 

 

 

 

EDIT: to murph, pretty sure its got that many miles, everything is in great condition and the pedals, seats, carpet arent worn down enough for it to have more than that, unless a small asian woman drove it. lol

Edited May 21, 2010 by rpholz

[idosubaru]

no luck with heli-coils? what problems did you encounter? when i've used them, they work really well for Subaru timing bolts like this. I've done a few of them and never had a problem.

[idosubaru]

maybe you missed it, you could try a longer bolt first, no drilling required. i was saying i run a same size (not oversized) tap through to clean the threads up and reach the bottom unused good threads.

 

drilling isn't hard at all, the aluminum is very soft.

 

good luck, sounds like you got it covered either way you go.

[rpholz]

maybe you missed it, you could try a longer bolt first, no drilling required. i was saying i run a same size (not oversized) tap through to clean the threads up and reach the bottom unused good threads.

 

drilling isn't hard at all, the aluminum is very soft.

 

good luck, sounds like you got it covered either way you go.

 

oooooooh 10-4 i did try to tread the bolt in without the tensioner there and it caught something but it probly just wasnt enough. i shall try this on sunday(my next day off)

[rpholz]

so i got it running off of starter fluid.

 

 

t-belts are straightened out. and tensioner are holding.

 

 

so now onto the wiring, what a effing nightmare.. the injectors were rewired and hacked to crap, does anyone have a pic or something of which wires coming off the ecu are the injector wires and/or a fsm wiring diagram.

[idosubaru]

we have the complete XT FSM's hosted through subaruxt.com. pretty sure others have had injector wiring issues too, typically under the front passengers side seat, i think there's a thread about that.

[rpholz]

I think what I'm going to try doing is running wire around the car straight from the ecu to the injectors and see if they fire if that doesn't work the obviously I have other issues too

[Sonicfrog]

If XT's are somewhat common in your area, you might go to one or two of the J-Yards and see if there is one that is intact. Examine, take pics, and you're off to the races.

[rpholz]

rewired the injectors with the pin outs john in ky supplied to me (THANK YOU!!) and it fired right up and ran awsome didnt drive it anywhere because it is on a battery charger since my alt isnt hooked up or anything. so tomorrow i soder the wires and tuck them away and all should be well.

 

 

 

but thanks to my buddy (dragonfire) i am now fully aware of some rust issues, albeit small issues but still enough allow a good bit of water into the trunk and a the cab.

[rpholz]

If XT's are somewhat common in your area, you might go to one or two of the J-Yards and see if there is one that is intact. Examine, take pics, and you're off to the races.

 

i don't think any old subaru is common in my area, seeings how between me and dragonfire those are the only 80s models subes i've seen (except for where i used to live, farther south, i knew where every 80's model resided in that town mwhaha!)