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93 legacy timing EPIC! Please Help!


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So here's the story... 93 subaru legacy with loud engine clacking, I check the HLA's for bad ones, no problem there, I suspect a bad camshaft bearing. seems like that's where the noise is coming from. first I decide to try and replace the little o-ring on the back of the pump, because I had read that a leak there can cause bad oil pressure.

pull it all apart change the o ring and put it back together marking the belt.  start it up its still clacking but doh the oil pump didn't seal

take it apart again and use aenerobic sealant this time and it's good put the belt back on and fire it up to make sure its not leaking before  I put the timing cover back on. New insanely loud clacking noise! I check the marks to see if it skipped a tooth, marks line up. Then I count the teeth, 44 to crankshaft then 40.5. my mark is off from when I took it apart which puzzles me. I try it and the the right camshaft mark is off by a tooth, fire it up anyway and it sounds like spoob so I put it back the way it was at 41.5 teeth and the marks all hit 12oclock on two rotations. at both marks I'm hearing a ping on the compression stroke. valve springs? It's a non interference engine what could I have done?

  did I bleed out the HLA's messing around with it? why won't the slack in the belt match the timing marks. did a piece of sealant I used the first time get in the oil pump and and is blocking the flow? can I hurt the motor running it? pretty sure I didn't drop a bolt in there :)

I've researched all I can and I'm dead in the water, the sound is horrific and I afraid to start it.

 

Anyone have any Subie saving advice?

Cheer, Josh

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Others with FAR more experience will chime in soon, but...

 

...my first thought is tensioner bearing:  It seems to be a common source of noise and trouble.  It might also be the tensioner itself.  Did it feel OK when you SLOWLY compressed the piston back into the cylinder?  Did you remember to pull the lock pin out of the tensioner?

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yeah I have the crank pulley off, there's only 1 line one the crank sprocket and it is lined up with the mark on the top of the oil pump. Do you mean cam pulley? I still can't figure out why I'm one tooth off from what the book says, it lines up at 41.5 teeth on the drivers side cam. Had a buddy listen to it, he thinks it sound like the oil isn't circulating, Maybe my fears that the grey peratex i used the first time is cloggling my oil flow. Damn I should have left the clacking noise alone

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