Hello, all. I recently bought a 1992 940 turbo for my daughter, and we have loved it (only 120k miles), until last week. The outer portion of the crank shaft pulley separated from the inner (rubber damper tore up), so I replaced it and the three outer belts (with help from this forum).

But here is the problem: I started it yesterday after finishing the work, and it chugged a little bit (daughter said this happened to her before it quit), so I gave the engine more gas. As I revved it up, I heard this clicking or popping sound at about 3k rpm several times, then the engine just died. Now I can't get it started (turns over, though).

I checked the timing belt by looking in the oil-filler while engine is being cranked, and the camshaft turned. So where do I look next? Did something go wrong that pushed the crankshaft pulley to finally give up? Did I do something wrong? The pulley was set to TDC, so where do I start looking? Might this be a fuel relay?

Help!!!

Thanks so much.

 

did you set all your marks? crank pulley at zero, and camshaft? try rotating the crank pulley 360 degrees back to zero mark and try again.

 

The absolute, all time error in replacing the cam belt is not timing the jack shaft (intermediate shaft) that runs the block mounted distributor. I think in 92 the distributor was still on the cam shaft so that wouldn't be a factor. Assuming you got the harmonic balancer installed on the key way and torqued down properly and had it set at 0...then I would definitely check it again and,as mentioned...check the cam timing. I feel certain this is a simple timing issue. The fact it did it to your daughter prior to the work is a result of the 2 piece harmonic balancer spinning internally. Once the rubber shears, it is impossible to keep timed.

 

Thanks for the input so far. I had the opportunity to check the spark, and it is great (I know you all did not mention that yet). As soon as I finish here I will take the belts and everything off and look at it all over again. So if the timing is off the car might not actually start?

If there is no problem with the new crank shaft pulley installation (or the timing belt adjustment), how do I check to see if fuel is getting to the engine? How do you get the dang relays out from under the radio? I know how to get to the fuses, but the relays are so far back in there. The Chilton manual gives no instructions.

 

You folks are awesome!

First, I didn't check my marks when replacing the pulley, and I did not take off the timing belt cover (I was trying to avoid all that). Today I took the plunge: replaced the timing belt and tensioner pulley, put it all back together, and the 940 runs great.

This car is so much fun to drive, and thanks for helping me to get it running again.