Crank Pulley install help!! Please help..

[schanne]

My buddy's 1991 m-30 just broke down and needs my help. The crank pulley just came out and the bolt and belts are just laying there.

Isthere any guide's, how to's, or step by steps on puting the pulley back on.

[yodawill2000]

It has a keyway that you line up.

Then you torque the bolt to 160 Ft Lbs.

Hopefully you still have the washer that goes on the crank bolt.


Modified by yodawill2000 at 11:52 AM 8/24/2008

[schanne]

I hope the washer is still there too!

Do I need to set the crank at TDC or anything like that? Adjust timing?

[yodawill2000]

No.The timing belt should still be intact.The pulley has nothing to do with timing.It only drives the accessory belts.The keyway ensures Its lined up timing mark wise.
Modified by yodawill2000 at 1:56 PM 8/25/2008

[schanne]

Problem. Looks to me that the keyway is rusted out and snapped off. Nice...So here's some pics. First, the crank pulley is damaged. Rust is lodged in the slot and a chunk of metel is missing from another spot.

Second, the shaft looks shot to me... Can I or how do I replace the shaft?

[schanne]

[yodawill2000]

Not good.Someone that's dug deeper than I should chime in but as far as I know that's the front end of the Crankshaft.

[schanne]

Yea, thats what I thaught. can someone else please chime in too....
Modified by schanne at 7:38 AM 8/26/2008

[GerryO]

Not good.Someone that's dug deeper than I should chime in but as far as I know that's the front end of the Crankshaft.

Yup, but the rusted, broken-off, imbedded piece should be removable using penetrating oil, maybe a small torch/bit of heat (no fires please!) and a small punch in order to be replaced, and it would also be a good idea to replace the oil seal behind it too, if any heat is used.

http://www.bimmerboard.com/forums/posts/16848

The crankshaft itself should be higher quality steel than the woodruff key. The pulley probably took the worst beating and it's key way now probably widened, so it should be replaced. Rust never sleeps.

[yodawill2000]

Looks like in the pics the woodruff key snapped and took a chunk of the crankshaft with it.Some highly skilled welding may be needed.
Modified by yodawill2000 at 9:51 AM 8/26/2008

[GerryO]

Looks like in the pics the woodruff key snapped and took a chunk of the crankshaft with it.Some highly skilled welding may in needed.

It does look like a piece got caught between the rotating crankshaft and the now stationary pulley.

Some two-part epoxy or red Loctite on the new key, allowed to fully cure before installing the new pulley? Part of it may depend on whether or not things will ever be taken apart again.

And is the bolt still tight in the crankshaft or was it put back in after the pulley was removed? A larger washer may be missing, as I would not expect the pulley to slip off of the crankshaft with the bolt still in place.

[yodawill2000]

Yes .. There is definitely a larger washer not shown. It must be in place when torquing that puppy back down.

[schanne]

The bolt was put back in there, don't see any other washers.... That should be the only one.

So let me get this right. Pulley needs to be replaced obviously. But what do I do with the crank shaft??? Is welding only option?

[Victor]

Maybe you could take a dremel tool with the right sized grinder bit and make a new slot for a key on the other side of the shaft, and fill the old one with JB Weld.

[yodawill2000]

Trust me schanne, there is a larger (Diameter) washer that is missing.I just pulled my pulley last week when replacing the Timing belt.Victors Idea might work but the timing marks on the new pulley would be 180 off.GerryO's Idea is what I would try first.
Modified by yodawill2000 at 11:36 AM 8/26/2008

[schanne]

Alright, sounds like fun! lol I'll update shortly..

[GerryO]

Trust me schanne, there is a larger (Diameter) washer that is missing.I just pulled my pulley last week when replacing the Timing belt.Victors Idea might work but the timing marks on the new pulley would be 180 off.GerryO's Idea is what I would try first.

Modified by yodawill2000 at 11:36 AM 8/26/2008

I'd also get an OEM washer (exactly the right inner and outer diameters, probably thicker than normal and hardened) along with the new Woodruff key. I wonder what happened to the old one? Cutting a new groove in a crankshaft for a half-moon shaped Woodruff key probably isn't an on the car with hand-tools type of operation.

A web search would indicate that your friend's engine isn't the only one that this has happened to, and one might also turn up other fixes.

[yodawill2000]

I cant think of anything sheering the woodruff key other than a seize up of one of the three belts , Either a device locking up .Or the lower cover wasnt installed and something lodged into the pulley/ belt intersection.None of the the things the pulley drives would cause that without major failure.Unless of course this car sat up somewhere, moist, for years allowing that nasty rust to form where it shouldn't.


Modified by yodawill2000 at 4:58 AM 8/27/2008

[GerryO]

I cant think of anything sheering the woodruff key other than a seize up of one of the three belts , Either a device locking up .Or the lower cover wasnt installed and something lodged into the pulley/ belt intersection.None of the the things the pulley drives would cause that without major failure.Unless of course this car sat up somewhere, moist, for years allowing that nasty rust to form where it shouldn't.

Your thoughts make me feel a little bit better about not having replaced mine when I had the chance (and they even included a new one in the kit) and I imagine if a crank pulley were at all loose to begin with, each time the engine was started, it would cut into the key a bit more.