Crank pulley slipping

[salamander]

timing belt sprocket (not turning with shaft)

[lozz]

got the autodata fired up

ew timing.PNG

[lozz]

EW instructions.PNG

[lozz]

Ew instructions 2.PNG

[salamander]

I'm now wondering if the toothed sprocket was mounted the wrong way round at a previous belt change as the key is there and the sprocket had to be slid across it to get it on the shaft but it is sat in the recesed part so it is not fixing it on the shaft. Ive found the hole at the back of the engine, naturally in the most inaccesable part. Now I think I need to make somthing up to fit.

[salamander]

I’ve progressed a little further and the belt’s now off. There is a second key way for locating the timing sprocket and unbelievably the car has done 60,000miles without this key in place the sprocket was only held by the aux drive belt up against it. How it has not slipped and bent some valves in all that time I’ll never know. The dealers tell me they are both the same key but the one supplied needed the end fileing down to fit against the block and even then was not that tight on the pulley so I’ve swapped the two keys round. There’s still the issue of the timing being out so if anyone has the relevant dimensions of the locking pins so I can make a set I’d appreciate it, particularly the bell housing pin.
Haynes is unhelpful about the water pump removal on this engine which has a rigid pipe from it so is there a specific way of getting it off? Access is difficult of course.

[jasper5]

The crank pin will probably be 6mm diameter and the cam pins will usually be 8mm or 10mm.....you can easily check by using drill bits.

[salamander]

made from M5 and M10 bolts

[lozz]

nice