[GeckoXL7]

I had it since it was 3 years old only had 15,000ks on the clock. The pulley may of been off before by the dealer who said the seal was leaking.

There is also no part number listed in the service manual or part catalog either, the slot is there i expected something to be in it which is why i wanted to double check.

Another thing about the pulley is i never could read the timing (just never saw the mark) i thought this was just because it was dirty but when the pulley was off the actual notch is quite clean so i should of seen it clearly.

The car had maintanace records as was in its warranty years, but i dont know what dodgy work went on it, there are little things i noticed and some big things after i bought the car that was the transfer case low range wasnt working properly. CAM sensor bolt was chewed out like someone tried to undo it , and various hoses etc unclipped to secure them, to now the spark plug seals which i can see should of been there (again not mentioned in manual) and the crank pulley.

[GeckoXL7]

Ok has to come from melbourn quite cheap but still not in stock locally, getting one shipped express so will be here tomorrow.

Not being a common stock item makes me wonder more do they use the part or glue it on?

[henno]

I've stripped the keyway off a crank before (not a zook, dirtly old holden 308) and I noticed straight away because the power steering instantly became useless under load. I'd suggest that unless that glue was holding on with the force of 1000 elephants, there surely must have been a key there?

[GeckoXL7]

If you look at the crank pulley there was RTV red silicone where the bolt rests against there was enough there to hold it, i did have a load squeeling problem i am thinking it may of been comming from the crank pulley as should of been much harder to remove than it was.

Thinking about the slot on the pulley being filled up with the Silicone how would the key even fit in there? It would of been harder to pull off to if the key was actually in there and all the silicone around it?

[GeckoXL7]

THis is a photo of the front, the slot is pointing at the water pump - no key

[JrZook]

I would have thought that the pulley was a tapered fit to the shaft and the key was just for alignment as its a high load application

[GeckoXL7]

That is possible its only there for alignment, the tightening torque is listed at 150nm.

Its a moon shape slot on the crank shaft so ill just put one there anyway. Suzuki had found the part number linked to the crank shaft he didnt say if that was for the h27a as it didnt show at all in the Parts catalog i have (got it when working with the SDT)

[GeckoXL7]

Instructions for pulley

Removal
14) Remove crankshaft pulley bolt.
To lock crankshaft pulley, use special tool (camshaft pulley
holder) as shown in figure.
Special Tool
(A): 09917-68221
CAUTION:
Be sure to use the following bolt for fixing special tool
to crankshaft pulley.
Bolt size: M8, P1.25
= 45 mm
Strength: 7T
15) Remove crankshaft pulley.
If it is hard to remove, use special tools (Steering wheel remover,
Bearing puller attachment) as shown in figure.
If bolts of steering wheel remover are too long, replace them
with those of suitable length.
Special Tool
(B): 09944-36011
(C): 09926-58010
15-1) Disconnect CKP sensor connector and remove CKP sensor
if necessary.

Installation
4) Install crankshaft pulley.
To lock crankshaft pulley, use special tool (camshaft pulley holder)
with it at shown in figure.
Special Tool
(A): 09917-68221
CAUTION:
Be sure to use the following bolt for fixing special tool to
crank pulley.
Bolt size: M8, P1.25
= 45 mm
Strength: 7T
Tightening Torque
(a): 150 N.m (15 kg-m, 108.5 lb-ft)

[fordem]

JrZook wrote:

I would have thought that the pulley was a tapered fit to the shaft and the key was just for alignment as its a high load application

What "high" load would that be - the belt drives the alternator, water pump, cooling fan, a/c compressor & power steering pump.

[GeckoXL7]

There isnt much load on it at all really apart from when first start (alternator around 90amps) and if both front and rear aircon are on, power steering is next to nothing unless full lock.

I had a good look at it the crank pully after a good scrub and clean, it is really just all cast iron metal i cant see any rubber in it apart from around where the bolt goes, (bolt head sits against.)

I have to make something up to lock it a piece of mettal and two bolts that wont buckle under 150nm of torque, did use 3mm steel bolted to the engine where alternator was but that just bucked trying to undo it.