Technical Crankshaft pulley breaking repeatedly

[redpalio]

Hello,

This is my first post, so please bear with me if my post is not up to the mark.

I have a 2004 Palio 1.2 Nv Sports (Petrol, India). Since about a year I'm having issues with the crankshaft pulley and driving gear. First had a breakdown in Jan 2015 at 97K kms, replaced timing gear, water pump, sending unit and driven pulley. Next breakdown in Jun 2015 at 99K kms. Replaced timing gear again. All service was done in Fiat service.

The FIAT service adviser told me that the crankshaft key (lever) has worn out because of which the pulley is not sitting in place.

Now the pulley is broken again at 108K kms. They've replaced the timing belt and pulley again. The car is running, but there's a noticeable wobble in the crankshaft and I'm afraid the belt will slip up again.

Does anyone have any recommendation on how to fix this for good? Is the crankshaft key wear serious enough for the crankshaft to be replaced??

Any guidance will be much appreciated!

 

[portland_bill]

Looking at the Panda manual, it appears that the pulley has an integral key that engages with a slot in the crankshaft. This should be a tight fit, so that it does not have any slack once bolted up to the correct torque. From your description it would appear that if a new pulley does not fit tightly, then the keyway (slot) in the crankshaft is worn. That means a new crankshaft, unless you can find an engineering shop that can weld it up and cut a new keyway in exactly the right place and the right size. Even that means removing the crankshaft from the engine.

In the UK, we'd find a replacement engine from a breakers yard. Hopefully you have that option there too.

 

[Damion143]

Hello,

This is my first post, so please bear with me if my post is not up to the mark.

I have a 2004 Palio 1.2 Nv Sports (Petrol, India). Since about a year I'm having issues with the crankshaft pulley and driving gear. First had a breakdown in Jan 2015 at 97K kms, replaced timing gear, water pump, sending unit and driven pulley. Next breakdown in Jun 2015 at 99K kms. Replaced timing gear again. All service was done in Fiat service.

The FIAT service adviser told me that the crankshaft key (lever) has worn out because of which the pulley is not sitting in place.

Now the pulley is broken again at 108K kms. They've replaced the timing belt and pulley again. The car is running, but there's a noticeable wobble in the crankshaft and I'm afraid the belt will slip up again.

Does anyone have any recommendation on how to fix this for good? Is the crankshaft key wear serious enough for the crankshaft to be replaced??

Any guidance will be much appreciated!

I had the same problem on my Palio 1.2 EL. I took the crankshaft and crank pulley into the engineering shop and they put a dowl in for me. The pulley keyways seem to be wearing out rather quickly for some reason but now I haven't had a break since.

 

[redpalio]

The dowel option looks like it's worth a shot. The problem would be to find a good shop who would do it here, but I'm going to try.

Thanks for the advise guys. I've got something to go about now.

 

[varesecrazy]

The dowel option looks like it's worth a shot. The problem would be to find a good shop who would do it here, but I'm going to try.

Thanks for the advise guys. I've got something to go about now.

OR - to save stripping the whole engine,

:idea:see IF you can get an adaptor made ,

that is better supported on the crank journal..

Charlie

 

[redpalio]

OR - to save stripping the whole engine,

:idea:see IF you can get an adaptor made ,

that is better supported on the crank journal..

Charlie

I'd like to know more about this. Will the standard pulley fit inside the adapter?

I looked up the internet a bit and got some examples of this being done on small engines like a snow mower. Is it an option that's been tried on car engines as well?

 

[varesecrazy]

I'd like to know more about this. Will the standard pulley fit inside the adapter?

I looked up the internet a bit and got some examples of this being done on small engines like a snow mower. Is it an option that's been tried on car engines as well?

Hi again,

once you've made 5 x posts on FF , you can add pictures of YOUR crankshaft , and damaged pulley,

then we can check for sure if an adaptor would be suitable..

 

[redpalio]

Hi Charlie,

I don't have any pictures of my old parts :-( The FIAT service where I took it to earlier have temporarily fixed it and it's running for now.

I've taken it to a couple of shops since. They hadn't heard of the adapter option at all.

Nonetheless, I'll continue to look for a good mechanic. And will remember to get pictures the next time.

Thanks!