1990 Mitsubishi Montero Logo
Posted on Jan 30, 2009
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Crankshaft pulley bolt broke. How do i get it out????

I was attempting to take off the crankshaft pulley to put in a new seal and i broke the bolt that holds the pulley to the crankshaft (the pulley is off now by the way). It broke off about 3/4 inch inside the hole. How in the world do I get this off?? Also, i can't even budge the timing belt gear that is on the crank, any ideas on how I can remove that as well? It doesn't appear like you could use a gear puller on it.

Thank you.

Eric

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  • Posted on Feb 12, 2009
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You will have to drill the bolt out completely. You could first try an extractor set, it will have to be drilled to the size on the extractor set, use a product called PB Blaster and let it soak for a few days reapplying every 12 hours or so. If it broke off you may not be able to get it out with an extractor set but use the biggest extractor that will fit. If you have the head of the bolt and any threads showing you will have to fid a HSS Drill bit a little smaller than the outer diameter of the threads. then carefully drill the bolt out, it will take forever so take your time, I have set up drills with blocks and bungee cords so it will drill itself without you being in atendance, but the drill has to be positioned precisely as to not damage the inside diameter of the threads for when you install the new bolt. I even went so far at times at home to install a video camera to a small tv inside the house so I could monitor if the drill had changed position. I recently had to do exhaust bolts (6) and a spark plug that had rusted and broken off inside the motor, just the threaded portion of the spark plug was all that was there.

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Does the crankshaft pulley on a 1999 dodge grand caravan SE 3.3 engine have a bolt ?
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How do you remove the crankshaft dumper pully?
Published: 11-May-2011
Engine - V8 4.4L Petrol - Crankshaft Pulley
In-vehicle Repair
Special Tool(s)

Holding Tool Crankshaft Pulley
303-893(LRT-12-080)
Adapter
303-191-03
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303-191-04
Remover, crankshaft pulley
303-588
Remover, crankshaft seal
303-D121
Installer, crankshaft seal
303-1100
Adapter - Crankshaft seal installer
303-1100-01 Removal
  1. Disconnect the battery ground cable.
    For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
  1. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise and support the vehicle.
  1. Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt (303-05B Accessory Drive - V8 4.4L Petrol, Removal and Installation).

  1. Remove the cooling fan shroud.
    • Release 2 clips from the cooling fan lower shroud.
    • Release and remove the cooling fan lower shroud from the cooling pack.

  1. Using the special tools, retain the crankshaft pulley.
  1. CAUTION: Under no circumstances should the crankshaft setting peg, 303-645, be used in the following operations, to restrain the crankshaft. NOTE: The crankshaft pulley retaining bolt will be very tight.
    Remove the crankshaft pulley retaining bolt.
    • Discard the bolt.
  1. Remove the special tools.

  1. Using the special tools, remove the crankshaft pulley.
    • Collect the locking ring.
  1. Remove the special tools from the crankshaft pulley.

  1. Using the special tool, remove the crankshaft front seal.
    • Remove the outer section of the seal.
    • Repeat the process to remove the inner section of seal.
  1. Check the crankshaft damper pulley and locking ring for damage.
Installation
  1. Clean all the crankshaft pulley mating faces.

  1. Using the special tools, install the crankshaft front seal.
    • Lubricate the seal with clean engine oil.
    • Use the discarded crankshaft bolt with the service tool.
  1. Install the crankshaft pulley.
    • Lubricate the seal with clean engine oil.
  1. Install the crankshaft pulley locking ring.
  1. CAUTION: The screw thread in the crankshaft pulley must be cleaned out before installing a new crankshaft pulley bolt. Install, but do not tighten, the new crankshaft pulley bolt.
  1. CAUTION: Under no circumstances should the crankshaft setting peg, 303-645, be used in the following operations, to restrain the crankshaft. Using the special tools, retain the crankshaft pulley.
    • Tighten the crankshaft pulley bolt to 380 Nm (280 lb.ft).
  1. Remove the special tools.
  1. Install the cooling fan lower shroud.
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt (303-05B Accessory Drive - V8 4.4L Petrol, Removal and Installation).
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    For additional information, refer to: Specifications (414-00 Battery and Charging System - General Information, Specifications).
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Jan 27, 2016 • 2006 Land Rover Range Rover Sport
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How to install balance drive gear on crankshaft 2007 Camry 2.4
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Then remove harmonic balancer, with a PULLER, which requires 2 bolts, in the threaded holes, one on each side of the now empty center bolt hole, autozone , advance, has these to loan out, only requires deposit, which they give back to you, when you return it.
Put square key in slot on bare crankshaft, slide harmonic balancer,(crankshaft pulley,while lining up the square key,and tighten crankshaft bolt.
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Oct 24, 2014 • 2007 Toyota Camry
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Replacing crankshaft pulley on 2001 Ford Taurus SES, V6
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Now did the crankshaft break OR the bolt(s) that hold the pulley on broke?
If crankshaft is broke, you are better off finding a replacement engine for what it will cost to repair UNLESS it an expensive special built engine you might want it repaired.
If it is the bolt or bolts your best bet would be an - easyout- set, it looks like a drillbit set kind of. PB blaster and some heat (propane torch) will help. DONT get too hot because you will destroy front engine seal(s) from heat. It will be a tight fit job depending on if it is a sideways engine of standard with radiator in front that you can remove for more working room. Any issues I'll help u out. Done plenty. Paul
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Jan 16, 2013 • 2001 Ford Taurus
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4cyl 2000 honda accord engine stalls while idling, recently died and will only start for short periods... possible problems/solutions?
check for spark and fuel after it dies.

If there is spark but no fuel, then the fuel pump may be bad or a clogged fuel filter.

If there is fuel but not spark, then the ignition control module or the ignition coil could be bad.

Also, check that the timing belt is timing the engine correctly.
Timing Belt & Balancer Belt

Removal & Installation

2.3L Engine

To Remove:



  1. Record anti-theft code for radio.
  2. Disconnect battery negative cable then positive cable.






    honda-03-23-3542.gif



  3. Turn crankshaft pulley until TDC is achieved.
  4. Raise and safely support vehicle.
  5. Remove front tire assembly.
  6. Remove splash shield.
  7. Remove power steering belt.
  8. Remove alternator and alternator bracket.
  9. Safely support engine under oil pan.





    Upper bracket removal
    honda-03-23-3420.gif



  10. Remove stop, detach ground cable and remove upper bracket.
  11. Remove cylinder head cover.
  12. Remove upper cover.
  13. Remove dipstick and tube assembly.
  14. Remove crankshaft pulley.
  15. Remove adjusting nut rubber seal and remove lower cover.





    Timing belt/balancer belt removal
    honda-03-23-3544.gif



  16. Loosen adjusting nut 1 turn.
  17. Push up on balancer belt tensioner to relieve belt tension.
  18. Push down on timing belt tensioner to relieve belt tension.
  19. Tighten adjusting nut 1 turn.
  20. Remove balancer belt and timing belt.


To Install:


NOTE: Clean balancer belt drive pulley, timing belt pulleys and
upper/lower timing cover prior to belt installation.








honda-03-23-3425.gif






  1. Set timing belt drive pulley to TDC by aligning dimple on pulley with dimple
    on oil pump.






    honda-03-23-3426.gif



  2. Set camshaft pulley to TDC so that "UP" mark is at top and grooves align
    with top of cylinder head.





    Timing belt installation
    honda-03-23-3549.gif



  3. Starting with driver pulley, install timing belt in a counterclockwise
    sequence.
  4. Loosen and ten retighten adjusting nut.
  5. Install balancer belt drive pulley.
    NOTE: Inspect rubber seal on lower cover and replace as necessary.

  6. Install lower cover.
  7. Install crankshaft pulley and bolt.
  8. Rotate crankshaft pulley counterclockwise several times to seat belt.
  9. Loosen adjusting nut 1 turn.
  10. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley.
  11. Tighten adjusting nut to 33 ft lb (44 Nm).






    honda-03-23-3542.gif



  12. Turn crankshaft pulley until TDC is achieved.






    honda-03-23-3426.gif



  13. Ensure that camshaft pulley "UP" mark is at top and grooves align with top
    of cylinder head.
  14. Remove crankshaft pulley and lower cover.
  15. Rotate crankshaft to TDC again and lock timing belt adjuster arm with a 6 mm
    timing cover bolt.
  16. Loosen adjuster nut 1 turn and ensure that belt tensioner freely moves.
  17. Push tensioner up and tighten adjusting nut.





    Balancer shaft alignment
    honda-03-23-3556.gif



  18. Remove bolt and washer from maintenance hole.
  19. Using a 6 X 100 mm bolt, scribe a mark 2.9 in (74 mm) from end.
  20. Insert bolt into maintenance hole and hole in balancer shaft.
  21. Install bolt up to scribed line.





    Balancer shaft alignment
    honda-03-23-3557.gif



  22. Align groove on balancer shaft with pointer on oil pump housing.
  23. Install balancer belt and loosen adjusting nut 1 turn to tension.
  24. Retighten bolt.





    Balancer shaft alignment
    honda-03-23-3556.gif



  25. Remove bolt from maintenance hole and install bolt and washer. Tighten to
    22 ft lb (29 Nm).
  26. Reinstall crankshaft pulley.
  27. Loosen adjusting nut 1 turn.
  28. Rotate crankshaft pulley counterclockwise 1 turn and tighten adjusting nut.
  29. Remove bolt from timing belt adjuster arm.
    NOTE: Inspect rubber seal on lower cover and replace as necessary.

  30. Remove crankshaft pulley.
  31. Install lower cover.
  32. Install seal at adjusting nut.
    NOTE: Crankshaft pulley, bolt and washer must be cleaned prior to
    installation.

  33. Lubricate crankshaft pulley bolt between head and washer and bolt threads
    with clean engine oil.






    honda-03-23-3537.gif



    CAUTION
    Do not use impact wrench to perform
    following step.

  34. Install crankshaft pulley and tighten bolt using special tools to 181 ft
    lb (245 Nm)    .
  35. Install dipstick/tube assembly.
  36. Install upper cover. Tighten bolts to 9 ft lb (12 Nm).
  37. Install cylinder head cover.
  38. Install alternator bracket and alternator.
  39. Install power steering pump belt and alternator belt.





    Upper bracket installation
    honda-03-23-3420.gif



  40. Install upper bracket and tighten fasteners in proper numbered sequence.
  41. Install stop.
  42. Install battery and enter radio anti-theft code.


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Oct 29, 2010 • 2000 Honda Accord
0helpful
1answer

Hiwich timing mark I used to time the balancer shaft on a 99 honda accord with a 2.3L
To Install:
NOTE: Clean balancer belt drive pulley, timing belt pulleys and upper/lower timing cover prior to belt installation.
honda-03-23-3425.gif

  1. Set timing belt drive pulley to TDC by aligning dimple on pulley with dimple on oil pump. honda-03-23-3426.gif

  2. Set camshaft pulley to TDC so that "UP" mark is at top and grooves align with top of cylinder head. Timing belt installation honda-03-23-3549.gif

  3. Starting with driver pulley, install timing belt in a counterclockwise sequence.
  4. Loosen and ten retighten adjusting nut.
  5. Install balancer belt drive pulley. NOTE: Inspect rubber seal on lower cover and replace as necessary.
  6. Install lower cover.
  7. Install crankshaft pulley and bolt.
  8. Rotate crankshaft pulley counterclockwise several times to seat belt.
  9. Loosen adjusting nut 1 turn.
  10. Rotate crankshaft counterclockwise 3 teeth on camshaft pulley.
  11. Tighten adjusting nut to 33 ft lb (44 Nm). honda-03-23-3542.gif

  12. Turn crankshaft pulley until TDC is achieved. honda-03-23-3426.gif

  13. Ensure that camshaft pulley "UP" mark is at top and grooves align with top of cylinder head.
  14. Remove crankshaft pulley and lower cover.
  15. Rotate crankshaft to TDC again and lock timing belt adjuster arm with a 6 mm timing cover bolt.
  16. Loosen adjuster nut 1 turn and ensure that belt tensioner freely moves.
  17. Push tensioner up and tighten adjusting nut. Balancer shaft alignment honda-03-23-3556.gif

  18. Remove bolt and washer from maintenance hole.
  19. Using a 6 X 100 mm bolt, scribe a mark 2.9 in (74 mm) from end.
  20. Insert bolt into maintenance hole and hole in balancer shaft.
  21. Install bolt up to scribed line. Balancer shaft alignment honda-03-23-3557.gif

  22. Align groove on balancer shaft with pointer on oil pump housing.
  23. Install balancer belt and loosen adjusting nut 1 turn to tension.
  24. Retighten bolt. Balancer shaft alignment honda-03-23-3556.gif

  25. Remove bolt from maintenance hole and install bolt and washer. Tighten to 22 ft lb (29 Nm).
  26. Reinstall crankshaft pulley.
  27. Loosen adjusting nut 1 turn.
  28. Rotate crankshaft pulley counterclockwise 1 turn and tighten adjusting nut.
  29. Remove bolt from timing belt adjuster arm. NOTE: Inspect rubber seal on lower cover and replace as necessary.
  30. Remove crankshaft pulley.
  31. Install lower cover.
  32. Install seal at adjusting nut. NOTE: Crankshaft pulley, bolt and washer must be cleaned prior to installation.
  33. Lubricate crankshaft pulley bolt between head and washer and bolt threads with clean engine oil. honda-03-23-3537.gif

    CAUTION
    Do not use impact wrench to perform following step.
  34. Install crankshaft pulley and tighten bolt using special tools to 181 ft lb (245 Nm).
  35. Install dipstick/tube assembly.
  36. Install upper cover. Tighten bolts to 9 ft lb (12 Nm).
  37. Install cylinder head cover.
  38. Install alternator bracket and alternator.
  39. Install power steering pump belt and alternator belt. Upper bracket installation honda-03-23-3420.gif

  40. Install upper bracket and tighten fasteners in proper numbered sequence.
  41. Install stop.
  42. Install battery and enter radio anti-theft code.
prev.gif next.gif
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Jul 03, 2010 • Cars & Trucks
0helpful
3answers

I would like to know where the crankshaft gasket is? I have a 1994 dodge spirit, a 6 cyl. How hard is it for me to replace the gasket?
3.3L and 3.8L Engines
  1. Raise and safely support the front of the vehicle on jackstands.
  2. Remove the right front wheel and inner splash shield.
  3. Remove the accessory drive belt from the engine.
  4. Remove the center bolt of the crankshaft pulley.
  5. Using a claw-type gear puller, remove the crankshaft pulley from the crankshaft. When using the puller, make certain that the claws are situated on the inner section of the pulley. If the claws are used on the outer section of the pulley, the pulley will be damaged.
  6. Use tool C-4991 or the equivalent to remove the oil seal from the timing chain cover. Make certain not to damage the crankshaft seal surface of the cover. Fig. 10: Use a claw-type gear puller to remove the crankshaft pulley/damper — 3.3L and 3.8L engines 86723231.gif
    Fig. 11: Use the seal remover tool C-4991 to remove the crankshaft oil seal — 3.3L and 3.8L engines 86723230.gif
    To install:
  7. Install the new seal by using tool C-4992 or the equivalent. Place the seal into the opening with the seal spring towards the inside of the engine. Install the seal until flush with the cover.
  8. To install the crankshaft pulley to the crankshaft a 5.9 in. (150mm) long bolt, a thrust bearing and washer, and plate L-4524 or equivalent.
    1. Tap the crankshaft pulley onto the crankshaft with a rubber or plastic mallet making sure to hit the pulley on the center portion.
    2. Once the pulley is started onto the crankshaft, install a nut the thrust bearing and washer, and the plate L-4524 onto the bolt.
    3. Thread the bolt into the end of the crankshaft and screw it in at least 2 or 3 complete turns.
    4. Tighten down on the nut on the bolt to slowly press the pulley onto the crankshaft until completely seated.
    5. Remove the bolt, nut, washer and thrust bearing, and plate L-4524 from the crankshaft. Fig. 12: Installing the crankshaft pulley — 3.3L and 3.8L engines 86723229.gif

  9. Install the center crankshaft pulley bolt and tighten it to 40 ft. lbs. (54 Nm).
  10. Install the accessory drive belt and tighten by following the instructions in Section 1.
  11. Install the splash shield and front wheel.
  12. Lower the vehicle to the ground.
Read full answer
Jul 16, 2010 • 1994 Dodge Spirit
1helpful
1answer

Bolt on crankshaft to remove clockwise or counterclockwise?
prev.gif next.gif Crankshaft Damper/Pulley counterclockwise to remove pulley:
REMOVAL & INSTALLATION
  1. Remove the drive belts from the crankshaft damper.
  2. Remove the crankshaft damper-to-crankshaft bolt. Hold the crankshaft stationary by placing a suitable tool in the ring gear teeth on the flywheel. Fig. 1: Use a breaker bar to remove the crankshaft damper bolt 89613g41.gif
    Fig. 2: The crankshaft can be held stationary by using a suitable tool to place between the flywheel teeth 89613g42.gif
    Fig. 3: Be sure to lubricate the threads of the crankshaft damper bolt to obtain a proper torque reading 89613pi9.jpg

  3. Remove the crankshaft damper from the crankshaft by pulling it straight off the shaft. A puller may be required to remove the damper from the shaft. Be careful not to lose the woodruff key when removing the crankshaft damper. Fig. 4: The crankshaft damper can sometimes be pulled from the shaft by hand 89613pj1.jpg
    Fig. 5: A puller may be required to remove the crankshaft damper 89613g40.gif
    NOTE: If working on a VE30DE or VQ30DE engine, it would be a good idea to replace the crankshaft oil seal when the crankshaft damper is removed. Fig. 6: The timing chain cover oil seal should be replaced whenever the crankshaft damper is removed; this seal is leaking severely 89613pj2.jpg
    Fig. 7: This crankshaft damper may have a problem sealing properly due to the groove that was worn into it from the seal 89613pj4.jpg
    To install:
  4. Install the crankshaft damper onto the shaft, making sure the woodruff key is in place. Dip the damper bolt in fresh oil and torque the crankshaft damper-to-crankshaft bolt to the following specifications:
    • VG30E engine — 90–98 ft.lbs. (123–132 Nm.)
    • VE30DE engine — 123–130 ft.lbs. (167–177 Nm.)
    • VQ30DE engine — 29–36 ft.lbs. (39–49 Nm.) followed by 60–66°clockwise angle torque
  5. Install the drive belts to the crankshaft damper; be sure to properly set belt tension.
prev.gif next.gif
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Jul 08, 2010 • 1996 Nissan Maxima
0helpful
2answers

Crankshaft Pulley..98 Subaru Forester
just a socket set will do the job.But remove the bolt and put thread lock-tight on the threads and tighten to manufacturers toque
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May 30, 2009 • 1993 Buick Park Avenue
3helpful
1answer

Do not know how to remove crankshaft pulley to replace timeing belt
Ignore smart a$$ comments.
Disconnect negative battery terminal.
Remove front right wheel.
Remove splash guard.
Place jack under engine.
Remove left engine support bolts from body.
Remove engine support plate bolts from engine.
Unbolt air conditioner pump and move it out of the way.
Get under vehicle and remove steering pump bolts and move it out of the way.
Remove 6 crankshaft pulley bolts, should be 12mm.
The engine support bracket shoud come off now.
Remove the main crankshaft bolt.
Remove crankshaft dampener.
Remove the timing cover bolts and take off the covers.
Take off the old belt & replace with a new one, don't use a previously used belt.
Make sure the belt tensioner is installed correctly.
Put all the stuff back on.
Get a Haynes manual, pages 3-41.
Read full answer
Apr 30, 2009 • Plymouth Voyager Cars & Trucks
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