Crank pulley install tips

Hello all I just recently replaced the timing belt on my wife's '98 Neon. I'm installing the crank pulley. My issue is that the crank pulley is about 1/4 in. off alignment with the water pump pulley. I am having a bear of a time trying to get the pulley to slide on the last 1/4 in. any help in this area would be greatly appreciated.

Thank you in advance for any input.

Assuming you have that crank sprocket on the right way - it can be put on backwards I think - then I would think it is either a burr on the crank surface or on the inside of the pulley, or that the woodruff key isnt seated properly. I recall it has to be really 'flat' down into the groove so as not to interfere with the groove in the sprocket sliding over it. You might need to take a file and remove any burrs or gouges on the sides of the woodruff key.

I call the crank 'pulley' a sprocket, since it has 'teeth' on it.

Assuming you have that crank sprocket on the right way - it can be put on backwards I think - then I would think it is either a burr on the crank surface or on the inside of the pulley, or that the woodruff key isnt seated properly. I recall it has to be really 'flat' down into the groove so as not to interfere with the groove in the sprocket sliding over it. You might need to take a file and remove any burrs or gouges on the sides of the woodruff key.

I call the crank 'pulley' a sprocket, since it has 'teeth' on it.

Whoops, sorry I meant drive belt pulley. I didn't take the crank sprocket off. Sorry for lack of clarity.

As far as I know, the only way the belt pulley (also the vibration damper) is going to go that last short distance is when the bolt holding it onto the end of the crankshaft is torqued up. This also implies holding the engine from turning; using the teeth on the starter ring usually. Again, the woodruff key needs to be aligned nicely with the pulleys that are going to slide over it.


I may start taking the engine out of our family's 97 Neon, since its smoking a little blue, and is misfiring due to damage to the back part of the engine wiring harness.