1. The crank sprocket keyway looks undamaged, BUT appears larger than I would expect. The sprocket has nearly 1/2 tooth worth of rotational play on the crank when not torqued down. It fits rather loosely onto the crankshaft as well. Can anyone confirm if this is normal? The woodruff key itself is extremely tight in the crank keyway, so I didn't try to remove it.
This just caught my eye and maybe its just terminology differences...
1. The crank sprocket keyway - do you mean the woodruff slot machined into the end of the crankshaft? or the lower timing belt sprocket? either way - the woodruff key should be tight in the crankshaft, the timing belt sprocket and the harmonic balancer.
I just did the timing belt on my '92 last month. although not the same engine as yours, the concept is the same. The lower timing belt gear is not loose rotationally on the end of the crankshaft, it is a nice slip fit (not press) and should not be loose. Very precision machined tight tolerances on these components.
I replaced my woodruff key also, for sure it is held in the crankshaft very tightly, not a press fit, but close. I very carefully tapped it out of the crankshaft with a tiny screwdriver and soft mallet. After cleaning the crankshaft slot very well I pushed the new woodruff key in with my thumb. Its tight. Maybe even gently tapped it home with the soft mallet - don't quite remember. The woodruff key is a common size part. Cost me about $0.80 for a 10 pack at a hardware store.
I'm still leaning towards the bolt thou. Unless the inside diameter of your harmonic balancer is really oversize as Kevin mentions.
About your crankshaft bolt, does it look like the pink one in this photo?
http://www.expeditionportal.com/forum/at...072&thumb=1
