So - check this - I just took off my pulley today, armed with my new O-Ring. Of course, the crankshaft pulley spacer (as it's actually called) came out. I sat there for what felt like forever trying to get it back in. I eventually gave up when the cold got me (~15f).
Now, what I think may be complicating this is there is really TWO parts of this that come into play here... One is that stupid key, and the second is a moveable ring on the inside of the crank tunnel.
See photos -
In this image, you can clearly see the key on the end of the crankshaft. (red arrow)
The Yellow call-outs and arrows point to the two side keys, WHICH are on a ring that rotates freely. So, you need to have both those items lined up to get it back in.
This is the backside of the crankshaft pulley spacer
So, If you only get it seated with the outside ring, it won't slide in flush as seen in this DIY:
Also - take note, as Perrin says if you don't get it flush in there, the pulley will wobble. When i put it back in this time after changing the o-ring, I did not have it flush and it did wobble for a few seconds.
Now, I'm not sure if this is going to be an issue for me yet, but it seems it could be easy to damage the spacer and/or crankshaft key.
This is what my spacer currently looks like which has me a bit concerned:
It looks like a bit was sheared off when the engine started and the pulley was wobbling.
And a closer look at my crankshaft might show a little damage too
This makes me a bit nervous - but I'm going to order a new spacer and maybe play with it some more before I do anything drastic.
So - Let this be a strong warning to all - MAKE SURE YOU GET THE SPACER FLUSH before you start the engine.
I'd like to do a quick callout to @
thejevans and @
PERRIN and see what they think, and specifically to thejevans - how did you get it realigned?