Crankshaft Pulley Keyway Wear (Short-Nose Crank Failure)
SeriousEngineEarly 1.6-litre B6-ZE engines produced between 1989 and mid-1991 feature a 'short-nose' crankshaft design where the crankshaft snout is shorter and utilizes a narrow woodruff key to locate the timing belt gear and crank pulley. If the central crankshaft bolt is not tightened to the correct torque specification during a timing belt change, or if an old bolt is reused, the pulley begins to wobble. Over thousands of miles, the woodruff key chews into the keyway slot in the crankshaft snout, throwing off ignition timing, causing engine misfires, and eventually ruining the crankshaft snout completely. Later engines from 1991 onwards received a revised 'long-nose' crank that eliminated the vulnerability.
Visible wobble or flutter from the front crankshaft pulley while the engine idles, Engine misfires, hesitation, and sluggish acceleration due to fluctuating ignition timing, Metallic tapping or chattering noise from the front lower timing cover
- Look directly down at the front crankshaft pulley with a torch while the engine idles to check for any visible lateral wobble
- Count the slots on the front crankshaft pulley face (4 slots indicate a short-nose crank; 8 slots indicate the updated long-nose crank)