2.1 dj with crankshaft pulley wobble throwing auxiliary belt

[keytouch]

My friend recently got herself a camper. However she hasn't had much luck with it so far.

On the way from collecting it, it threw a con-rod destroying the engine.

After a replacement 2.1 dj engine was fitted she had it trailered home as she didn't have time to go get it.

First outing with it, it chucked off the auxiliary belt and also pee'd coolant all over the road due to a broken coolant level sensor.

The camper is now miles from engine supplier or fitter so I've been lumbered with trying to fix it.

I have replaced sensor and topped up and bled coolant system.
However it chucked off a new auxiliary belt when I was working on it.

The alternator and water pump both seem fine and are running smooth. However there is quite a wobble on the crankshaft pulley and it is this I think is causing the belt to come off.

I'm a diesel person normally so not used to these petrol engines.
What cab cause this pulley to wobble? Is it the whole crankshaft end wobbling or can the pulley be fitted off centre?
What can I do to fix this?

Here is a vid (hopefully) showing the wobble.

http://youtu.be/pvH6Fz_3naI" onclick="window.open(this.href);return false;

Any advice gratefully appreciated.

[CJH]

Looking at the video I'd say the pulley bolt looks stable enough, so it suggests a distorted, broken or loose pulley. The wobble doesn't look particularly regular, which might suggest it's loose or broken, although that might just be an odd side-effect of video frame rate and engine speed I suppose. Can you wobble the pulley while the engine's stationary?

[Mocki]

I can't see too well from the video, has that pulley bolt got a big thick washer on it ?
They fit on a woodruff key , over the shaft and the bolt holds it up to the shoulder from memory
Long time since I took one off .....
Recon either the pulley is bent ( hard to tell from video) or loose
Don't think it's the shaft from the video ?

[keytouch]

I won't be able to get to the can til tomorrow afternoon or maybe Friday.

I just took a screen capture of the end of the video and things certainly don't look right.

[silverbullet]

Pulley bolt washer looks wrong for a start. Should be a bit thinner and significantly bigger diameter. Its actually a special "Belleville" conical spring washer, designed to keep the pulley bolt tight.
I have seen bent single pulleys and washers that were just plain flattened.

[silverbullet]

...pulley is either badly bent or very loose (watched video more carefullythis time)

[MGP]

It looks like the top of the washer comes into view a couple of times near the end. My money is on the pully being loose.
It's a bit worrying that the engine installers didn't notice this, I would advise going over the rest of their work with a fine tooth comb.

[silverbullet]

If it is loose then the nose of the crank wont be very pretty...
More investigation needed. Suprised that it isnt throwing oil out by the cupful.

[keytouch]

It certainly didn't feel loose when I was putting the belt on, but I didn't give it a good yank. Hopefully I'll get down there tomorrow.
I'll take lots more pictures and some measurements.

[keytouch]

Anyone know off the top of their head what size socket is needed?

[Mocki]

27mm i think

[Smiffo]

Looks like a bent pulley wheel to my untrained eye....
The middle of it doesn't seem to wobble - only the outer part does.

Take it off and lie it on a flat surface perhaps?
( That should show if it's buckled. )

[keytouch]

Will oil leak out if I take it off for a while?or is the oil seal on the shaft?

[silverbullet]

Sump level is well below the crankshaft.

[300CE]

Pulley bolt washer looks wrong for a start. Should be a bit thinner and significantly bigger diameter. Its actually a special "Belleville" conical spring washer, designed to keep the pulley bolt tight.
I have seen bent single pulleys and washers that were just plain flattened.

Hi Jonathan, here's a pic of the washer on my pulley (1.9DG) - presume it is the same(?), but as Ian says is thinner: