New crank pulley, still misaligned, not water pump pulley

[tkelly27]

My car keeps on chewing up alternator belts. I thought my crank pulley had separated, but I got a brand new one and it's in the exact same spot as the old one.

When the water pump pulley is put on in the same direction as shown in the FSM it is properly aligned with the alternator, but not with either crank pulley, new or old, front or rear track. When flipped it's out of alignment with everything, being too far away from the block. The crank pulley is about 1/4" further away from the engine block and forces the belt up onto the sharp retainers between the pulleys.

The only components of this system removed were the water pump pulleys and the crank pulley for doing the timing belt.

Any ideas how to fix this?

*edit* just re torqued the crank sprocket bolt, crank pulley is still misaligned. The picture is what I'm going off of.

*second edit* Since I can't get the crank pulley to go closer to the block I would like to see if I couldn't get it further away with a set of washers. Then the alt and water pump can ride on the larger interior AC groove. Overdrive, bad news

 

[Pyrice4]

Make sure you put the power steering pully under the water pump pulley...

 

[luv2rallye]

If your 1g is like the 2g, make sure you have the 2 water pump pulley halves put together properly or they will give the wrong belt offsets. One fits into the other so the alt and PS belts are about 1/8" apart. Only 1 of the 4 ways of putting them together is correct. One way fits on but has one belt at a slight offset like you describe and is difficult to tell. Site down the length of each belt from 1 pulley to the other and you will see if one pulley half is incorrect.

 

[tkelly27]

Thanks for your replies, I finally figured it out.

The former owner blazed a new, not quite long enough, trail for the key in the crankshaft sprocket. Lucky me. Now my car is a time bomb until I can get to the junkyard and get a new one. After searching through 40 or 50 threads and pulling my hair out, I'd like to point out that not every belt throwing problem is something simple and stupid like misaligned pulleys or separated crank pulley. The good news, it will run like a beast when it's all back together and timed properly.

Something else I figured out. If you take some rough sand paper to the inside of the sprocket and the outside of the crank, you can knock off the shtuff that keeps it from wanting to slide on nicely, which will prevent you from trying to blast the sprocket on with an impact gun. I also had to use a file to file down the high marks where the former owner again tried to create his own keyway 180* out. That would have ruined their day had they got it running.

Hope that helps someone in the future, as I'm sure there's someone doing something stupid like that as I type this...