06 Convertible with 76000 miles. PO replaced the timing belt, WP, tensioner, and idler. The belt walked and was destroyed against the timing cover. I put a new belt on and it started walking so I shut it down. Tried to measure the crank gear distance from the block and could not get my .035 gage behind it. Tried to move the gear with my 3 point claw and broke the lip. Got a new one and removed the old one properly with M6 bolts. I noticed 3 places on the engine case and 3 places on the gear where a measurement could be taken. How exactly do I install the gear to the correct distance? I believe the gear distance is why the TB was walking. Thanks.

Is the measurement to be done from the tooth, center valley, or the inner rise?



Rubber is 1 mm above the case. Is that correct?

Does the .035 measure on the ridge by the seal, on the seal, or on the flat part below the ridge?

 

Gapped the timing gear .035 from the hump around the rubber seal. Put the timing belt on without the timing cover and no more walking. PRAISE GOD I thought... it is fixed. Put it all back together and drove down the street. Nice ride. Only has 73000 miles. Got back home, looked under the hood, and smelled rubber burning. Looked at the timing cover and shreds of the timing belt were coming out of the crease between the front top and rear timing covers. I'm not sure what to do at this point but to go back in and replace the timing cover...that is if I tear it down again and the belt does not walk without the timing cover installed. Gotta take a break from this project and lick my wounds for a few days lol. If a new timing cover does not work, an engine replacement is in my future.

 

check the tensioner for play

 

Well, tore it down today and found the harmonic balancer and TB pully walked away from the motor. Looks like I will have to cut threads inside the crank or drill into the broken (threaded) part of the bolt, then install a bolt to hold the HB and TB pulley in place. Thanks for the help. Will post an update when I get time and figure out which way to go.

 

Was the crank bolt loose? Assuming it was torque to spec, and you put everything back in correctly the first time, it should all line appropriately. If you have confirmed the pulley and balancer can be pushed farther in towards for the motor, is there any chance you perhaps lost a washer? If the harmonic balancer does protrude from the crank snout, and the bolt is indeed bottoming out on the hole, a washer of appropriate thickness would probably be the most expedient way of solving the problem.

 

The crank bolt was broken at the top of the threads. I am having trouble drilling in the middle of the bolt because of how it was broken.

 

I believe Tim https://www.facebook.com/groups/155115055245302/user/100007283533575/?__cft__[0 on FaceBook PT Cruiser Enthusiasts solved my problem. He suggested to look at the T55 bolt. I made the decision today to take it to a friend's shop who said he could weld onto the broken bolt and remove. As I am putting it back together, I noticed the tensioner bolt's head was damaged. I remembered the original bolt head was damaged as well. Put a new bolt in and noticed the T55 bolt runs right into the tensioner bolt. I ground about 1/2" off the bolt (the non-threaded guide portion) so it would not hit the tensioner. Put it back together (still missing a crank bolt) and drove for 3 miles. Brought it back and opened the top TB cover and no damage to the belt! FINALLY! Thank the Lord it might be fixed. I did not want to chance it at 1 am so tomorrow I will drive it after work. Will post when I run it for a few days. Thanks again to everyone...especially https://www.facebook.com/groups/155115055245302/user/100007283533575/?__cft__[0! You sir are a BaddAss.