Have a video camera running when you take the crank bolt off.

Bet you a beer that Dr Bob is correct about the washer being on backwards.

Show the shop the video, and show them the invoice from 928 International for a used pulley, balance and washer (if you need one). No real need for part numbers. Just tell whoever answers the phone what you need. They'll know.

Edit to add:

It's not "just a washer". It has one side with a step on in (center steps down from the outer rim). That step is what holds the pulley & balancer tight.

 

Proper way.

 

^^^^ This. Deal with someone who actually knows the cars.

 

I would like that to be an option in the future, however I don't have the funds to tow and service the vehicle currently. At best, I can buy a new bolt, crank pulley and harmonic balancer then repair the car myself with the help of someone who knows what they are doing. I'll keep you guys updated and post pictures of the damage. At least I'll learn more about the car and how to repair it more. I did an intake refresh 2 years ago on my own so I am not completely hopeless with the vehicle but messing with the crankshaft in anyway will definitely be new and not something I would attempt on my own the first time.

 

Crap. My pic didn't post in the last reply.

 

Oh I see what you're saying about the cone and the way it needs to face. Thank you.

 

Get with Rich and let him know your situation. Guessing he'll help out. The community is pretty darn good at sharing knowledge, time, and tools. More than several 928's have had surgical procedures done in my garage/workbay over the years.

 

To the OP, who did their own intake refresh, this is way easier than that. Get a flywheel lock tool, a good torque wrench, you may need to move the cooling fan if working from above, no biggie. That bolt should be installed DRY, so clean out the crank snout threads with solvent and compressed air if possible. Inspect the crank and balancer for damage, file down any burrs to allow easy install of balancer. See PET for part numbers. Avoid anybody who charges $2000 for a tune up! Cheers!

 

If you're military, you may have access to an "auto club" facility on base that would have lifts, tools, etc.

BUT, the guys on this list are THE best resource you can get.

 

+1 they didn't use a flywheel lock, bent the pulley and got the washer backwards. I'd want someone knowledgeable to give the whole system a good once over, just to be sure they didn't bugger up anything else.

 

Well took the pulleys off and the crank bolt, the pulleys are ground up where they make contact with each other around their centers. The washer was placed on the correct way based on the picture from SeanR. The balancer seems to be alright but the crank bolt threads are beat up towards the bolt head. Does anyone know what the bolt specs are or where to get one? I haven't had much luck online. I don't think a timing belt has ever been replaced on this car. Its been in my family since 86 and no one remembers doing one she's got 89,000 miles on her now, so maybe this is a good time to do that. Should I file pulleys down so they are flush again or just replace? Any suggestions on where to get affordable replacements?

 

http://www.928intl.com/

 

Expanding on what Glen said, yes you want to replace the pulleys (a good used set is fine), and replace the bolt with a new factory part. If the washer is beat up then replace that also, used is fine. Call Tom at 928 International and explain the problem, he will know what you need.

If the timing belt seriously hasn't been done in 89K miles and thirty years then it is more than a bit overdue... like twenty years and 30K miles, so a high priority. I would get the car to Rich or someone else who knows 928s, even if it means a long trip.

Pictures are always helpful, sometimes things aren't as bad as they seem.

 

Sometimes it's good to let people explore the material.

I you're not familiar with them, 928 International is a wonderful emporium of used 928 parts with a full line of new parts, too. Their website works best if you have the part numbers. Then you'll find that they offer a new X and a used X. Their used parts are always first-rate and they offer complete refunds if it's not right.

It's hard to tell what's too far gone to re-use. When you put the new bolt on , torque to spec and use some blue Loc-tite.

And that belt has got to be changed.

 

Here are the photos of my pulleys what do you guys think?