D9 406 HDI 90 - Crank pulley

[jazzermurphy]

Hi All,

First post here, hope im in the right place

I have a pretty serious problem really hope someone can help and tell me its not so bad...

Heres the story :

I bought a D9 406 HDI 90 a while back, and gradually the famous crank auxillary pulley started to deteriorate, so I went and ordered a new one, what I found was that the replacement pulley didnt match the one i removed. So after a bit of research

I found that this pulley: Part no 0515-t0, from a 1.4 or 1.6 hdi was the one that was the same, happy days, picked it up today



However,

While i quickly took off the old pulley i did not see what would await me when i went to put on the new pulley, so tonight I went out to fit the new one and here is what I see



as you can see the end of the crank has a chip gone out of it, and the "key" for the pulley seems to be worn down,





The plastic cover on the side of the block has serious scoring marks also,




Im wondering, is this fubar, or is there a way around this issue, smells lemony but im here to see if i can be helped...

[Piston Broke]

I'm thinking new crank, although im away from home on a Smartphone so dont have the best view of those pics. The slightest imperfection in the key and the pulley will be off again.

When these cars where current Peugeot did advise, but not insist, that the pulley was replaced when the cambelt was, but because of the expense not everyone bothered and the pulleys would eventually let go with age.

[oldpug]

Two choices,a replacement engine or try to fix that "mess"? I had one where the engine had been running with a loose pulley causing damage to the key,its groove and the end of the crank.The important question is can you get whats left of the key out of its groove? If so why not try what I did,you have nothing to loose,if it does not work then its an engine change.
Get yourself a two pack chemical metal kit,a new key and crank bolt.Clean and degrease,fit a new key with lots of chemical metal together with the pulley,treat the bolt with lock tight and tighten up.preferably with an air gun and leave to set 24hrs.As you may realise if it works that pulley does not want to be removed again so before you start a new cambelt could be considered.As said its difficult to see how bad the crank is in those images,two choices??

[frank]

ive stuck the pulley back on with "bearing fit" glue before. As a get me out the s*** measure lol