Crankshaft pulley replacement mishap

Hi all, 

 I done messed up.

 Had a bit of a mishap whilst having a go at replacing the crankshaft pulley on my 2015 Jimny (the outer tyre of the pulley had separated from the inner wheel) and didn't get the pulley lined up with the key properly before tightening the bolt up. The result of this is that the front of the key is now mashed in and will not fit the groove on the new pulley. From some schematics I have come across online this key also seems to locate the timing chain cog on the inside of the engine casing, is that right? If so does this mean that I'll need to take the front of the engine to bits to get the key out or should I be able to pull it out and put a new one in without getting myself further into trouble? Also am I right in thinking its a half moon key?

 Any advice would be humbly and gratefully received!

I doubt that the same key is used on the crank pulley outside the engine and also inside as you couldn’t get an oil seal on the shaft, or a bearing surface. The diagram I have just looked at appears to show it on the outside of the bearing and seal.

I didn’t take the key out when I did my crank pulley but looking on a schematic diagram it does appear to be half moon.

Can you take some photos of the problem areas. A photo speaks a thousand words.

Roger

The key is a half moon key (08341-31059-000    Woodruff Key - £3.09)

I believe it does also fit within the cam sprocket and therefore you have to take the timing cover off and the cam sprocket to get it out. I have not done it myself but have sold a Woodruff Key to a lady who has done exactly what you have done and she described having to take the front of the engine apart to recover the situation so I guess that is what happens.

Thanks for the responses and the advice, I found that it does indeed also key into something on the other side of the timing chain cover (oil pump I think from the schematics I have seen). I also found that, while trying to pull it out using some mole grips I managed to squash the key back down a bit. Some careful filing allowed me to get the new pulley started on to the key then it tightened into place when torqued up. Once it was all put back together the engine seems to be running fine and the belts are running smoothly on the pulleys. Think I had a lucky escape there!

I imagine that the key isn't exactly factory fresh now but dismantling the front of the engine sounds like a lot of work and as long as the key keeps everything that relies on it turning I'm going to let that be a future me problem.