This was very helpful. For do-it-yourselfer's, I modified Mark's plan successfully, without having to remove the Shaft. I used cobalt drill bits in a pneumatic to create two new 3/8" holes into the drive shaft, without removing any engine assembly. Essentially, I took apart the front (cooling, belts, etc.) and of course, harmonizer. I drilled directly into the shaft, where the harmonizer meets it. Mark your points carefully, of course. The two new holes were matched with precision to the same two new holes that I also drilled into the harmonizer, drill press of course. I inserted two roll pins into the two aligned holes, torqued the bolt, and she's better than new. It worked very well, cost only $3.00 for the pins, and thank you Mark for the brilliant idea! I couldn't be more thrilled and relieved.
I have been reading your attempts to correct this issue. And having recently purchased an 03 sorento without prior knowledge of this issue. I have an idea I am contemplating. Adding an extension to the crank, while modifying the pulley with a 'cup' that would distribute the forces involved to the crank, instead of a single bolt attempting to keep the pulley mated against the crank.
Mark, Thanks for sharing your ideas on fixing the Kia Harmonic Pulley issue. DO you know the size of the original bolt? Mine has not failed, but I would like to replace with the beefed up design. Can I use a grade oversized 5/8 bolt witout tapping the crank?
It's metric, so I'm going to go with a STRONG NO : ) I did squeeze 250K out of this before I donated it. Repairs seem to last about every 2 years before something would happened
This was very helpful. For do-it-yourselfer's, I modified Mark's plan successfully, without having to remove the Shaft. I used cobalt drill bits in a pneumatic to create two new 3/8" holes into the drive shaft, without removing any engine assembly. Essentially, I took apart the front (cooling, belts, etc.) and of course, harmonizer. I drilled directly into the shaft, where the harmonizer meets it. Mark your points carefully, of course. The two new holes were matched with precision to the same two new holes that I also drilled into the harmonizer, drill press of course. I inserted two roll pins into the two aligned holes, torqued the bolt, and she's better than new. It worked very well, cost only $3.00 for the pins, and thank you Mark for the brilliant idea! I couldn't be more thrilled and relieved.
I have been reading your attempts to correct this issue. And having recently purchased an 03 sorento without prior knowledge of this issue. I have an idea I am contemplating. Adding an extension to the crank, while modifying the pulley with a 'cup' that would distribute the forces involved to the crank, instead of a single bolt attempting to keep the pulley mated against the crank.
Great idea . . how would you add an extension to the crank without removing the crank from the engine, or casting a new crank?
Great did you use a locktite glue on the bolt as well ?
Hi, Interesting idea, have you had any problems since doing this modification.
Mark, Thanks for sharing your ideas on fixing the Kia Harmonic Pulley issue. DO you know the size of the original bolt? Mine has not failed, but I would like to replace with the beefed up design. Can I use a grade oversized 5/8 bolt witout tapping the crank?
It's metric, so I'm going to go with a STRONG NO : ) I did squeeze 250K out of this before I donated it. Repairs seem to last about every 2 years before something would happened
It's metric. The original bolt is whimpy. Go big or go home : )
I sold the car. It worked the day I sold it