Crankshaft pulley bolt came loose causing the pulley to rattle and shear the key in half. Part of the key in the crank and part in the pulley. I really don’t see a way to remove the key in the crank because it’s sunken and lodged in there.

Also wore off the teeth on the crank but not so much on the pulley. Bolt is fine.

Wondering if anyone has run into this and or has some suggestions on how to fix it.

I was thinking maybe weld pulley on.

 

I'd probably hit the key remnant with a punch a few times and then try pulling it out with a magnet.

 

Doesn't the D16Y7 have TWO woodruff keys ? One for the timing belt crank gear and another for the crank pulley itself ? I know the "B" series does... especially the '96-00 versions with the CKF sensor.

If the key slot is damaged on the crankshaft snout, you will either have to get it welded up and re-cut the key slot OR replace the crank. Also, do not try and use the crank pulley that wobbled off... replace it as well.