I was just changing the timing belt on my 1994 940 Wagon turbo (178K -- it's due -- last timing belt change at 128K) -- and everything looked fine until I got down to the gear on the crankshaft (sandwiched between 2 shims). Took it off and the pin that supposed to engage with the pulley/harmonic balancer (PHG) looks worn down / sheared off. The result is that when I go to re-install the pulley/harmonic balancer (PHG -- the big pulley on which 3 belts ride) it (the PHG) doesn't lock in place, rather, you can rotate it a few degrees right and left.
The slot in the PHG seems a bit worn on 1 side, too, but I suspect it will probably lock OK with a new crankshaft gear (part number 1336972).

1 -- Is this a common occurrence with these cars? I don't see many instances of this issue on the web.
2 -- I believe the system was torqued properly. However, could the missing crankshaft gear pin have put the timing off, and resulted in low-ish power and inconsistent starting? I have experienced these symptoms for several years now and never been able to understand why ...

Thanks,


Rob