[Vwdiesel] Engine eating pulley

[Iain Hunter]

Hello.

Every since renewing the injection pump, my van had been on and off the road (more off than on!).
When I fitted the pump, I also renewed the cam-belt and tensioner, but accidentally removed the crank-shaft end pulley for the cam-belt during the fitting, instead of just the pulley for the water pump. Anyway, I re-fitted everything and timed her up and everything was OK for a while. Weeks later I had trouble starting her up in the mornings again, and on inspection found that the timing was slightly out. The said pulley had worked loose and the key-way had been ground smooth. 
The end of the crankshaft looked OK, (had a lost maybe 0.2mm from the facing surface, but the key was fine) so I ordered a replacement from VW, fitted it, making sure that I seated it the best I could and tightened it up using thread lock and plenty of grunt. 

A week later, and the ****ing thing has worked loose again, wrecking the new pulley in the process. This time, the end of the crankshaft, has more shiny metal, although the key still looks OK. A friend of mine has suggested we get a new pulley and this time use his compressed air gun to tighten it. Would this work, or am I looking at something much worse?

Someone else suggested that I could have another key cut in the end of the crankshaft 180 degrees to the original. I take it this would mean engine and crankshaft out and down the machine shop and a big financial outlay (One that I cannot afford in this climate, and having already forked out mega£££ for a recon pump).


Please help.

Any information would be greatly appreciated.


Iain.