[Vwdiesel] Engine eating pulley

Rudy petersenrudy at hotmail.com
Sun Feb 15 11:43:22 PST 2009

VW has an upgraded Bolt that doesn't use the thick Washer.  This one is a
torque to yield Bolt.  I always replace the Bolt, that is if it's the 14mm
Bolt rather than earlier 12mm one.  Not sure what year Engine you're working


-----Original Message-----
From: vwdiesel-bounces at vwfans.com [mailto:vwdiesel-bounces at vwfans.com] On
Behalf Of Erik Lane
Sent: Sunday, February 15, 2009 10:19 AM
To: Iain Hunter
Cc: VWfans
Subject: Re: [Vwdiesel] Engine eating pulley

Which engine do you have? If it's the earlier 1.6D then I have some
experience with the *exact* same issue!

I would take a look at the two step bushing/washer thing that goes between
the bolt and that pulley. It has a kind of locking teeth on the backside of
it that seem to get worn down. (At least mine was.)

I've also put loctite on both the threads of the bolt and on the crankshaft
nose/inside of the pulley. Once you've torqued it down and have the addition
of the loctite holding it hopefully it would hold.
One time I even welded the bolt to the washer and to the pulley and then
installed the whole thing as one piece without using the keyway at all
because mine was worn away. I also put loctite all over that thing just
hoping that I could keep from having to rebuild the engine as it was still
in great shape otherwise. It ran great that way until I eventually sold it,
and the only thing I risked (other than it coming loose again, which was
already the problem) was having to go buy a new washer/bolt and pulley. You
have to be careful and get the bolt and washer dead center or they'll never
go back together, of course. I installed everything on the engine and then
tack welded it together before removing it and doing a more complete job. It
wasn't pretty, but it did work.

Good luck!

On Sun, Feb 15, 2009 at 10:04 AM, Iain Hunter <sagspottery at tiscali.co.uk>
> 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.
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