300Tdi Crankshaft dead

hello, I changed the timing belt on my 300tdi 90 about a month ago. id previously noticed that the crank pulley that drives the alternator etc was wobbling. when i removed it the key was badly worn so i replaced it. now a month down the line it started wobbling again but even worse this time. Ive taken it off again and it turns out that the pulley has been worn so the bit the key sits in is shaped like this \__| and even worse so is the crankshaft where the key sits is the same but worse. why has this happend?? and what is the best thing to do? Ive rang a couple of landy garages and both said its probably easier/cheaper to just buy a new engine rather than replace the crankshaft. Or even buy an cheap disco 300 with low miles as a donor, any ideas??

The pully can't have been tightened up properly, it should be bloody ****ing tight, and it's been able to move on the crank and wear the keyway. If you know someone who's dead good at welding you could have it built up with weld and file it back to shape. you could put it all back together with a plastic metal type thing, there are some really good ones on the market. I've used something called "molecular E metal" to hold the clutch on on my Triumph in the past and it has worked quite well.

I thought that about the welding, but as you say you'd have to be dead good, which im not. Its not gona be just your average mild steel either i suppose. You think that plastic metal things would be strong enough?? ive never really used anything like that before. The first time i took the pulley off, i noticed that threads on the bolt had been slightly rounded off so maybe i thought i'd done it up really tight but infact it wasn't at all , Thanks for the help

Just realized it's a 300 TDi so I've been talking bollocks. Hang on a mo.

It's nowt like as tight on a 300TDi only 59 ftLbs then a further 90 degrees. Have a look at the nut and if it's damaged then I'd get a new one. I reckon a decent plastic metal would do the job, I couldn't recommend one though I've not used any for years. Put a bit of threadlock on the nut when you put it back together and it should be OK. Are you sure you're putting it back with all the washers and things on.

Heres a pic

Kinnell. It almost looks as if it's s'posed to be like that.

Is the keyway in the pulley as bad. From here it looks as though it's a woodruff key, I'd still be tempted to gob the keyway up with Emetal or summat similar, get a new key a new pulley and a new nut and tighten it all up using locktight. Next time you come to do a belt change a bit of heat should make it possible to get it all apart.

call me a bodger but ad weld the key in then clean up any rough bits around it. then go fer the noo pulley and nut. and if i was thinking abart selling it soon ad weld the nut on aswell

top Bodge !!!:d

Yeah the keyway in the pulley is pretty bad also. where can i get some E-metal or something similar? I think selling it soon might not be such a bad idea or perhaps Part-ex it. Thanks for the help

Locktite do a good un!

I once had to glue an injector in (threaded) wi that stuff on a VW 1600 Diesel lump,shat mi self for the first few hundred miles with visions of it coming out and blowing a hole through the bonnet,never budged though

Well thats good 2 know . only thing is im struggling to find a decent plastic metal kinda thing, The only one ive found so far is a B&Q own one which doesn't seem too bad but I just dont trust something that only cost a few quid. I suppose its not the end of the world if it doesn't work but i'd rather find a really good one to do the job. does anyone know where i can find some??

would araldite work?

ah think you might find aradite is too brittle but it is good fer patching large holes in radiators

I got mine from a mate who uses it at work. Try a car parts type place halfords'll probly do it.