Crankshaft Threads Stripped 2.2L

the key way is boogered widened, in the bolt removal direction. if you use a new key, crank sprocket and pulley (new means not damaged, used) you can put it back together and the sprocket will not move when you tighten it. the key way should be good in the tightening direction. and if you tighten it enough, 125 ft lbs (i use 140) it will not loosen.

the key way gets boogered because the bolt is not tight enough. the key is not supposed to HOLD the sprocket or pulley against the rotational force of the crank, that's the bolts job. the key way is primarily a locator for installing the sprocket. (the cams have a locator pin.) if the bolt is tight enough, the key way never sees any real force.