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Sorry to hear your problems..... I've replaced about everything on my two 740's myself. Saved a ton of money. On the in-tank and external pumps, I did use aftermarket(autozone) parts and have not had any problems after about 15-20K miles.
As for your crank pulley problem. Could you be getting the wrong roll pin (the nub). I think that when I redid mine, I had to go to a OEM one, because I could not find one that fit perfectly. I doubt that the fan banging into the shroud could cause the pin to break.
If you were doing the job I might suspect that you were not torquing the bolt enough, but if a pro is doing it....
anyway, after some initial problems, both my cars start and run reliably, Handle very well, (IPD swaybars and Bilstien shocks). And are very easy to work on.
good luck and keep everyone posted on you progress.
jc
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1985 740gle na, 1990 740gle 16 valve
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