removal of injection pump pulley

[chrissev]

Hello, I've noticed on my rebuilt pump that there is a slot in the shaft where the pulley is placed, and I am presuming that a key goes into this slot and the pulley goes on top.  Regarding this key:  is it possible to remove the key from the old pump shaft and re-use it on the new pump or should I grab another key from the VW dealer?  When I am installing this key, should I use some lock tite sleeve retainer or such thing or is this not necessary?  My main concern is to prevent any problems with the key coming loose and subsequent major engine damage from timing belt failure.

[chrissev]

Just reuse the old key, dry. This part is not subject to any real stress and should perform fine for many rebuilds to come.

thanks.  Ever have any trouble getting the key out of the old pump?  I'm putting the rebuilt pump in this Sunday.  Should solve my erratic idle and hard starting when hot problems.

[fspGTD]

If the old woodruff (aka "half-moon") key doesn't fall out, just hold a flathead screwdriver up to it and tap it lightly with a hammer.  It's much harder getting that injection pump pulley off than the woodruff key!

[vwmike]

How do you guys normally get that gear off? I've tried a puller, but it broke. I ended up using 2 chisels behind it to wedge it off. I'm sure that's not good for the pump but I didn't see much of a choice.

[fspGTD]

Read this thread, vwmike: http://www.vwdiesel.net/phpBB/viewtopic.php?t=330&highlight=pulley+remove

[chrissev]

I have the right puller (the real VW one).  I guess I'll just tighten it as much as I can then whack the pulley with a hammer.  Hopefully it pops off.