Changing my TB, in the middle of it, having problems

[hamradio]

Hi,
I'm in the middle of changing my tb on the rabbit (and shift bushings).  I have the bentley, too.  All is going well (but slow, IMO).  The main issue right now is, I can't get the lower belt cover off.  I got the belt off, but so much gunk came out of the cover, and onto the sprocket on the crankshaft, I need to get it off now, to clean it.  It seems impossible to remove without pulling the water pump pully.  I messed around for a few hours with that cover, and can't figure out a way to get it off, without pulling the wp pully.  Do I really have to pull the pully, or does somebody have a trick for getting the cover off?  

Second issue is, I pulled the sprocket on the cam, to change the oil seal.  Changed the seal, but when I went to put it back together, I realized that I was missing a key, it seems (there is a slot for a key in the camshaft, but no keyway in the sprocket).  Is there a key for this, or not?  If so, I think it is gone.  I can't find it anywhere on the ground, or anything.  

Hopefully, tomorrow, if I get home at 5, I'll be done with this by 10.  At least the tb.  I thought I'd have it done in under 4 hours, as I don't have ac or PS, but worked on it for 5 hours tonight, and have it half done.

Thanks.

[Vincent Waldon]

Don't worry about slow... much better than fast, with loud expensive crunching noises at the end !!

For the 30 seconds it takes me I usually pull the water pump pulley... I find it makes life much easier.  Can't remember for sure if it's a must on the Rabbits but go for it and see.

Forgive me if this is obvious:  have you pulled the passenger tire off ??  Way easier to see what's going on if you do.  Have you pulled the crankshaft pulley off ??  DON"T remove the centre crankshaft bolt even though it looks like it holds everything on.  The pulley is held on with the four allen-head nuts.  The cover won't come off with that pulley in place.

To your second question:  nope, the camshaft has no key.. it's a tapered shaft.  As part of the timing procedure you rotate  the engine at TDC, lock the pump, and then lock the camshaft at TDC.  Install the camshaft sprocket loosely, then install and tension the timing belt.  Tighten the camshaft bolt to the correct torque.. this locks the sprocket to the tapered shaft.  

The rest of the procedure involves the dial gauge and adapter... the Bentley has all the correct steps.

Holler if you get stuck !

Vince

formally VE1BAI... many years ago...

[burn_your_money]

You either have to cut the cover off or remove the WP pulley. Removing the pulley is easier.

As Vince said there is no key on the cam. On the other end of it you will notice a large flat notch in it. Use that to hold it in position with a hinge or something else. Use a deep socket to hold the pump in place