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On 22 Aug 2003 at 18:02, Jeff Palmer wrote: > Finally figured out what that rattling noise was. The crankshaft > pulley seems to have come loose. I didn't hear the bolt rattling > around before this happened. How big a job is this to fix? > > Bentley tells me that the engine must be taken out to remove the air > intake housing. Is this true just to fix the pulley? I see also that > a new paper gasket is required. Any other tips? You may not need a new paper gasket. If the old one is still intact you can reuse it. If you need a new one I should have one. You only need to pull back the cooling air intake bellows and get in there with a 1-3/16" socket and a long extension. The difficulty comes when you have to torque it to 100 ft-lbs. The engine will move before you get to that point so you have to keep the crank from turning. To do this, remove the # 2 spark plug and turn the engine one full turn from TDC for # 1. The dist rotor should be pointed opposite to the # 1 mark. Then stuff a long length of rope down the # 2 SP hole until it gets tight; leave a foot or more still hanging out of the SP hole. Now torque the bolt. The engine will turn until the rope packs up in that cylinder and then you can finish the torquing. Once this is finished, use the generator belt and pulley to back off the engine and pull the rope out. -- ******************************* Jim Adney, jadney@vwtype3.org Madison, Wisconsin, USA ******************************* ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org