Originally Posted by chowdan
The old pulley was custom made - and there is a SECONDARY slot for a key as well in the shaft. They obviously had this engine torn apart. I'm not entirely sure why they would have machined a second key slot instead of using the existing one.
Should I be concerned about oil leakage from the key slot?
Typically a second key at 90 degrees would be added if there was a problem with (or anticipation of a problem with) deformation of the single
key due to peak torque.
If you are reinstalling the previous pulley and using both keys, then oil leakage should not be a major concern. You can use Loctite Sleeve Retainer 640 (green) if you want to be sure it does not leak and does not come apart, however, be aware that heat will have to be applied if you decide to remove the pulley at some future point. In many if not most cases this is a good tradeoff.
I've put everything back together to keep any goop or dust or moist air out of the area. Friday I am receiving the new oil seal. Does this seal just press into place, or does one need to remove that entire cover?
The advantage of removing the cover is that doing so makes it easy to remove the old seal, clean the surfaces, and press in the new one. Also you then don't have to worry about getting debris into the crankcase.
It is always more work
to do it in place and it is harder to do a good job. The tradeoffs are a judgement call. If you remove the cover you will probably need a new gasket
While I'm at it, with the pulley in place in the old seal, I am going to be cleaning this side of the engine. Anyone have recommendations on good cleaners for belt/oil/dust buildup?
The gold standard is stripping the block and leaving it in a boiling tank of lye overnight. For various reasons most machine shops now bake the block at around 550 F for a few hours instead; this also works well.
Anything else is a compromise. You can use a power washer. You can use detergents (Gunk Engine Brite etc). You can use solvents. Questions are how clean do you want it, how much of a mess are you willing to make of the surrounding area, how much work
do want to do, how much fire risk you'll accept, and how much toxicity to yourself and the environment
are you willing to tolerate. Perchlorethylene works great, anything you inhale goes straight to your liver and stays there. Acetone works well especially in mixtures with other solvents, nontoxic, extremely flammable. MEK works great and is toxic and flammable. Or you can use a rag and a scraper and work slowly. You decide.