[v8volvo]

There is a way you can use a hammer and large screwdriver, tap the screwdriver into place gently, and pop the sprocket off easily without bending the rear T-belt cover. If you insert a flat-blade screwdriver between the back of the sprocket and the front of the cylinder head on the driver's side of the motor, in such a way that the force will go against the head itself and not just against the tin rear cover, then gently strike the end of the screwdriver a few times (after having loosened the cam sprocket bolt of course). The sprocket will pop off easily. It's the best trick for this that I've found so far. Tom Bryant showed me this method, so he is the one who deserves credit for it.

Don't worry about the slot in the end of the cam -- it doesn't serve any purpose, it's just there. There is not supposed to be any kind of key there. It is an infinitely-adjustable taper fit, and the taper fit is able to hold more than enough force to turn the cam if the sprocket is installed and torqued properly and the surfaces are dry and clean. VW has been using this method for decades, all the way up to the late-model TDI engines, and it works perfectly if done right. Some engines, like the Ford Zetec, use just a flat friction fit, not even a taper... that does scare me a bit. The VW taper design is just fine though.

Don't forget to find a way to counterhold the sprocket when re-tightening the bolt (the manual shows Volvo tool # 9995199 being used for this, but any similar generic sprocket-buster tool will work). You'll also need to get your hands on the tools for removing and reinstalling the front crank sprocket assy, which requires massive torque to remove and reinstall.

I'm wondering if "the board" ought to have a set of crank counterholding and timing-setting tools, that could be rented out to members for a deposit and small fee? I would be willing to help invest in a set of group tools, since it is hard or impossible to do the job without several of them, and questions about which tools are needed and procedures for working on the timing belts come up again and again.