URGENT! Pulley trouble with swap

[dubCanuck1]

Hi all,

I'm putting the NA engine into my father's car while I rebuilt the 1.6 TD. The problem I have is that the pulley on the crank that runs the power steering pump doesn't want to come off. I imagine I'll have to pull it for the rebuild, but the dealer quoted me $300 for a new one.

My NA engine has the non-power-steering pulley, which I've pulled off without too much hassle. How do you remove the one from a TD? Do you have to use a puller or is there something else other than pulling the 4 bolts that mount it to the crank?

The other option is just to let the engine run without hooking up the pump. What are the ramifications of not running the power steering pump, but having it all attached otherwise; other than harder steering, which isn't really an issue?

The urgent part is because my minivan got stolen earlier this week and this is now my only means of transport. Please help!

[BlackTieTD]

i'd throw it in there without the power steering if you need it done asap. mkI or mkII i'm guessing? don't need the p/s anyway. you could switch to a manual rack, it will make turning a bit easier, but i wouldn't say its required. there would be no harm in running it like that for a couple weeks until you have time to sort out that crank issue for instance...

[DVST8R]

I just used a 5lbs sledge and a block of wood, I just knocked on one side and then the other and slowley worked it loose, If you have a proper 3 or 4 arm puller this would go much quicker, DO NOT take out the big crank bolt, it is NOT nessacary. They are just seized on from corrosion and years of being stuck together. Just keep after it.

[dubCanuck1]

Thanks guys. That's why I love this forum. I'll work on the pulley, but go with the "simulated broken p/s belt" scenario for now.

So for the sledgehammer treatment, you just kept whacking it from the exposed side on the back of the block, turning the engine as needed to position the pulley for the next "shot"?

I actually used the big crank bolt to keep the engine from turning over while pulling the others on the NA. I broke 2 hex tools (snapped a craftsman socketed allen key and made a candy cane out of the other one), but finally got them all off.

[BlackTieTD]

happy easter  

[dubCanuck1]

You're all heart!

[DVST8R]

Thanks guys. That's why I love this forum. I'll work on the pulley, but go with the "simulated broken p/s belt" scenario for now.

So for the sledgehammer treatment, you just kept whacking it from the exposed side on the back of the block, turning the engine as needed to position the pulley for the next "shot"?

I actually used the big crank bolt to keep the engine from turning over while pulling the others on the NA. I broke 2 hex tools (snapped a craftsman socketed allen key and made a candy cane out of the other one), but finally got them all off.

I guess that would have been quicker... :oops: I just would hit it from the back until it moved some and then hit it from the front, and then grabed it and tried to wiggle it back and forth, and repeated this till it came off. I probably spent 40min b4 it came off, now they take almost no effort once the 4 bolts are off.  

[dubCanuck1]

Well, that's the difference between a well-maintained car and a non-well maintained car. I took an off cut of 2x4 and using it as a dampner for the sledgehammer, I gave 3 sharp blows and POP! Off it came.

I should have the car back running by end of day tomorrow.

Cops found my van. That's a good thing. I have to spend $150 on a new ignition cyllinder though as the buggers hammered it off.

[fspGTD]

Moved to troubleshooting.  Not power enhancement related.