broken pulley

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Comment by Steve Kerswell on February 21, 2015 at 21:30

good result, glad it worked.

Comment by Dave Price on February 21, 2015 at 21:25

Got it off.  Thanks for the advice.  I drilled two sets of holes one at 3 O'clock, the other set at 9 O'clock.  These were 3 holes at right angles to the crank.  Then drilled through these parallel to the crank by drilling a long hole from the front.  Then kept increasing the drill size to enlarge the long hole.  Then put a chisel in the slot and tapped it a couple of times and it split into two no problem.  Thanks for all your suggestions

Comment by Dave Price on February 20, 2015 at 22:23

Daryl, I thought the same, once I saw that much oil, I thought this won't be too difficult to get off.  I was wrong.

Ade, the engine is sort of in the car.  It has the engine mounts in place mounted, but no gearbox, just a bell housing with timber packing underneath.  So the engine is fixed sideways, but tilts front to back. Managed to get a sort of slot cut over the area of the crank key, some work with a hacksaw blade to finish off.  Then some impact work.  I will let you know he I get on.

Comment by Adrian Southgate on February 20, 2015 at 18:15

Is it on a stand, the floor or in the car?

Do you have a compressor and a wheel nut gun? If not I can lend you my wheel nut gun. Put the bolt back in with the gun on max torque and allow the hammer action to go at it a bit, then undo it the same way, rinse and repeat. After a few goes you should see puffs of dark red dust appearing from the back on the remains of the pulley, keep going with the impact wrench and it should loosen without damaging the crank nose. WD40 on the inside edge of the pulley and as you still have the cambelt in place you could take the plugs out and allow the engine to rotate as you do the bolt up. Its a taper crankshaft to prevent the pulley from being fitted backwards (well mine is) so once you get 1/2 a mm of movement it should come free. 

Comment by Steve Kerswell on February 20, 2015 at 16:01

if you try to do it that way, you could end up with a smashed front casing as well ! Never try to "wedge" anything off until it starts to move.