Lower pulley headache
Thread Starter
Heel & Toe
Joined: Sep 2015
Posts: 18
Likes: 0
Lower pulley headache
It's been discussed before, but your opinions are valued. I'm changing the opti on my 94 C4. I have done this before many years ago. I can't recall now if I removed the lower pulley outer, by undoing the three bolts, or just the centre bolt at the crank. This time I have gone for removing the three, but even with them all taken out, the pulley does not move. I've beaten it with a 2x2 piece of wood and a club hammer, but nothing. I don't have a puller, as I didn't need one last time I did it, not sure how you would get it in there anyway.....I've hit it pretty hard which I'm not altogether happy about as it's bolted to the crank....anyone else had this issue? I guess next I could try the centre bolt and remove the whole thing, but I'm guessing that'll be stuck too.
Racer
Joined: Jul 2017
Posts: 422
Likes: 53
From: PA
It's been discussed before, but your opinions are valued. I'm changing the opti on my 94 C4. I have done this before many years ago. I can't recall now if I removed the lower pulley outer, by undoing the three bolts, or just the centre bolt at the crank. This time I have gone for removing the three, but even with them all taken out, the pulley does not move. I've beaten it with a 2x2 piece of wood and a club hammer, but nothing. I don't have a puller, as I didn't need one last time I did it, not sure how you would get it in there anyway.....I've hit it pretty hard which I'm not altogether happy about as it's bolted to the crank....anyone else had this issue? I guess next I could try the centre bolt and remove the whole thing, but I'm guessing that'll be stuck too.
Le Mans Master
Joined: Sep 2013
Posts: 6,192
Likes: 750
From: near the thumb in the mitten
If you have to; take motor mounts loose, raise engine, take hub crank bolt out and slide pulley and hub off together. Hub isn't keyed and it's supposed to just slide off. Since you already have a hammer and a block of wood; a couple whacks may free it if it's stuck.
Thread Starter
Heel & Toe
Joined: Sep 2015
Posts: 18
Likes: 0
Thank you for your quick reponse paco. I'm doing this job outside in the cold and was hoping for an easy result. Guess I'll have to jack it up and crawl under. Hitting the pulley from above just isn't the correct angle, I'm sure if I get behind it as you suggest, it will have to pop off.
Melting Slicks
Joined: Jul 2008
Posts: 2,269
Likes: 142
From: Ottawa Ontario
Do not hit the pulley on the outside edge! You'll damage the rubber isolater. There is space to get a small 2 arm puller positioned just over the steering rack though you might have to disconnect one of the lines and tie it up out of the way.
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Intermediate
Joined: Jul 2017
Posts: 38
Likes: 1
From: Richmond, VA
I had the same problem when I replaced my Opti back in December. It was cold and mine was frozen. I definitely couldn’t get a 2x4 to fit but eventually found a smaller piece of wood. It eventually came off after a ton of walking but my pulley definitely has a small wobble to it now. It’s been driving fine for 200 miles since but I’ll probably replace it when I get a chance.
Thread Starter
Heel & Toe
Joined: Sep 2015
Posts: 18
Likes: 0
Thank you for the replies guys....well I went out and braved the elements this morning, determined to shift that pulley. I refitted the belt, locked the pulley by putting a half inch extension bar through it and over the steering rack, and undid the centre bolt. That seemed to free it up, and with some gentle coaxing, off it came, leaving the hub in place, despite the centre bolt having been removed.
The new Optispark is now mounted, although lining up the spline drive of the opti with the drive on the engine was proving tricky, until I remembered that in the glove box is a short splined shaft, presumably removed from an old opti...with this it was easy to work out the correct position needed, and the unit then went on easy. I'm waiting on a new water pump, thought I may as well while it was apart, and then I can button it all back up.......fingers crossed it runs again.
Thanks again guys.
The new Optispark is now mounted, although lining up the spline drive of the opti with the drive on the engine was proving tricky, until I remembered that in the glove box is a short splined shaft, presumably removed from an old opti...with this it was easy to work out the correct position needed, and the unit then went on easy. I'm waiting on a new water pump, thought I may as well while it was apart, and then I can button it all back up.......fingers crossed it runs again.
Thanks again guys.