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Re: Idler Pulley Removal

At 01:30 PM 4/1/98 -0500, you wrote:
>Hi All:
>Did my timing belt and water pump yesterday.  I wanted to replace the
>idler pulley but couldn't get it off.  I don't have the special puller
>and my regular puller wouldn't fit in the confined space.  No, I didn't
>pull the IC.  Any McGiveresque solutions out there?
>Mark Pollan, '86 5KCSTQ 250K Miles
Harbor Freight tools has a cheap steering wheel lock plate remover for
$6.99.  Just use that and the washer and nut that comes with it.  Get a
10mmX1.5 boltX80mm long, then cut 1.5" off of each leg.  File or grind 2
parallel flat surfaces on the end of the bolt (so you can grab it with a
crescent wrench).  Fits perfectly.  To remove pulley put washer on bolt and
stick thru hole in puller.  Thread bolt into pulley and try to keep the
legs in line with the oil pump housing boltheads.  Turn bolt to pull out
pulley.  DONOT use the mounting bolt to install the pulley!!!  On my 4kq,
you can use the puller to press in the new pulley.  Remove bolt and washer,
then thread on nut that came with the puller, then the washer.  Reverse the
puller so the legs face the body.  Place the head of the bolt with another
washer against the face of the pulley right where the holding bolt goes.
Holding the end of the bolt with a crescent wrench, use another open end
wrench to unscrew the nut.  Make sure the pulley is straight before you
apply real pressure!  You may have to repeat several times, take your time
and go slowly.  Popped right in for me.  YMMV



Tony Lum                                                    1987 5000CS
Turbo Quattro
Berkeley, California, U.S.A.                               1985 4000CS Quattro
Audi Owner/Driver/Mechanic by Necessity ;^)        1980 5000S  Sedan