boylinator

i'm in the process of installing my pulley and can't get the bolt off to remove the factory pulley. i mean, i'm seriously pulling and not getting anywhere......any advice?

TimmyC230boy

do you have an auto or manny? You need a 1/2 inch socket to loosen the pulley bolt/

boylinator

it's manual, i'm using the instructions that buellwinkle supplied.....w/ 27mm socket and the car in 6th gear

TimmyC230boy

so the bolt will not come loose? you may have to use a air powered gun. not sure though. try to PM Buellwinkle. If you have instant messenger My name is "timmyc230benzboy". I'm on now and will give whatever help i can.

vadim

what tool are you using? I used a torque wrench with a long handle, and it didn't take much effort to undo the bolt in mine.

avlis

Long handle is the key. If that doesn't work, slide a long piece of pipe over the handle for additional leverage.

TimmyC230boy

i was talking to him on IM about 15 minutes ago and he said he would use some liquid wrench or WD-40. he also said he would be back in 5 minutes to let me know if it worked. My guess: It worked and he is too busy installing pulley to talk to me. lol

boylinator

well, didn't have any luck today getting that bolt off. i tried wd-40 and pulling like hell, neither of which worked. don't have an air gun so i'm going to have to find a piece of pipe and try that old tricker whenever i get a chance......until then

avlis

WD-40 isn't a good penetrating oil. Even if it was, it still wouldn't free that bolt. The oil will only penetrate a couple threads a month, if that. Oil only works if the bolt is snagging on rusted/burred threads and you can squirt the oil on the BACK side of the bolt (the part that hasn't gone through the nut yet). Squirting oil on the head just makes the head slippery.

Next time you try to loosen it, get the engine up to temp so things are nice and hot. Heat always works better than penetrating oil.

Matt230K

Are you trying to do it from above or below? I had my car on a lift and had a long breaker bar. But I still had to push VERY hard to get it loose. And I was standing up pushing with both my arms and legs, so it requires a lot of force.

I have a question too. What did you guys torque the bolt to? I think I saw someone post a pretty low number one time. But I got the number from a computer at my dealership that has information on all cars. It said 220 ft.-lb. It was even harder to get the thing torqued back to this number, but I figured its right since it was so hard to get off.

Buellwinkle

You have to use a long 2 foot at least breaker bar to get that bolt off. Pipe will work on a small rachet but may break the rachet mechanism so make sure it's Sears so you can get a new one. Also, if you are weak like me then an extra pair hands on the breaker bar will help. Make sure you expend the same energy tightening the bolt so it doesn't come off easily.

boylinator

alright.....as i restarted my car, and checked to see how disconnecting the battery effected the radio, etc.....i soon realized that my windows will not auto up now and my sunroof won't open either.....i go into the dealership tomorrow for service, what do i tell them?

TimmyC230boy

you just have to resync the windows and roof. Hold down the windows buttons a couple seconds once they are down and do the same for the roof. That should work.

You did take off the belt before you tried to take off the crank pulley right?

Buellwinkle

I don't think he took the bolt off yet, no need to remove the pulley or belts until that bolt comes off.

boylinator

just picked up a 2.5' piece of 1" steel pipe that should certainly give me the leverage i need to get this dang bolt off. to buellwinkle especially, will i run into any more little problems when installing this. remember that your dealing with someone who isn't exactly a mechanic, but can certainly follow instructions. how do you get the new belt tight on the pulleys? Thanks

Buellwinkle

If you put the belts on correctly they will all fit nice and snug. The tensioner will take up the correct amount of slack.

Once you get the bolt of (actually the easy part), removing the pulley can be a challange. You can try wrapping a pair of crowbars in rags (so you don't scratch everything up) and prying evenly from behind while someone pulls from the front. I put WD40 but I don't think it did much good, it's just a very tight fit. It's easiest to pry from below and pull from above.

vadim

Here... You want the crankshaft key to face up - that way you won't misalign the pulley groove when sliding it on. After you remove the original pulley, chances are, that the key is not at the desired position. You may want to crank the engine to bring it to the top, as Buellwinkle suggested in his manual. It didn't work for me, however - I kept trying this for quite a while, and the key would always end up either at 10 or 4 o'clock (if memory serves me right). So I figured another way: with the original pulley still on and belts off, bolt undone, disconnect the battery (it should be disconnected by this time, anyway), put the car in neutral (essential!), and with both hands spin the pulley until you see the timing marks. The key is between 25 and 30 (use a flashlight - you'll see what I'm talking about). It's very easy.

TimmyC230boy

could you post what size torx sockets you need to remove the air box.
thanks

boylinator

C230Jeff
Sorry to hear that! It was definitely a challenge and I actually thought I could do it in the one hour time frame. Heck, I tried for an hour to get the bolt off. I had to give up for the night, put the air box back in, and think about it a little before trying to tackle it again tomorrow.

TimmyC230boy

so for the install is it just regular screws and a some clamps to get the airbox off?

avlis

Heat it up?

Buellwinkle

OK, I'll post this again even though I just posted this a few replies ago;


Once you get the bolt of (actually the easy part), removing the pulley can be a challange. You can try wrapping a pair of crowbars in rags (so you don't scratch everything up) and prying evenly from behind while someone pulls from the front. I put WD40 but I don't think it did much good, it's just a very tight fit. It's easiest to pry from below and pull from above.



As for torx bit, you guys are way too fancy. I removed the airfilter screw with a pair of pliers, it's not on their tight at all. Also on the tensioner pullies I just used a regular hex socket, works like a champ.

TimmyC230boy

I have 2 of the gator grip sockets. 1 for anything up to 1/2 inch and the other for 1/2 - 1 inch. I will probably use that.

hey Buell, where are they instructions again, with pics. Are they online?

Lynn

Can a gear puller be used to remove the pulley?

avlis

I surprised there aren't any threaded holes in the pulley for attaching a puller or some jacking screws. What does MB use? Prying it off with crowbars does seem a bit barbaric.