Unfortunately my crank pulley ate some of the bolts that hold it to the crank. 3 of them to be exact. 1 bolt was removed without issue. However I had to remove that one bolt due to the fact that the others are broken. 1 broke off right at the head, so it sticks out of the pulley boss. 2 are broken off inside the pulley boss.

The crank pulley is removed, as is the large crank bolt, and the timing belt is loose. I can't get the pulley boss off (11-411 in the below picture). I guess I was just hoping that the large center crank bolt is what holds the boss to the timing gear, however I'm becoming concerned that the 4 outer bolts that hold the crank pulley to the motor go through the boss and into the timing gear. So, is this the case, or am I just a wuss? I've tried everything I've thought of, and I'm bleeding pretty good from a couple of fingers, but the boss has not budged from the timing gear.

 

The four bolts just hold the crank pulley on, its the center crank bolt that holds the rest.
--Alex

 

That is what my memory was too, but this dang thing is on there. I'll hit it with some penetrating oil and give it a rap with a mallet then. Thanks.

FWIW, my goal was to take this thing off, and bring the whole assembly, boss>factory trigger wheel>pulley>trigger wheel (aftermarket) to a machine shop, have them extract the broken bolts, then drill through the assembly and tap for larger bolts. Possibly machine the ID of the aftermarket trigger wheel to open the ID up a little more for even larger hardware.

 

No problem. Glad my "taking things apart so many times I cant help but remember it" helped someone else too....

That's what I ended up doing with the crank pulley bolts. Half because of FMs bolt shear warning, and half 'casue allen headed cap screw were easier to reach.
--Alex

 

Failboat. All aboard.





Sorry for camera phone pics.

 

DUDE! Fail indeed. I feel for you. I can't handle that kind of thing. That would be the point where I would throw in the towel and either sell the whole car, or at least the engine for scrap.

How in the **** did that happen!? Were they the wrong thread pitch and got forced in there or something. Those aren't even supposed to be that tight, like 15 in-lb if I recall correctly

 

If you hit the center bolt with an impact, It should come off no problem.Noty that big of a deal to remove the bolts.Good Luck,if you need a mmachine shop dont calll my shop,we dont do any automotive.
(G)

 

Greg, the center bolt is out. That's just a matter of locking the cams together with wrenches and a vice and leaning on said bolt with a 3' breaker aka jackhandle.

The problem is the pulley boss doesn't want to come off. I can't use a puller (not sure if I have one that would fit anyway) because there are bolts broken off in 3 holes.
Got the thing soaking in penetrating oil. Tomorrow I need to buy a brass hammer and I'll see what happens if I give it a little tap-tap-taparoo.
I didn't want to bother you with this since it should be a pretty easy thing for the most novice machinist.

 

With enough light tapping with a hammer and oil, it should eventually loosen up. I think mine had to be pried off, or put force on it while tapping. Something that got my blood pressure up.

 

You can use a puller. Re-install the crank bolt with about a 1/4" of runout remaining. Use the bolt as a rest point for the puller screw.

That piece shouldn't be that difficult to remove. It only has about 3/8" of contact with the crank snout.

 

damn mine always falls right of your keyway is probly aili rusted man some tapping and wedgeing should get it off no problem.

 

Penetrating oil is your friend. Couldn't get the timing belt pulley off my old engine when I was tearing it down, but a few days of sitting with liquid wrench on it and it came irght off.

--Ian

 

Liquid wrench FTW. Now gotta get this assembly to a machine shop for some massaging.

 

Dude.. If that does not work I might have a few of those with crank pulleys from a 99-00 engine. Let me know if you are in need. I remember some on the wall in my personal garage when I did my last clean out.