Problem with vibration damper removal

[minny]

Started to do the timing belt replacement today, Took everything off, including the upper timing belt cover which left the pully (vibration damper) and lower timing belt cover.

In everything I have seen, haynes manual, elsawin, youtube and forums, it says undo the 4 bolts (cheese bolts) and remove the pully, simple. With a bit of a hassle i finally got the 4 bolts off and tried the pull off the pully, wouldn't budge no way no how. I even tried to lever it off with a screw driver but slightly chiped a bit of the pully away so quickly abandond that idea. Then I tried a soft head malet thinking it was just rusted on and a few taps would free it, i didn't want to hit it too hard for fear of breaking either the pully or causing some internal damage to the crank.

On looking closer, it looks the be that the crank bolt (A on the pic below) is actually holding the pully on. The 4 smaller bolts fit in to housing that protrude out (B), these are clearly moulded as part of the pully (C) but this in turn looks to go behind the centre bolt with what looks like a washer over the top (D).

So, do i have to remove the central bolt as awell as the 4 smaller ones? or do a need to be a bit more brave and hit it harder with the mallet?



Thanks.

[zollaf]

no, just remove the 4 smaller bolts and struggle like a donkey for the next few hours to get the pully off. its a tight fit anyway and the slightest bit of rust stops it coming off. your bolts look very rusty so i would imagine you are proper going to struggle. its one of those things in the trade, you quote for a job then the pulley take 4 hours to remove, will the customer be happy to pay, of course not cos they wont believe you.

[Rob69]

have you got the bumper and lock carrier off, or trying to do it in the 'service position'? You'll get clear access with the carrier off and it will be worth the bit extra effort for access to setting the belt tensioner up. At least it was when I did my B5 passat.

[minny]

Ok, right, at least that will stop me fighting against the big bolt and make me seem foolish, it really does look like that 'washer' is holding it on.

I suppose second hand pullys are fairly cheap if i wreak it, don't want to do any damage to the crank though.

All 4 small nut rounded, i hate those types of nut, but i got them all off with a bolt extractor.


thanks for your reply.

[minny]

The whole lock carrier is off, i find it's much easier and can do other stuff as well.

I did one on my petrol version and the pully came off fairly easy, but it didn't have that 'washer' D on the above picture, or at least not that I remember.

[minny]

Are people sure that there is no way the crank bolt can be over the vibration damper? week later still not budged, I even bought an harmonic damper puller set and that doesn't do anything either except turn the engine, though not sure how they are suppose to work if they screw in the sprocket behind the pully.

thanks.

[rowdy-999]

I'd give it a proper wack with a lump hammer with a piece of wood in between. A soft mallet won't do a thing.

[zollaf]

the centre bolt holds the pulley on for the timing belt. the damper is then screwed to that. you can undo the centre bolt and take lot off if you need.

[zollaf]

and if the centre bolt is holding the pulley on, its been done wrongly in the past.

[minny]

and if the centre bolt is holding the pulley on, its been done wrongly in the past.

Well, I decided to go to the local garage, but they were busy so went to the local car parts and was looking for a crank wrench to keep the crank steady so I could remove the central bolt. Whilst there I saw a crow bar for £10, couldn't see the other so I decided to give it one last go with the crow bar - came off like hot knife throw butter.

Such a waste of time and effort for nothing.

Problem is, when trying to pry it off the first time a small part of the pully chipped off in a couple of places. It's the larger ridge at the rear, the bit that keeps the belt on; will this be ok or will i need to renew the pully; both are a few millietres. 5 or 6mm at most.

thanks.