Tensioner pulley removal

[Ranga]

I need to replace the bearings in my aircon tensioner pulley (300Tdi). I've slackened off the tension, removed the bolt, but the pulley won't come off.

Before I try brut force, is there any trick to getting the pulley off?

[langy]

Undo the 3 bolts and remove the whole tensioner - that lets you play with the assembly easier. I know from experience that the pulleys do not like hammers, so go easy on them. Usually it's only a bit of corrosion causing them to stick on the tensioner, so wd40 and maybe a gear puller should do the trick.

[Blknight.aus]

a bit of plate steel, a rubber mallet, a drift and an oven.

cut a notch in a bit of plate steel to to fit under the pulley between the idler arm
put the idler in the oven and heat to about 120ish, while thats happening secure the bit og plate steel to something solid.
wind the bolt so its about halfway in to the arm, place the pully on the bit of plate steel so the arms under.

put the drift onto the head of the bolt and give it a whack with the rubber mallet. (giving it a squirt with some penetrating lube will help)

[Ranga]

a bit of plate steel, a rubber mallet, a drift and an oven.

cut a notch in a bit of plate steel to to fit under the pulley between the idler arm
put the idler in the oven and heat to about 120ish, while thats happening secure the bit og plate steel to something solid.
wind the bolt so its about halfway in to the arm, place the pully on the bit of plate steel so the arms under.

put the drift onto the head of the bolt and give it a whack with the rubber mallet. (giving it a squirt with some penetrating lube will help)

WTF?! If that's what it takes, maybe you should do it :)

[Blknight.aus]

sure why not, you know the number and the place, line it up, riday arvo if you like.