300TDI WATER PUMP REPLACEMENT - PULLEY REMOVAL TIPS??? HELP

[TACO]

Any one have an idea of how to get the 3 x M10 bolts off the pulley below the Alternator>???????

Ive tried to keep the belt on and keep pressure but these are on tight and the whole pulley just spins (suspect past shop using a rattle gun) and I can't get these to budge...

Sidelined until I can get these off to access water pump bolts.

Any Help Appreciated!!!!!

Cheers guys :)

[shack]

Any one have an idea of how to get the 3 x M10 bolts off the pulley below the Alternator>???????

Ive tried to keep the belt on and keep pressure but these are on tight and the whole pulley just spins (suspect past shop using a rattle gun) and I can't get these to budge...

Sidelined until I can get these off to access water pump bolts.

Any Help Appreciated!!!!!

Cheers guys :)Which engine?

[TACO]

SORRY 300TDI CHEERS

[AK83]

if you have an impact driver, I'd try this first.
If you tried this, then a few other things you could try:

make a small bar lever type tool to go over and around two of the bolt heads, which gives you leverage to hold the pulley better and undo each one in turn.

if you have a blow torch, remove belt and give them a small amount of heat.

sometimes a few taps on the heads of the bolts can loosen them a teeny bit too.

[TACO]

if you have an impact driver, I'd try this first.
If you tried this, then a few other things you could try:

make a small bar lever type tool to go over and around two of the bolt heads, which gives you leverage to hold the pulley better and undo each one in turn.

if you have a blow torch, remove belt and give them a small amount of heat.

sometimes a few taps on the heads of the bolts can loosen them a teeny bit too.

Cheers mate - looks like radiator out to fit a impact driver.... joys. ill try some heat first.. these aren't budging

[BathurstTom]

Any one have an idea of how to get the 3 x M10 bolts off the pulley below the Alternator>???????

Ive tried to keep the belt on and keep pressure but these are on tight and the whole pulley just spins (suspect past shop using a rattle gun) and I can't get these to budge...

Sidelined until I can get these off to access water pump bolts.

Any Help Appreciated!!!!!

Cheers guys :)
If it is the pulley pictured, have you tried an allen key in the centre?

[TonyC]

Hi,
I've had luck by getting some thin rope, tying off one end, and wrapping several turns around the pulley so the rope tightens as the pulley turns, pull hard on the free end as you loosen the bolts. Like a capstan winch in reverse.

Have have aso tightened a ratchet strap around the pulley, tying off the end and loosened the pulley

I would also get yourself a 6 point 10mm socket (I use an impact socket) grind the chamfer off.
This will give you the best grip on your damaged bolt heads.

Tony

[Tins]

They're not big enough to be that tight. They'll be loctited. As suggested impact gun, or heat, or both. My little impact gets in there.

[mrb505]

Try putting a rag between the pulley and the belt so it tries to pull the rag in as you turn the bolts

[AK83]

Hang on!

I re read your initial post, and you say "pulley below the alternator" ... but you're doing water pump removal?

Unless the Defender 300 tdi was somehow made differently in some models, but I'm sure that the waterpump and pulley is above the alternator on the 300 TDi.(at least it is on the Disco version of the 300 TDi)
The pulley below on that side should be power steer pump.

So from your image, the pulley half in frame with FRONT on showing in the image should be the waterpump .. pulley you want to remove.

ps. the bolts are not M10 either(just in case ....) they are in fact 10mm hex heads, but IIRC they are M8 bolts .. and 12mm length too.

I've had similar issues on some of my pulley bolts(in fact I think all in some manner).
Many of them on my Tdi had been rounded partially, and I got stuck not being able to get some off.

On a money back guarantee from the sales rep at Bursons ... I bought a set of Kingchrome Lok-On sockets, and they gripped like some proverbial stuff and removed the already half damaged bolts!
I now swear by these tools(I got a 3/8 drive set).
Once removed I replaced the bolts with new but I stupidly thought any short bolts would be OK. I got 15mm length bolts which fit nicely, but once fitted they would bind with the extra thread length! ... arrgghh!

Anyhow... sorry for the slightly off topic rambling, but just be sure you are removing the correct bits.

[TACO]

Hi,
I've had luck by getting some thin rope, tying off one end, and wrapping several turns around the pulley so the rope tightens as the pulley turns, pull hard on the free end as you loosen the bolts. Like a capstan winch in reverse.

Have have aso tightened a ratchet strap around the pulley, tying off the end and loosened the pulley

I would also get yourself a 6 point 10mm socket (I use an impact socket) grind the chamfer off.
This will give you the best grip on your damaged bolt heads.

Tony

Cheers Tony - ill give this a try today yes bolt heads are getting a little soft and troublesome..

[TACO]

Try putting a rag between the pulley and the belt so it tries to pull the rag in as you turn the bolts

Good idea - ill give it a whirl cheers mate!

[TACO]

If it is the pulley pictured, have you tried an allen key in the centre?

Didn't think it was an Allen key centre - just a round centre but will look again - cheers!

[TACO]

Hang on!

I re read your initial post, and you say "pulley below the alternator" ... but you're doing water pump removal?

Unless the Defender 300 tdi was somehow made differently in some models, but I'm sure that the waterpump and pulley is above the alternator on the 300 TDi.(at least it is on the Disco version of the 300 TDi)
The pulley below on that side should be power steer pump.

So from your image, the pulley half in frame with FRONT on showing in the image should be the waterpump .. pulley you want to remove.

ps. the bolts are not M10 either(just in case ....) they are in fact 10mm hex heads, but IIRC they are M8 bolts .. and 12mm length too.

I've had similar issues on some of my pulley bolts(in fact I think all in some manner).
Many of them on my Tdi had been rounded partially, and I got stuck not being able to get some off.

On a money back guarantee from the sales rep at Bursons ... I bought a set of Kingchrome Lok-On sockets, and they gripped like some proverbial stuff and removed the already half damaged bolts!
I now swear by these tools(I got a 3/8 drive set).
Once removed I replaced the bolts with new but I stupidly thought any short bolts would be OK. I got 15mm length bolts which fit nicely, but once fitted they would bind with the extra thread length! ... arrgghh!

Anyhow... sorry for the slightly off topic rambling, but just be sure you are removing the correct bits.


Yes you're right - they are in fact M8 bolts. You need to remove both pulleys to access all the water pump bolts on a 300TDI. Top Pulley came off no trouble but this one is a PITA! ill check out those sockets sound like a good bit of kit - cheers mate!

[TACO]

If it is the pulley pictured, have you tried an allen key in the centre?

Bathurst Tom - your a LEGEND!

It is an Allen key centre so for anyone doing a water pump on a 300tdi this will save you hours of mucking about with a spinning pulley!

#9 Allen key in my kit pictured here for reference.... handy kit as fits to socket spanner

FYI Hard to see its an Allen key centre with the amount of grease and muck lurking so there you go peeps. :)