How to Remove a Crankshaft Pulleyby TJ Hinton
There are two basic types of crankshaft pulley: those that incorporate a harmonic balancer and those that don't. While both power the accessory drive belts, you must not use the typical claw-type puller on those with balancers or you will damage the rubber isolators between the balancer ring and hub. Most models also use a torque-to-yield bolt to retain the crank pulley. These bolts stretch when torqued, so you'll have to replace yours with a new one.
Position the puller in front of the pulley. Hold the point of the central threaded puller bolt in the detent on the end of the crankshaft and rotate the puller until at least two of the slots in the puller align with the threaded holes in the pulley.
Install the puller-to-pulley bolts. Thread the bolts in by hand, and adjust the depth of the bolts so that the puller is square with the face of the pulley. Tighten the central puller bolt until you remove all the slack.
Using a breaker bar and socket, tighten the central puller bolt until the pulley slides off the crankshaft. Support the pulley during removal as it may suddenly pop off the shaft. Do not drop the pulley or the puller during this procedure.
For installation, ensure that the crankshaft, pulley bore and keyways are clean and free of any debris or corrosion. Install a new key in the crankshaft keyway. Position the pulley on the shaft, and align the keyways. Be careful to avoid disturbing the key or knocking it out of the keyway.
Install a new crankshaft bolt. Torque the bolt according to your manufacturer's specifications, using a foot-pound torque wrench and socket.