Intermediate Pulley Removal on way to Water Pump Removal
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    Intermediate Pulley Removal on way to Water Pump Removal

    As I'm working my way to timing my 1.6D engine with A/C I realized it might be easier to remove the water pump pulley to get the lower timing cover removed. It was. But to remove the wp pulley I had to drain the antifreeze out of the system to gain access to the impeller. Well the pulley would move while I had a screwdriver jammed in the impeller. I just ordered a new pump, thermostat, o-ring, etc.

    My plan is to just replace the pump, not the housing. Yes, I know, when I break a bolt I will pick myself up and move on to removing the ip, compressor and whatever else I will need to do to get to the wp housing and remove it then.

    Question: When I get to the Intermediate Shaft Pulley (to reach the last wp bolt) is there anything I should look out for? I have a sprocket buster so that should make getting the bolt out easier. It is a Hex bolt, haven't checked the size yet. Are they reusable?

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    Super Moderator briano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond repute briano1234's Avatar
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    Re: Intermediate Pulley Removal on way to Water Pump Removal

    There isn't a bolt on the water pump that goes to gets near the intermediate pulley,
    There is a 10mm nutted t-bolt that you have to remove to take the pump loose.
    I have done it both ways, on the car and remove all the stuff and 4 bolts and the water pump is off (save for the 10mm nut on the t-bolt.).
    It is way easier to do to replace it from the top than the bottom.

    If you break a bolt most of them are through bolts, so you can try drilling them out from the back side.
    If the WP is old, then you may be wiser to order the pump and housing and replace both.

    Key Tip. Clean and Never-sieze the bolt before you install.
    6pt 10mm 1/4 drive anything else and well get a housing and start all over.

    Going back is the 87 in/lbs torque on the wp bolts.

    In the engine section I have a how do I do that on a cabby.... almost same set up on a diesel....

    Be careful.....
    What do Divorces, Great Coffee and Cars all have in common?
    They all Start with good GROUNDS.
    Replace all of them that you can, 99 percent of flakiness will disappear.


    92, 93 Cabriolet.... 89, and 90 are Deceased.


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    Re: Intermediate Pulley Removal on way to Water Pump Removal

    So to remove the water pump, not the housing, you are saying that I do not need to remove the intermediate shaft pulley to gain access?

    And the nutted t-bolt (aka hammerhead?) only needs to be removed to take the housing off?

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    Super Moderator briano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond reputebriano1234 has a reputation beyond repute briano1234's Avatar
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    Re: Intermediate Pulley Removal on way to Water Pump Removal

    No, you don't need to remove the intermediate pulley if you take off the housing with pump.
    You have to remove the "t" nut/bolt (aka hammerhead) as it is one of the bolts that hold the pump to the housing.
    Going back 87 in/lbs and never-seize.

    I don't remember ever taking the intermediate pulley off which ever way I did it. Pump or pump/housing....
    What do Divorces, Great Coffee and Cars all have in common?
    They all Start with good GROUNDS.
    Replace all of them that you can, 99 percent of flakiness will disappear.


    92, 93 Cabriolet.... 89, and 90 are Deceased.


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    Junior Member absenth is a jewel in the rough absenth's Avatar
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    Re: Intermediate Pulley Removal on way to Water Pump Removal

    Ok. Thanks.

    Quote Originally Posted by briano1234 View Post
    No, you don't need to remove the intermediate pulley if you take off the housing with pump.
    You have to remove the "t" nut/bolt (aka hammerhead) as it is one of the bolts that hold the pump to the housing.
    Going back 87 in/lbs and never-seize.

    I don't remember ever taking the intermediate pulley off which ever way I did it. Pump or pump/housing....

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