Crankshaft Pulley Installation

[bigworm0860]

Can anyone offer some advice on installing a crankshaft pulley. I found only one video on youtube and the guy boiled his in water for 5 minutes before putting it on. Another guy recommended putting it in the oven. I'm hesitant to try this method. Is there any other ways?

[Danwvw]

They do what? Boil that pulley! I never did heat mine up. Now I like the degree pullies. They are cheap aluminum and stretch to fit and it's better to never take one of and put it back on because it will be a little loose fitting the more you take it off and put it back on but the steel pulleys don't do that.

Nothing wrong with heating it in the oven if it's clean probably could heat it to 300' F or so without issue. Just check the threads on the crank and the pulley nut that they are good. I just use grease on mine.

If you have a sand seal make sure that you have the right pulley for it don't heat the pulley very much, wouldn't want to burn the seal.

Don't over tighten the pulley, they don't need to be as tight as the flywheel. Probably 32'/lbs is plenty?

All torque specifications for engine bolts and screws.

The insides look like this on a stock non-sand seal pulley case, Note the oil slinger washer is held in place inside the case by the pulley. Stock Style Pulleys have oil threads on the pulley that direct any oil to the slinger washer and the oil goes back in the engine.

Oil Threads on a stock pulley:

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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[kman]

I don't know about the crankshaft pulley, but the cam gear I boil in vegetable oil before installing. The crankshaft pulley usually slides right in when tightening the bolt.
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71 vert build. http://www.thesamba.com/vw/forum/viewtopic.php?t=572951&highlight=dead

[Danwvw]

I just throw the crank cam gear and brass crank gear on the electric stove top on medium-low heat check them with the IR thermometer an make sure they don't go over 350' F and I have been known to put the crankshaft in the freezer the night before. I wear leather gloves to handle the hot gears. The whole thing usually takes place on the kitchen floor. When I have frozen the crank, heated gears drop into place. With the crank room temp, and the gears hot, the gears usually get stuck but go on most of the way and I use a drift to seat them.
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1960 Beetle And 1679cc DP W-100 & Dual Zeniths!

[bigworm0860]

Thank you guys for the responses. Very helpful. I'm going with a chrome stock style EMPI pulley I got from JBugs. I feel better about putting it in the oven at 300 degrees but not sure how long.

[Eric&Barb]

[Starbucket]

If you go with a chrome one sand the V-groove with 150 sandpaper to roughen up so the belt doesn't slip. 350 for 10 min.s in a pre-heated oven, use oven mitts, and move fast to the crank and slide it on fast or it will heat the crank and keep an eye on the woodruff key. A little anti-seize will do wonders on the crank if you get stuck 1/2 way.

[bigworm0860]

Sanding the inside of the pulley won't mess nothing up?

[Starbucket]

Have you just tried putting it on as is, like a test run? If you can measure the inside and compare to the crank, THAT would me ideal.

[Eric&Barb]

[rcooled]

[swavananda]

I was told long ago that a good aluminum pulley should fit tighter because They will expand more than steel. But bets are off with anything empi. Especially chrome empi.

[bigworm0860]

Thank all of you again for the responses. I tried the oven method. The pulley went on about half way and got stuck. I tried lightly tapping it on with a rubber mallet at first. Then got pissed and hit it harder and ultimately bent it. Of course I had to remove it with a pulley remover and further destroyed a brand new pulley. So, awaiting another one (I have to order everything) and will most likely try the sanding method.

[Eric&Barb]

Damn, sorry to hear that. Please do keep us all updated.
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In Stereo, Where Available!

[Starbucket]

End your problems and find a used steel pully and paint it. If you insist on Empi Junk (it's from China) you have to measure the ID as they have limited "Quality" control, one might fit perfect or could be too big or too small.

[amjady]

I just installed an Aluminum pulley last week on my 1600 dp engine. Installed at room temp. The pulley slid right on about half way then got stuck but it was on far enough for the bolt to reach the threads and I simply tightened the bolt and it pulled the pulley right down with very little effort.

Did the same thing a few years back on another car.

Just my experience.

[bigworm0860]

So my second crank shaft pulley showed up Saturday. I went with an aluminum one this time. It was EMPI and I ordered it before I got your (Starbucket) post about EMPI being junk. As much as I see EMPI everywhere, I just assumed (I know, don't say it) EMPI made good stuff. Duly noted. Anyway, the aluminum slipped on fairly easy with a little sanding and grease. Everything else went back together pretty easy and I think I just need to set the timing and I'm good to go.

Can any of you guys recommend a VW supplier that sells GOOD quality parts?

[John Moxon]

[bigworm0860]

Roger that. Thanks John.

[Eric&Barb]

Hopefully the pulley you got is the same size as the 1500/1600 or better yet the bigger one used on the dual port engines. Using a smaller pulley will result in less gen/cooling fan RPMs and thusly less cooling air being pumped over the engine.
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In Stereo, Where Available!