Falcon waterpump pulley not coming off - urgent

[fgpsi]

Hi guys,

I am replacing the waterpump on an FG Falcon na 6 and purchased a Toledo power steering pulley removal kit (part number 245380). I can't for the life of me get the damn water pump pulley off with it and even though the new water pump I bought has a pulley on it already, you have to remove the pulley from the old water pump to get the bloody bolts out

It comes to a point when turning with the pulley removal kit on it where it won't go anymore

Urgent help required

[aussiblue]

Like this: https://www.youtube.com/watch?v=1-ZG3ZKjF5A while using a strap wrench (e.g. https://www.supercheapauto.com.au/p/...=en_AU&start=3 )to hold the pulley so it does not turn

[fgpsi]

Originally Posted by aussiblue

Like this: https://www.youtube.com/watch?v=1-ZG3ZKjF5A ?

Yes mate exactly the same

[aussiblue]

Note if it's a plastic pulley it's oftem bonded on (glued on) and you will need to buy a new metal pulley e.g. https://www.ebay.com.au/itm/13442272...Bk9SR_akjp-HZA

[fgpsi]

Originally Posted by aussiblue

Note if it's a plastic pulley it's oftem bonded on (glued on) and you will need to buy a new metal pulley e.g. https://www.ebay.com.au/itm/13442272...Bk9SR_akjp-HZA

the replacement waterpump I bought is this aftermarket one from repco which already has the pulley on there. The genuine ford one doesn't come with a pulley https://www.repco.com.au/parts-servi...fg%20waterpump

But as I said I can't even get the pulley off the old one that's in the car

[aussiblue]

Ok if need be out with the dermal and cut through the plastic pulley near the shaft although you should be easily able to get a low profile or flex head ring spanner (e.g. https://www.supercheapauto.com.au/p/...=en_AU&start=2 or https://www.repco.com.au/tools-equip...flex%20spanner ) or an open ender in behind the pulley to loosen the bolts.

[foxtrot3]

Hi. If it is the same as a BA you can remove all bolts bar one which is partially covered by the pulley but you can loosen this bolt and move the pump away from the engine and then continue to undo it until you can remove the pump. With the pump off the engine the bolt should angle away from the pulley enough to remove it from the pump. Use the same method to install the new pump without removing the pulley. Cheers MD

[fgpsi]

Originally Posted by foxtrot3

Hi. If it is the same as a BA you can remove all bolts bar one which is partially covered by the pulley but you can loosen this bolt and move the pump away from the engine and then continue to undo it until you can remove the pump. With the pump off the engine the bolt should angle away from the pulley enough to remove it from the pump. Use the same method to install the new pump without removing the pulley. Cheers MD

Ended up getting it off like this, installed the new genuine ford waterpump with dayco steel pulley as aussieblue suggested. Installed the dayco pulley with the toledo kit no worries. Installed new genuine idler pulley and tensioner. Got a new motorcraft genuine belt and its fitting abit loose near the alternator and around the waterpump pulley and screetches when I started it

I'm a bit stumped

[Citroënbender]

Have you the correct length belt? They vary from BA-BF Barra motors.

[fgpsi]

Originally Posted by Citroënbender

Have you the correct length belt? They vary from BA-BF Barra motors.

It's an fg mk II xr6 na

Got the motorcraft SX8620A. As far as I can tell it's the correct one ?

https://www.jeffersonfordparts.com.a...sx-sy-territor

[AMB]

Originally Posted by foxtrot3

Hi. If it is the same as a BA you can remove all bolts bar one which is partially covered by the pulley...

Pretty sure it was the same for E and AU series

[Jastel]

It does come off with the pulley ON, as others said its fiddly but. Try an open ender or 1/4 drive socket as they are smaller.

Worse case cut it off...

It would be simpler if the diameter was a few mm smaller...

[aussiblue]

its fitting abit loose near the alternator and around the waterpump pulley and screetches when I started it

Sound like you either:

a) need a new tensioner; or
b) have incorrectly routed the belt; or
c) haven't tightened the tensioner belt to the correct 25Nm, or
d) the tensioner alignment pin is not correctly located on the timing chain cover.

See https://fordforums.com.au/wsmpub/fg/303-05.html

[fgpsi]

Originally Posted by aussiblue

Sound like you either:

a) need a new tensioner; or
b) have incorrectly routed the belt; or
c) haven't tightened the tensioner belt to the correct 25Nm, or
d) the tensioner alignment pin is not correctly located on the timing chain cover.

See https://fordforums.com.au/wsmpub/fg/303-05.html

Mate I have done everything correctly and used a torque wrench

New belt, new tensioner, new idler pulley

I'm completely stumped

[Jastel]

Put the old belt back on and compare it...
As Citroen said they did make them slightly different sometime...

I have always used non Motorcraft code ....2220 number belt, which is the length in mm.

[aussiblue]

Is there a difference in diameter between the old and new water pump pulleys? The harmonic balancer is not starting to separate and walk the belt forward is it see the links I posted here https://fordforums.com.au/showthread.php?t=11499293 ? As they say here https://automotiveden.com/harmonic-balancer/

If the Harmonic balancer fails, the drive belt tensioner may begin moving abnormally. This can cause clicking or squealing noises when the car engine is running.

[aussiblue]

Also humour me and double check the belt routing carefully as it is very easy to get it slightly wrong and it will look and feel right and while it will runm the tensioner won't work correctly.

[fgpsi]

Originally Posted by aussiblue

Also humour me and double check the belt routing carefully as it is very easy to get it slightly wrong and it will look and feel right and while it will runm the tensioner won't work correctly.

Mate it is perfect, just checked it again lol

The old belt is gone but I put the old dayco tensioner back on to see if it will be tighter with the motocraft belt and it was tighter but not as tight as I'm seeing on videos. But still squeeking . Regarding the pulley they look to be the same size but the old waterpump is already gone to auto heaven so can't check exactly. It's a direct replacement isn't it ?

I'm thinking of getting the Dayco 6PK2220 kit with tensioner and idler puley since the old (Dayco) tensioner made the belt tighter. Maybe Dayco pulley wants a tight Dayco belt and tensioner ?

Really doing my head in this

[aussiblue]

Next time you have the bet off spin all the 6 pulleys by hand to see if they spin freely without squeaks. Perhaps you have worn bearing on a pulley that sticks and creates belt slack.

[aussiblue]

What was the part number for the Ford tensioner and pulley you installed? Same as this: https://www.ebay.com.au/itm/15150271...Bk9SR87v4bOLZA

[fgpsi]

Originally Posted by aussiblue

What was the part number for the Ford tensioner and pulley you installed? Same as this: https://www.ebay.com.au/itm/15150271...Bk9SR87v4bOLZA

Yes its the same

[aussiblue]

So the harmonic balancer looks OK too? Does it seem to move forward slightly if you watch it while you stab the throttle at idle?

[fgpsi]

Originally Posted by aussiblue

So the harmonic balancer looks OK too? Does it seem to move forward slightly if you watch it while you stab the throttle at idle?

Hi mate. It seems the car might have one of these :

https://www.tuffcarparts.com.au/ba-b...bond-20-underd

Which requires the 6PK2160 belt

[fgpsi]

OK so I accidently took a pic of the old drive belt before I threw it away and it says 6PK2160 which
means its shorter than the 6PK220 that is recomemmnded and what I bought

[aussiblue]

Hi mate. It seems the car might have one of these :

https://www.tuffcarparts.com.au/ba-b...bond-20-underd

Which requires the 6PK2160 belt

Well that would explain a lot.