help with underdrive pulley
Drain the radiator using the petcock valve on the bottom passengers side.
Remove the air lid, maf, throttlebody.
Remove the serpentine belt by using a 15mm socket on the tensioner pulley (it's spring loaded, just torque it clockwise until you can get the belt off. it's the small pulley to the passenger side of the water pump)
Remove the water pump. Disconnect all of the hoses and remove the 6 bolts.
Remove the radiator support (it's what the air lid sat on). This is a real bitch by yourself but it's possible. It's not bolted in, just lift it and the a/c condenser (small radiator) out together and pull them apart. Be careful with the hardlines on the a/c. There is plenty of play without having to discharge the a/c though.
I used a bungie cord to hang the a/c condenser from the hood while I was working in the car.
Now you should be able to access the pulley. you should rent a 2/3 jaw pulley puller from Autozone. Get the smaller one, there won't be enough room for a larger one. The jaws will actually go inside the pulley in the slots rather than around the outer diameter of the pulley.
You'll need a big *** breaker bar and probably a pipe on top of that to break the crank bolt loose. Then get creative with a socket that fits inside the pulley bolt hole and rests on the crank snout. Use that as the pressure point for the pulley puller.
Blammo, now your pulley is out. You should DEFINITELY find a longer bolt (specs on the ls1howto site) to use to pull the new pulley on. If you use the shorter, original bolt and the threads actually reach (mine didn't) you will most likely strip the crank threads out doing it, which will suck.
Just check the ls1howto site anytime you need to install something. That site seriously rocks.
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I didn't need to remove the water pump. But I did get the rad out to give me more room to work.


