How the 'eck are you supposed to remove them? I had to buzz the 30mm nut off with my impact gun, cos no amount of breaker bar could shift it (I was worried about the main bearings but don't think I had much choice). Now the nut is off, the pulley is stuck fast. I've tapped it all round with a rubber mallet, done light taps with a proper hammer, and harder taps with the same hammer and a block of wood. Haynes says to soak the boss in penetrant, Muir says to do the tapping thing, Bentley says to use a VW fan puller 203b. Do I need a puller? I guess I need a puller.
If you mean a CSP pulley, if you didn't take the paint off the inside of the boss before fitting, you are going to struggle!
I don't know if the pulley has ever come off. This is certainly the first time for me. I wouldn't have bothered but as I'm reassembling the engine ready to go back in the bus, I noticed some of the tinware is a bit crappy (the pulley piece is rusted through), so I'm going to replace at least that part.
I made a puller according to the VW instructions.. that catches bolt heads in the slots. Two leg pullers pull too hard in one place on the outside of the slot and just tear up the pulley. Somebody wedged the pulley on without removing the paint in the hole.. [edit for clarification, I want to make clear that not all new steel pulleys are junk] New (Brazilian made) tin pulleys are rubbish. Wobbly. The CSP tin pulley looks nice but doesnt have any puller slots .. hmm. Apart from aluminium ones that are also slightly smaller diameter so you need 900 rather than 911 mm fan belts..
