Idler Pulley won't come off - 2003 Windstar

[Lamorake]

I'm hearing a whining sound that follows with acceleration and from what I've read it may be an idler pulley, belt tensioner or alternator. I went out and bought an idler pulley and belt tensioner since it was in the budget.

I was able to get the serpentine belt loose and started to unthread the bolt for the idler pulley. Once it was out, the bolt was up against the wall of the car and I couldn't budge it. The idler pulley was stuck! I was able to get it back on without a problem.

Anyone ever run into this problem? I'd love to know a solution beyond having to take it to a shop.

[12Ounce]

I think most folks wedge something against the engine to force the engine over to the left .... making a bit more room to remove the screw. I went back together with a slightly shorter screw.

...Just wait 'til you remove the pump!

[olopezm]

It does comes out, you just have to play a little with it.

When I replaced mine, If I remember correctly, I pulled the pulley form the shaft and left it "hanging" on the bolt. After that I tilted the bolt (with the pulley) towards the front and voila! It came out easily.

Oscar.

[Lamorake]

Thanks, 12Ounze and Oscar. I think I may have to do the ole leverage push against the engine ever so slightly and go with a shorter bolt. There was absolutely no give with the bolt/pulley to wiggle it out. Believe me I tried... maybe some of the innards have slightly different dimensions that allows for the forced pull-off.

I don't want to think about doing the pump... not going there yet! lol

[phil-l]

I ran into this - and buggered up the end of that bolt trying to get it out and back in...

I didn't have the clearance to do it.

However: I had some other components off of the engine at the time - which gave the the clearance to simply remove the entire tensioner assembly itself. IIRC, there are 3 bolts that attach it to the block. Sorry, I didn't take pictures of that project - and don't recall exactly how difficult those bolts were to get to.

However, that approach dramatically simplified servicing the tensioner pulley.

[olopezm]

I'm sorry it didn't work out easily for any of you guys...

Really in my case it was very easy, both idler and tensioner pulleys were done in about 30 minutes plus 1 hour to drive to the store, get the pulley and drive back home. Even reinstalling the serpentine belt took me most of the time because I did it with a box end wrench (don't ask XD)

Oscar.