Bad water pump! Got the crank pulley bolt out but can't get the pulley off. Had two broken motor mounts a few thousand miles ago which let the pulley hit and break (replaced with new key and pulley for around $80). Searched & read some older posts which seem to all have a bolt removal problem but no mention of hard pulley removal. Also, read about the shaft being smooth and key/pulley/crank damage. My experience was the same but I found all the crank ends were smooth. I don't have a clue why the pulley is splined! It's the son's car and all his teenage "MASTER-BATER" mechanic friends are saying "just wiggle it and it should come right off". Bull crap!!! I've been prying as much as possible and beating where I can with a rubber hammer and nothing. Installed and tightened to spec's when replacing so what's next??? Heat??? Puller I borrowed from the parts store won't work either. Don't want to break the pulley or pull the engine. HELP!!!!!

 

One of the timing belt pulleys were stuck when I did my timing belt. I put a torch on it for ~5 min to heat it up. Came right off.

I can't remember if mine had splines. Maybe try pb-blaster or wd-40. Then try some heat.

 

Yea, I think its gonna be okay now. When the son gets frustrated after something goes wrong I tell him to walk away, calm down and think. I did just that, figuring tomorrow's gonna be a better day. Well I remembered using Loctite (green) on the threads when I installed the pulley. Checked out their website info and guess what? Heat will loosen it. Probably used way too much and it got in the splines between the pulley and shaft. Won't "wiggle" off!!!! Hope this helps someone in the future.

 

If you heat up the crank shaft I would suggest replacing the seal

 

Okay, thanks.