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  #1  
Old 28-03-08
CBC CBC is offline
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Question Crank Pulley Removal?

Good eveing fellow Saabers!

I've searched and read as many posts as I can find about removing the crank pulley, so I apologize in advance if this has been adressed in a previous post and I missed it.

I have a 1992 900 S 5 speed with a crank sensor problem. I've managed to get as far as removing the crank pulley bolt, but I cannot get the crank pulley to slide off the shaft. There is absolutely no room down by the firewall, so getting any kind of leverage with one hand is nearly impossible. Has anyone had an issue removing the crank pulley while the engine is in the car? Any tips you can give me? I guess I should go ahead and ask about the crank seal too. Will that pull out easily just using my fingers? Or will there more to it than that? Not being able to see what I am working on is frustrating. This all by feel only.

This is a bear of a job, and with so little room to work, it is definetely testing my mechanical skills. I thought changing the belts was tough, but the belts are nothing compared to this.

I'd appreciate any help you guys could give me. Thanks in advance. Brian
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  #2  
Old 28-03-08
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The crank pulley is a tight fit on the crankshaft.

Your big issue is trying to pry it, because when you are prying you are applying a torque on the pulley instead of a direct force, so in effect you are "locking" it in place and it won't come out.

Ideally try and pull it out "straight", the best way for this is to use a pulley puller I don't know if there is space, there must be some room...

For the seal, yes it is easy finger. But you can't really do it there AFAIK. You have to remove it with the cover. But with pulley gone this is easy.
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Old 29-03-08
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Try to get something down each side of the pulley to pry it off.

In both cases I did the job the pulley slid of easily.
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Old 29-03-08
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You would be better off if........

you removed the oil pump and removed/replaced the seal. If the seal can be removed by fingers, then the housing where the seal resides may be worn.
The seal should not be so loose as to be able to be removed by fingers or hand.

The crank pulley will move, with the gentlest of help, and I do emphasise 'gentle'!
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Old 31-03-08
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First, if you can remove the "woodruff" key from the shaft the pulley sits on that will help.

You'll need TWO pry-bars or large screwdrivers to coax this off--prying from only one side causes the pulley to "side-load" against the shaft and it won't move.

After you get the d*** pulley off clean up the shaft with emory paper so the pulley slides on and off easily. Coat the shaft with a very thin coat of "never seize" in case you have to do this again.

The shaft seal can be removed (you'll have to pry it out destroying it in the process) from the oil pump cover and you can install a new one by making a spacer that slides over the shaft to push the seal into the oil pump cover. You "push" the spacer by using the pulley shaft nut. Be careful, you get ONE chance to push the seal in evenly. I have successfully done this this way and would do it again. You can make the spacer from wood or buy several large washers at a hardware store...
Removing the alternator helps with getting wiggle room down there...

HTH
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Old 31-03-08
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I'm with the mouse...take the oil pump off and replace the seal. Also replace the oil pump cover seal (o-ring) at the same time. If it's not leaking now, it's only a matter of time....
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Old 19-04-08
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Question Crank Sensor Update

Just wanted to update this post I originally submitted and get a few opinions from you guys. 1992 900 N/A with a no start problem. Symptoms were - it was running beautifully then the next second stopped running. No warning, no hesitation, bucking, etc. Turns over fine but will not make any attempt to catch and actually start.

I tested what I could per Bentley and determined it had no spark at the plugs nor coil. Fuel pump works when jumped via fuses 27 and 30. Determined the crank sensor was the most likely culprit and attempted to replace it. Realized my mechanical skills were not good enough to complete the job so off the repair shop it went.

Fast forward 3 weeks - The mechanic has been diagnosing the problem and reported to me yesterday that the crank senosr on the car and the good used sensor I have for a replacement both have the same reading. He said they are both "open." This is leading him to believe the issue is not with the crank sensor.

Does both sensors being "open" tell you guys anything? I'm not sure excatly what he means and I could not get any additional details from him to clarify.

When I was testing the car myself a few weeks ago I ran across something odd as well - I read somewhere in a post here about a procedure to basically hot wire the coil to the battery to test it. When I did, I could hear one or more of the relays above the ECU (passenger footwell area) clicking. They would click everytime I touched the wire to the post. I could not try to start it because I already ahd all the belts removed. Curious if this means anything to you guys.

Any help or advice is appreciated, and I apologize for the long note.
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Old 19-04-08
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Quote:
Originally Posted by CBC
I have a 1992 900 S 5 speed with a crank sensor problem. I've managed to get as far as removing the crank pulley bolt, but I cannot get the crank pulley to slide off the shaft. There is absolutely no room down by the firewall, so getting any kind of leverage with one hand is nearly impossible.
One thing I've not seen in any reply so far...

I'm presuming, being a late US car, that you've got aircon. Have you unbolted the aircon pulley from the main crank pulley?
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  #9  
Old 19-04-08
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That's the exact spot I gave up and decided to have a mechanic work on it. I got one of the 3 small bolts loosened and that took me at least an hour or more. At that point I realized I was defeated!
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Old 19-04-08
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The sensors will not...............

show up or measure faulty easily.
The sensor is a hall element device, triggers via magnetic influence. I've only seen hall elements go short or measure suspiciously via dc resistance on a voltmeter on a few occasions during the 20 years I been fixing electronic gear.
The theory I have been told, is the crank sensor fails due to contamination via oil and grit, and a bit of coolant from weeping hoses, water pump etc. slowly working into the sensor.The sensor becomes heat sensititve, when it gets hot it fails,.....when mine became suspicious, a little wet road driving made the sensor unstable.

I put a used one in.........still going 3 years later.


HAVE THE OIL PUMP REMOVED, CLEAN EVERTHING UP. REPLACE THE 'O' RING AND PULLEY SEAL. MAKE SURE THE OIL SEAL IS FIRMLY IN THE PUMP HOUSING. GET THE WATER HOSES AND PUMP CHECKED AND CONFIRM THEIR INTEGRITY.

Otherwise you'll be doing all this again!


Sorry, to bang on about the seal....they can become loose, spin around with the crank pulley and wear the seal base in the pump body such that the seal will not sit tight. When I had to change the crank pulley, the seal came out lodged on the pulley, the seal was tighter on the pulley than in the pump housing, ............which meant, NEW pump housing. $$ $$ $$
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Woah! Don't expect men to talk to your face if you patronise that establishment!
RodentMaster, post links responsibly!
Eat the Pudding!
------------
ODE to the N\A
"I have not TURBINE to compress my buttocks, O lord,
Pity will be thine when thoust can crap on with boost.
We of the 'N\A - N\A' knowst nil of the pulling glory,
Yea, to post, thy blight the day of those who pressurise their pipes,
Alas, suck be mine that my chariot breathes,
Strike me down for mine is an unworthy existance"

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