DIY Warning - Removing the Crank Pulley
 

This warning has to do with installer error and has no bearing on the quality of any pulleys.

The above quote is from the Perrin blog. The part shown in the picture may come out slightly when you remove your crank pulley. If it does, it can be quite challenging to put back. It took me a little over a hour just to get it seated right. There is a keyway on the back side of it that links to a key on the oil pump. There is very little play in this connection. They must line up perfectly, or the part will not seat correctly. Pay close attention to this piece; it should be flush with the crank case. If it does not seat correctly, there will be a wobble in your crank pulley, and you may get oil leaking out. Look at it while it's idling. Is it wobbling? Cut the engine off and fix it. Don't end up a horror story.

ALWAYS CHECK YOUR WORK BEFORE TEST DRIVING.

Here, @Gopherboy6956 explains the process and the problems, in detail. I'd like to give a huge shoutout to him for great pictures, and even a video!

This should be stickied with all the recent threads that are having issues

This should get a bump and stickied

& it is sticky now

I ran into this issue when installing mine this weekend. The Oring came off with the old pulley. I tried to place it back in, but it was ever so slightly bigger than the area for it. So, i ordered a new one for about $2.

Found here:
http://wardmuscatellsubaruparts.com/...iagram=7610205

So I put my pulley on yesterday on my replacement frs so this is my second install. When taking the bolt out I actually got some oil that came out that I don't remember having the first time around. This sleeve stayed in as far as I can tell. Now you got me worried. I need to double check. Anyone have a pic of how fush the stock one sits in the block? Is it just pressed in?

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A picture of the backside of that little nugget might be helpful......so people know what the key-way mate up would be.

From what I remember, when seated correctly, it is almost exactly flush. The pulley will most likely wobble if it is seated incorrectly.

Yep, exactly.

When first took off the stock pulley, the end of the crank stayed in, but then when I took it apart a second time (because i forgot the oring, that end piece came out. Pretty easy to slide it back in, and yes, there will be a little oil, that's normal. It won't gush out or anything.

So - check this - I just took off my pulley today, armed with my new O-Ring. Of course, the crankshaft pulley spacer (as it's actually called) came out. I sat there for what felt like forever trying to get it back in. I eventually gave up when the cold got me (~15f).

Now, what I think may be complicating this is there is really TWO parts of this that come into play here... One is that stupid key, and the second is a moveable ring on the inside of the crank tunnel.

See photos -

In this image, you can clearly see the key on the end of the crankshaft. (red arrow)
The Yellow call-outs and arrows point to the two side keys, WHICH are on a ring that rotates freely. So, you need to have both those items lined up to get it back in.

http://i4.photobucket.com/albums/y14...ps9de4546e.png

This is the backside of the crankshaft pulley spacer

http://i4.photobucket.com/albums/y14...ps374b361f.jpg


So, If you only get it seated with the outside ring, it won't slide in flush as seen in this DIY:
http://www.lastonehere.com/misc2012/...perrin-12s.jpg

Also - take note, as Perrin says if you don't get it flush in there, the pulley will wobble. When i put it back in this time after changing the o-ring, I did not have it flush and it did wobble for a few seconds.

Now, I'm not sure if this is going to be an issue for me yet, but it seems it could be easy to damage the spacer and/or crankshaft key.

This is what my spacer currently looks like which has me a bit concerned:

It looks like a bit was sheared off when the engine started and the pulley was wobbling.

http://i4.photobucket.com/albums/y14...ps829c8dd0.jpg

And a closer look at my crankshaft might show a little damage too

http://i4.photobucket.com/albums/y14...ps5245723e.png

This makes me a bit nervous - but I'm going to order a new spacer and maybe play with it some more before I do anything drastic.

So - Let this be a strong warning to all - MAKE SURE YOU GET THE SPACER FLUSH before you start the engine.

I'd like to do a quick callout to @thejevans and @PERRIN and see what they think, and specifically to thejevans - how did you get it realigned?

OK!

6 hours, a sore back, lots of curse words, loss of hope, and a 15F degree garage, I got it!

I was so frustrated, and actually just gave up. I was going to get the BRZ towed to the dealership tomorrow and bite the bullet. I figured they may take pity on me, so I went about putting both the intake and pulley back to stock.

I took the stock pulley, put the new o-ring in place, attached it to the Crankshaft pulley spacer, lined it up as close as I possibly could to where I knew the key was (I used a mirror and light to better see inside) and gave her hell.

Just as with the Perrin Pulley, it went in, but not all the way. So, i decided i'd bolt it down anyways, got it to 94ft/lbs, and started to put the stock intake back on.

After that, i gave it one more cautious start, and to my *fucking* surprise, it ran WITH NO WOBBLE, absolutely perfect.

So, I cursed with joy and sorrow for time spent, and decided to take one more shot at the Perrin pulley, now that I knew the spacer was seated correctly.

Here is the part, that should be included in the DIY to keep that spacer seated:

When removing the stock pulley, wedge a socket extension (or two) into the bolt hole to keep pressure on the spacer in place. It would be much easier with a friend, but it's possible to keep pressure on the socket extension and pull off the stock pulley at the same time. I can take a shot of this just to make it easy to see tomorrow.

Here are two photos of how I used the socket to keep the spacer in - The bolt is obviously in place, I just wanted to show how I used the socket extension.
http://i4.photobucket.com/albums/y14...psb385313e.jpg
http://i4.photobucket.com/albums/y14...ps64fe8548.jpg

Here is my spacer completely in place.

http://i4.photobucket.com/albums/y14...psb31012f8.png

http://i4.photobucket.com/albums/y14...ps4e2e8db5.png

And a reminder of when it is NOT in place:

http://i4.photobucket.com/albums/y14...ps913be009.png


Also, here is a quick clip of my Perrin Pulley after this project:

http://www.youtube.com/watch?v=AJD-u...ature=youtu.be

Hope this info helps someone.

Fantastic. Thank you

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I got it back with lots of luck, and patience. The tolerance for that keyway is so low, that it's almost maddening. I actually filed down the outside corners of the keyway, slightly, to give the key room to slide in.

Thank you so much for your pictures and information. I'm glad you got it back in. I'm going to update the first post with quotes from yours.

That is funny... I actually filed down my edges as well!