Underdrive pulley interference

[truegearhead]

I tried to install an under drive pulley on my 97 2.5 and found that part of the casting was in the way. Looks like a protruding nipple near the pulley that the factory pulley fits over. Potentially housing a hall sensor to read the holes in the pulley. Can I just grind this down? It's hollow. Anyone run into this?

Edit. Here's what I'm dealing with

[jcslocum]

That will need to be ground down a bit. It's the TDC holder hole/boss. Grind as little as possible!!

[thstone]

Yes, common issue. Just grind it down the minimal amount so it clears the pulley.

This boss is used to hold the crank at TDC during engine work so you (or the next owner) might actually need it someday in the future.

I used a simple hand file and the aluminum is fairly soft so it didn't take too long (but the access can be a bit awkward).

[truegearhead]

Great, thanks guys. Shocked I didn't see it in the write ups.

[truegearhead]

Whew these underdrive pulleys really make a difference. What a nice little upgrade

[WorkInProgressK]

Looks like the crank seal needs replacement too.

[steved0x]

Originally Posted by truegearhead

Whew these underdrive pulleys really make a difference. What a nice little upgrade

It does! I like mine. Cutting down that boss was the worst part too