[HALFWAY]

I have to replace the idler pulley assembly on a 98 grand prix 3.8 liter non turbo engine.

My question(s) are:

This assembly also has the heater hoses connected to it and the hoses connect to "inserts" that fit into the assembly. How are these "inserts" removed from the assembly, They look to be press fit and held in place by a tab that is screwed to the assembly, but I don't want to break them or the casting.

After removing the bolts to the assembly there are two places that the coolant enters the block. One at the bottom of the assembly that is cast with the unit and has a rubber O ring around it. I assume this will pull straight out or perpendicular to the assembly.

The second outlet to the block is a 90° plastic elbow, which again looks to be pressed into the assembly and the block.

So which order do I remove these items. Right now I have the coolant hoses disconnected from the inserts and all the bolts removed. Now I need to know, do I pull/pry the idler assembly before/after/during the process of trying to disconnect the plastic elbow, and how is the plastic elbow held into the block or assembly.

I have included a picture to try and describe the assembly and where these items connect.

[LPete]

The inserts pull out -- they're not really a press fit. If they're stuck, there's probably gunk around the o-ring or the o-ring is stuck to the housing. Same with the elbow -- nothing holds it in other than the geometry of the design.

I'd strongly suggest replacing the plastic parts while you have it apart. They'll probably break anyway when you take it apart.