This is in regard to a 2002 Daewoo Lanos, but the principle should be the same on any car.
So I am close to putting the car completely back together after taking apart the engine to replace the head gasket. Of course, I had the head reconditioned, and replaced a ton of other parts as well, to ensure that the car will be reliable for a long time.
The problem I am having is that I cannot get the power steering pulley to clear the frame rail, no matter how much I raise or lower the engine. I have no idea how I got this pulley off in the first place, but it needs to be feasible with a reasonable effort, since this has to come off every 6 years to do the timing belt. (On this car, the power steering pump bolts to the passenger side of the engine block, and protrudes through a round hole in the timing belt cover.)
The pulley would, of course, clear if I traced out the tip of my thumb and took an angle grinder and ground off that much from the inner edge of the pulley. Presumably I’d have to make a second notch as close in size as possible, and as close to 180° from the first notch to prevent excessive noise/vibration.
This is a ribbed pulley, and the accessory belt is ribbed as well. The accessory drive system consists only of the alternator and power steering pump, as the water pump is driven by the timing belt, and the A/C/ compressor is driven by a separate V-belt. So if, for some reason, making this notch causes the belt to fail prematurely, it shouldn’t damage the engine, and the belt itself is not expensive.
Has anyone ever done this sort of thing on any vehicle, and did you get away with it, i.e. had a favorable result?