2.0 HDI 90 Crank Pulley Replacement!

[thedadio]

Hi im desperate for help, i have a 306 with a hdi 90 lump. The crank pulley is on its way out and presently my car in half in my garage on stands with the plastic guards out. Can anyone tell me 1. How to remove tension on the aux belt, and 2. How the hell do i lock the engine to loosen the pulley bolt?

Thanks so much in advance, im stuck at my mums with no fags and a new £55 crank pulley crying to be fitted lol

thanks again

[mjb]

2. How the hell do i lock the engine to loosen the pulley bolt?

If it's only one bolt, try to get 3 tyres on the ground, jam the handbrake on, chock the wheels and put it in top gear

for extra grunt get someone in the car to push the brake. ONCE ONLY (while the servo's still got some oomph!)

others have suggested you can put a breaker bar on it and crank the starter with the injectors disabled to crack it, but that idea scares me

[jasper5]

Hi im desperate for help, i have a 306 with a hdi 90 lump. The crank pulley is on its way out and presently my car in half in my garage on stands with the plastic guards out. Can anyone tell me 1. How to remove tension on the aux belt, and 2. How the hell do i lock the engine to loosen the pulley bolt?

Thanks so much in advance, im stuck at my mums with no fags and a new £55 crank pulley crying to be fitted lol

thanks again

Does your belt have a plastic tensioner pulley with a 15mm bolt in the middle?

If yours is this type, get a small pin (I use a small allen key) or even a nail...turn the bolt anti-clockwise until the holes in the tensioner block line up with the holes in the tensioner, then slip your allen key/pin/nail through the holes to stop the tensioner slipping back...this removes the tension so you can remove the belt.

If yours is the old 306 type with a metal tensioner pulley, undo the 6mm allen bolts in the pulley and the slider, then screw the lower allen bolt in until the tension is removed and the belt can be removed.

As for undoing the pulley nut....get a T bar or breaker bar, fit the 22mm socket on fit it onto the pulley and turn the engine until the bar rests against the driveshaft or subframe, turn the ignition key and the starter will force the bar against the driveshaft and crack the bolt undone, if it's tight after it has cracked, keep turning the key on and off until the nut is loose enough to undo with a ratchet.There is no need to disable the injectors.

This is not a conventional method, so, do this at your own risk....I always use this method, it takes just a few seconds, but I have many years experience.

BTW, mjb, yours will be easy, you don't have to undo the middle bolt, your pulley has 4 small bolts which you undo.

[Panda]

Sealey make a flywheel locking tool for this engine - your local tool specialist should be able to get one for you. Costs about a tenner but well worth it from a safety perspective alone. Dead easy to remove the crankshaft pulley bolt once the flywheel is locked. Just don't forget to take the locking tool off when you've finished!

I'm not sure about the aux belt tensioner on the 90 but on the 110 HDi you can use a ring spanner on the bolt in the centre of the tensioner to release the tension and then slip a small (e.g. 3mm) allen key into a hole in the side of the tensioner assembly which locks it in the un-tensioned position.

[mjb]

BTW, mjb, yours will be easy, you don't have to undo the middle bolt, your pulley has 4 small bolts which you undo.

Oh, it was

One of the bolts needed a blow with a hammer on a 10mm spanner to crack, but the rest came out easy as pie with my diddy little 1/4" ratchet

The hardest part by far was removing the wheelarch liner then having to come to terms with the fact I've run out of replacement screws so my liner's currently held on (both halves) with 2 knackered screws and a couple of zip ties

Good job I've ordered more screws and I've got to take it off again this weekend