Crank pulley slipping

[salamander]

Hi everybody,
I've found this forum very useful and I've attempted a few jobs so far but now I'm having a go at my first ever cam belt and water pump change on the 406.
I usually start a job full of confidence then it doesn't go as planned and this is no exception. Everything was going a little too well, even the crank shaft pulley removal right up to the point when I attempted to rotate the engine via the brake disk to the cam locking positions and found that the crank was turning but the sprocket mounted on it was not. Either the key has snapped or it was only ever held in place by the crank pulley up against it. I don't believe the crank rotated as I undid the bolt as I'd have seen the hub turn.
I've managed to turn the cams round to the locking position by rotating them and the crank small amounts separately and line up the keyways on crank shaft and sprocket but I can't lock the crank pulley as it is a single piece unit and has no locking hole in it so I've marked the belt and shaft positions. To top it all off in attempting to slacken the belt the adjuster fractured and now I can't take the tension off the belt so if I cut it off things will probably shift.
My current plan is to cut the belt, check positions against my markings, replace pump and idlers, remove the sprocket and fit a new key, transfer the markings to the new belt and fit it then turn the engine by hand many times to check for clearance.

But I'm sure there is probably a better way

[lozz]

Hi
firstly please can you add more detail to your post
what 406 is it? petrol, diesel. Hdi /xud

id never make up guide timing marks its not wise so put that tippex down they are easy to time up properly

[steve_earwig]

03 1.8s 16v estate

[salamander]

As he said, sorry I assumed it would be under my user name, I believe it to be a EW7J4L4

[markw]

If it's an HDi, their locking pin hole is not at the front (pulley end) it's at the back and it goes through a hole in the block to engage in another hole in the flywheel. The hole is on the bulkhead side of the block not the front, radiator side.

[lozz]

Sorry ididnt pick up no details in your post,
imust be getting old and blind.

[lozz]

unbolt starter motor,move to one side (out the way)
then you shouid see's timing hole

its just below starter motor /hard to see when its in place

link deleted

[jasper5]

This is a petrol engine guys!

I've not done the belt on the EW7 and unfortunately I lent my timing belt book to my mate.

Without looking in the book (can't seem to find it online) it's possible the pulley is similar to the Ford Focus 16 valve engine which has a pulley without a keyway.

Someone with a copy of Autodata should perhaps have a look until I can get my book back.

[lozz]

link deleted,

[jasper5]

http://www.jhmbuttco.com/downloads/vs4825ss.pdf

Lozz, what I was getting at is that the OP may have undone the big bolt when he didn't need to, according to what you you posted the crank pulley that carries the aux belt should only have had the 4 small bolts removed and not the big bolt, the main timing belt pulley may be like the Focus and not have a key.

[lozz]

Ah rite iget what you mean.

not sure how he wouid get round that.
ive got abook somewhere iwill see if ican find it.

is this the same lump as whats in 1.8 cistern Picasso's ??

[lozz]

just looked in book,

there is woodruff key on end of crankshaft.
and there is key way on end of crankshaft end plate. (pulley) The bit with the 4 holes in)
there is slot on there which locks off in hole in engine block around 11oclock (drill bit improvised tool.)

sorry no pics don't have access to a scanner,
this info from cistern Ew series book ipresume same lump

edit forgot to add * As for the cams. it suggests using alen keys to lock those off.
(so no special tools needed)

[salamander]

Ah thanks lozz that makes a lot more sense than Haynes did. I still don’t see why the crank sprocket is not turning with the shaft though as it does not lock in to the aux belt pulley which I have removed. I'll pick up a new key from the dealers tomorrow anyway before i take the belt off. if that set was £40 I’d buy one but at £140 I’m not quite so keen. If anyone has a link to the dimensions of the flywheel and proper cam locking pins, as opposed to my drill bits I could probably machine something up at work? Interestingly they don’t use an allan key to slacken the pulley which I tried and it fractured.
I have not bought a new aux belt pulley as the old one looks and sounds fine but is the general consensus to replace them at the same time? £90 from Peugeot.
Fortunately I have another car so I am not in a mad rush to get this one back on the road.

[lozz]

Have you taken the sprocket off?
imean the main one not the one with holes in ?

this book deffo shows a woodruff key on end of crankshaft so it shouidnt turn in theory if that's in place.
so im think'in your problem is just key related,
but imigh't be millions of miles out there,

[salamander]

photo 2.JPG

aux belt pulley