Crank pulley bolt problem

Discuss, ask, or get help with engine and mechanical queries in here.

Moderator: Moderators

Post Reply
User avatar
Doggy
Mod with a 2.2 HDi, De-Fapped!
Posts: 10010
Joined: Mon Oct 13, 2008 11:49 pm
Location: Northants

Crank pulley bolt problem

Post by Doggy » Sun Oct 07, 2018 11:26 am

Attempting a cambelt change, I've undone the crank pulley bolt, turned it 3 or 4 revolutions but it feels like the thread's picked up. It won't re-tighten without excessive force either. Letting some WD40 soak in while I ponder.
Feels like it will snap before it comes out, so now I have a dilema - I could:

1. Carry on regardless, but if it snaps or strips the thread so it won't go back in that's probably game over for a car I rather like.

2. Attempt to re-tighten it, outcome probably as above.

3. Try to slot some washers to fill the gap twixt bolt head and the pulley so it only needs say one turn to lock the pulley in place. Might work as a short term fix, but what then?

Guess I don't absolutely need to do the timing belt this minute, but it's 94k / 3 years since I did it last and I'm hoping to prove/eliminate the water pump as the cause of my minor fluid loss.

Any suggestions?
2003 HDi 2.2 6-speed Exec Estate

User avatar
steve_earwig
Moderator
Posts: 18922
Joined: Thu Oct 04, 2007 6:09 pm
Location: Jastrebarsko, Croatia http://www.jastrebarsko.hr/lokacija/

Re: Crank pulley bolt problem

Post by steve_earwig » Sun Oct 07, 2018 12:43 pm

Lord knows! :shock: I reckon jasper's your best bet. It's another one of them "whatever I do will be wrong" situations but, without resolving it one way or t'other, you'll be driving a car that could go pop! at any moment. I reckon I'd try rocking the bolt back and forth, try and work it out bit by bit and hope it's not damaged the crank too much.
Unskilled meddling sin©e 2007

2004 D9 2.0 HDi 110 Estate lhd VF38ERHZF81657352 - sold but being very well looked after.
1991 Yamaha TDM850 - fuel leaks galore!
2008 Toyota Recall4 2.0 VVTI ATM LHD JTMBH31V90D007261 - flimsy piece of crap.
1953 Matchless G3LS - It's alive!!

User avatar
Doggy
Mod with a 2.2 HDi, De-Fapped!
Posts: 10010
Joined: Mon Oct 13, 2008 11:49 pm
Location: Northants

Re: Crank pulley bolt problem

Post by Doggy » Sun Oct 07, 2018 1:07 pm

steve_earwig wrote:
Sun Oct 07, 2018 12:43 pm
without resolving it one way or t'other, you'll be driving a car that could go pop! at any moment
Worse than that, the crank pulley's loose so it ain't a goin nowhere.

---or wasn't. I took the semi cowardly way out and tightened it back up v e r y c a r e f u l l y.
The last turn or so was almost free, so I naturally tried undoing it again and again and then resisted adding to 40-odd years of not quite learning when to give up. So it's done up for now and therefore derivable, while I work on Plan B.
2003 HDi 2.2 6-speed Exec Estate

caprixpack
2.0 16v
Posts: 135
Joined: Sun Mar 11, 2018 5:00 pm
Location: Cumbria

Re: Crank pulley bolt problem

Post by caprixpack » Sun Oct 07, 2018 7:16 pm

Balls to the wall, get a windy gun on it :twisted:
1984 924 2.0 n/a crystal Green - The daily
2005 VW Passat tdi 130 Highline, now 170bhp & 290ft/lb
2000 Peugeot 406 2.0 hdi - stood for 4 years, fresh mot and mostly working.

grasmere59
3.0 24v
Posts: 1397
Joined: Wed Jul 28, 2010 10:23 pm

Re: Crank pulley bolt problem

Post by grasmere59 » Sun Oct 07, 2018 9:37 pm

In my experience once a thread has picked up it's game over,it's a weird phenomena no amount of force will undo it but it will do up again,not really a feesable option but the only way i can see to save the threads in the crank is to drill the bolt out.
2003 "53" 110 hdi Executive Estate in Diablo Red,chesnut leather
2001 "51" BMW 530i sport auto in Black,sandstone leather
2012 "62" Yamaha XT1200 Super Tenere
1974 "M" Honda CB500/4
1994 "M" Kawasaki Zephyr 1100
2002 "02"Triumph Tiger 955i
1998 "S" Honda XRV 750 Africa Twin

PeterN
3.0 24v
Posts: 1406
Joined: Sun Mar 04, 2012 7:04 pm
Location: Charmouth, Dorset

Re: Crank pulley bolt problem

Post by PeterN » Sun Oct 07, 2018 10:15 pm

Put a socket on it with a long bar that will reach the ground at the front of the engine and just 'blip' the starter, that usually gets them off.

Peter

User avatar
Doggy
Mod with a 2.2 HDi, De-Fapped!
Posts: 10010
Joined: Mon Oct 13, 2008 11:49 pm
Location: Northants

Re: Crank pulley bolt problem

Post by Doggy » Sun Oct 07, 2018 11:14 pm

Don't fancy my chances of drilling the bolt accurately enough to save the thread in the crank - not the easiest place to ensure you get it dead centre and the drill constantly on the right axis, but may have to try it if all else fails.

Impact wrench may be an option, half the problem is the inability to prevent the engine turning with a wheel off. I shall think about an effective way of locking it.

Least it's up and running again while I ponder my next move.
2003 HDi 2.2 6-speed Exec Estate

dirtydirtydiesel
3.0 24v
Posts: 1267
Joined: Sun Apr 28, 2013 11:02 pm
Location: Coalville, Leics.

Re: Crank pulley bolt problem

Post by dirtydirtydiesel » Mon Oct 08, 2018 10:09 pm

Eric,
When it was last done, did it have a new bolt installed ?
The reason I ask is I've done mine twice now each time with a new bolt from the main steelers.
These bolts come with locking paste already on them, this can make them feel as though there picking up
as you wind them out.
I have always done it John's way with the breaker bar on the floor & wind it out on the starter,
The last time I had already disconnected the ecu, so just kept it on the starter until if fell out :supafrisk:

As long as you don't, didn't re-use the old pulley bolt you should be golden 8)
2002 110 HDi estate, Rapier in monaco blue! ( found quite a bit more power :cheesy: )
1999 3.0 V6 SE coupe in Diablo Red ( my baby )
2006 206 1.4 16v sport in Aegean blue ( wife's shopping trolley :roll: )

pp2000 owner / user, can offer Diagnostic's / fault code, reading / clearing for beer tokens in Leicestershire.

User avatar
Doggy
Mod with a 2.2 HDi, De-Fapped!
Posts: 10010
Joined: Mon Oct 13, 2008 11:49 pm
Location: Northants

Re: Crank pulley bolt problem

Post by Doggy » Mon Oct 08, 2018 11:15 pm

New bolt fitted along with timing belt kit last time, 8)

..but then I changed the crank pulley last year and re-used the same one, since only normally get a new one with a belt kit. :oops:
came out easily last time, went back in easily and was torqued up correctly.

Didn't risk forcing it yesterday, I was having to use the breaker bar to turn it so the more it unscrewed the greater the sideways force/risk of snapping it. Going to have another go probably with a battery impact wrench so I can ease it back and forth without any load in the wrong axis.
Also plan to gather a set of cobalt drills, taps etc
ServiceBox describes the Crankshaft Pulley Screw as M14x150-70, which I suspect means a 70mm long M14x1.5 part-threaded screw, (M14 fine is 1.5mm pitch). A bit like this:
Image

If it does shear off, I'm hoping it might leave at least a little thread protruding from the crank. This would allow me to fit a s/s capped nut with a pre-drilled pilot hole spot-on centre, so even I can start drilling in the right place for once. We'll see.
2003 HDi 2.2 6-speed Exec Estate

PeterN
3.0 24v
Posts: 1406
Joined: Sun Mar 04, 2012 7:04 pm
Location: Charmouth, Dorset

Re: Crank pulley bolt problem

Post by PeterN » Tue Oct 09, 2018 10:15 am

If it should break off, even if its flush you could weld an nut onto the stub through the hole, not only will that give you something to grip but the heating will expand the hole more than the bolt which also helps.

Peter

jasper5
3.0 24v
Posts: 3654
Joined: Fri Nov 28, 2008 2:30 pm

Re: Crank pulley bolt problem

Post by jasper5 » Thu Oct 11, 2018 4:13 pm

I don't know if you have already sorted this problem, I've been away so didn't see the post.

My solution to this problem is this...
If you have got the bolt moving carry on with the WD40 into the threads and moving the bolt in and out gradually.
I usually use the starter motor trick but that might not be a good idea in the circumstances, but if you are brave enough....

If the bolt was similar to the one in the pic with thread lock on it's possible that it is jamming on the thread lock (99% of the time that is the case)...applying heat to the bolt would soften the thread lock then hitting the end of the bolt will free it up.
To lock the engine there are crank locking tools which slide into the teeth of the flywheel and then bolt into a bolt hole around the gearbox casing which is exposed where a tin plate might be....they aren't expensive...in fact the Peugeot locking kit has one of these in it.

If all else fails and the bolt breaks there is a foolproof method of drilling straight into the centre of the bolt...it requires a bit of engineering but it works....

Make up a round piece of metal that fits snugly into the bolt hole with a small diameter hole for a pilot then drill a pilot hole.
Gradually increase the hole with bigger drill bits until you get to the size of the bolt or intervene with an easy out somewhere in the process.
Hopefully you can get a tap in and clean up the thread.
If you can get hold of some left handed drill bits then the process could be easier if you think about it.

User avatar
Doggy
Mod with a 2.2 HDi, De-Fapped!
Posts: 10010
Joined: Mon Oct 13, 2008 11:49 pm
Location: Northants

Re: Crank pulley bolt problem

Post by Doggy » Thu Oct 11, 2018 10:04 pm

Not resolved as yet, waiting for a window when I can afford to have it off the road for a few days if necessary. There's no compelling rush to get it done, I'm hoping to confirm or eliminate the water pump as the cause of the minor coolant loss I've had on & off for a few months.

That's a good suggestion for getting the drill on centre, I may well try that. I'll look for a crank locking gubbins too.
Many thanks for your help, always appreciated.
2003 HDi 2.2 6-speed Exec Estate

Post Reply