Peugeot 205 tu1 engine timing belt

[Dolmenman]

Ok.. I've bought a 1992 205, with a petrol 1.1 tu1 engine to restore. The shell is in excellent condition but many bolts are rusted. It is supposed to have been in storage, but it looks like it's been stored on a beach.
I replaced brake hard lines and front calipers yesterday and had real difficulty sourcing rhd headlights (which had been stripped). I am going to tackle the timing belt next, but am really worried about the 3 bolts holding the auxillary pulley (alternator) which looks very rusted. Should I use heat, impact gun or just a normal socket. I'm afraid they will wring off, as did the 10mm bolts holding the inner wheel arch cover. I had to make little studs to hold the cover.
I would be grateful for any advice before tackling this..
I should add I've borrowed one of those induction bolt heaters.

[mickthemaverick]

I'd give the bolts an overnight soaking with penetrating oil and then use an impact gun. Just my opinion.

[Dolmenman]

Thanks mickthemaverick.. I've been soaking them for about a week in penetrating oil..might hit them with a punch first, then try the impact gun on lowest torque..I was going to replace rear brake shoes first but tbh I'm putting off facing this..or might heat the bolts, then let them cool (one at a time).. don't fancy drilling them out...

[penners11]

Try a mixture of Acetone and ATF for rust removal, be patient and keep spraying it over the bolts.
This may take a few differant attempts/methods starting with cleaning the area, gental heat, and then the Acetone mix

[Dolmenman]

Thanks penners11...to give you an idea what this is like, I decided to change the oil and filter today...broke a ratchet bar trying to get sump bung out, and had to heat it with the induction tool (a useful piece of kit)..
Then the filter...tried all manner of strap wrenched etc, but had to heat the base of it with the tool and use a 2 foot Stillson wrench to get it off...not looking forward to auxiliary pulley..

[penners11]

Ouch, I've had some tight ones in my time but never had to use Stiltons, crushed a few I admit. Good luck.
The problem is the aluminium reacts with steel bolts welding themselves to each other. I take it its a steel block, I hope for your sake.