front crankshaft gear removal

[dragon]

hi evryone
i need some help please

my c8 2.2 hdi is all in bits, head gasket gone
head in mashine shop now
got a small oil leek from front crank seal,so as i am waiting for head to come back, i will change front seal
now i have a problem taking gear of crank,
i can move woodruff key little bit,but no way of sliding gear of crank?
i gave it few hits with rubber mallet etc but not going or moving at all
screw driver from back of gear on both sides but no luck ,need to be care full as evrything round it is alloy

any ideas please
thank you

[myglaren]

Is there room for a three-legged puller in there? Most tool hire shops keep them.

[Gibbo2286]

You need to prise it off, carefully and it's damned tight on some cars, the Citroen workshop manual blithely just says 'remove the sprocket', no tools mentioned or specified,

[Gibbo2286]

Is there room for a three-legged puller in there? Most tool hire shops keep them.

Not really enough gap but I used a modified (ground thin) one.

[uncle buck]

Try squirting some release oil in where the woodruff key is and then try tapping the gear back towards the engine, if there is the tiniest amount of movement you can then carefully pry the gear forwards ...repeat until the gear starts to move further and further until it will come free.

However you get it off make sure to clean the inner face of the gear and the shaft and smear some grease on the surfaces so it will come off easy in future.

Good luck.

Cheers.

[dragon]

thanks for replays
its so tight fit
just been out and sprayed lot of wd40 and diesel over it
the lip on back of gear is too tin to take force of pulley it will snap as its moving with screwdriver
i think i have bent it a bit too
will need to sleep over it as i am loosing my rag with it a bit now
the plate at the back of it is alloy so need to be carefull with puting force with screwdriver over it

just cant belive i took whole top end a part etc without single problem
and little gear is make life hard
at least had a good day today cleening top of pistons and took all gunk out of cam carrier/inlet manifold, what a mess of a job
will need to ask few more bits as i dident took notes of few thinks then forgot it
first termostat housing has bolts and 2 studs? i took them all out but forgot where do studs go?
can anyone please check on they 2.2 hdi where do studs go?
and 2nd
in pug/citro manual it states apply sealant to cam carrier as there is no gasket
in they photo its only on outside edges of cam carrier? what about inside ?there is air inlet going it to head in the middle of cam carrier and injector holes too?
do you seal there or do you hope bolt with make it oil/turbo air pressure tight?
if it dosent seal turbo pressure could end up going in to oil or oil going in to intake ?
thank you
but photo

[RichardW]

Stat housing fixings... assume this an early 136 BHP engine? As you look end of the head, there should be the water outlet with 2 threaded holes above and 3 below? Studs go in the top left and bottom right holes. You should find one of the bolts is longer (70mm vs 60mm) and this goes into the top right hole.

Dunno about the rest I'm afraid! But I'd be tempted to see if I could get some heat on the sprocket to try and release it, or alternatively clamp a jubilee round it to allow something for a puller to grip onto.

[Xantidote]

I take it there are no holes in the sprocket, which on close inspection are threaded, so that some sort of home-made puller could be attached, bearing on to the end of the crankshaft?

[dragon]

hi lads

got it off, went to mashine mart and got pulley set
needed grinding down to fit and heated up with oxy to get it moving
ones rust is broken it slid off


now i need a new gear as end lip is broken ,lip that stops timing belt going over on to engine,
luck me will ring pug and ask monday,cant see it being cheep, cant find any on net for 2.2 hdi for sale
thanks for all help

[RichardW]

Looks like part no 0513A9 - £32 inc VAT. Appears to be widely used across the DW HDi engine family (ie all the later 2.0 and 2.2 engines), including the later 16V versions, so you should be able to pick up a used one