c5 hdi crank pulley - 110

[jgra1]

chaps..
my crank pulley finally gave up this morning.. it was a cheapy from ECP brought 10 months ago... easy I thought.. crawl to my workshop 5 miles away, take it off during lunch hour, and get a (better) replacement..

but... did all of that.. and it turns out the key has sheared, the pulley was spinning probably about 10 times slower than the engine..

I assumed one key went through cam and crank pulleys? PSA say there are two keys....
they want me to buy a pack of 10 of key 1, and 2 of key 2.. about £40 !
their pulley is £155 as expected, not going there

any help appreciated.. know I will have to get the cambelt off for starters..

the old boat engine did a key last week. Unbelievable.. never had one go before, now two in a week

John (trying to move house )

[Northern_Mike]

I welded a crank pulley up on a friend's Synergie when they were totally skint. About 9 years ago.. it still works.

I'm just a grumpy Northern git.

[RichardW]

Yes, service.citroen shows 2 keys - this is to be expected, as on engines past about 2001 they deleted the vernier cam pulley in favour of a floating crank pulley for the cam belt, so the inner key doesn't in fact drive the crank sprocket, it's just there as a back up if the bolt tension slacks off. So you should be OK with just replacing the outer crank pulley key(*) and making sure the crank bolt is tiiiiiiight! Think I would take the covers off and stick the timing pins in though, just in case....

* Trip to the scrappies....

[jgra1]

scrappies it is..hoping for a dry sat thanks Rich..

having had a quick look at lunch , I don't much like the look of the whole area.. I feel I should get cambelt sprok off tonight anyway..whatever is left of the outer key is all a bit mangled..

I am wondering if the crank pulley keyway failed in the first instance..

does the hdi have a flywheel locker, as per XUD? and is it a similar cam shaft and fuel pump locking setup?

[RichardW]

Flywheel locking is identical, cam pulley locked with an 8mm stud (but orientation is different to XUD), pump locking not required. Covers are a bit awkward as wrapped around the top engine mount / belt IIRC. Write up when I did my Xantia: http://www.frenchcarforum.co.uk/forum/v ... 11&t=33939" onclick="window.open(this.href);return false;

[jgra1]

perfect Rich, read through, will ignore coolant leaks..

[jgra1]

Well well.. can't post pics until tomorrow as not net here but .. The crank pulley woodruff slot slopes on the back edge ..took ages and even a grinder the get that key out..
So chaps.. car has been brilliant.only cost 600 and has been 2 years of pleasure and still hasn't needed recovering from anywhere .. what do I do.?

A crank change out of question I would think...

an engine change a pain really ..

welding a rubberised pulley on.... don't tjink it would work...

A used pulley .. A used key.. and what?

[myglaren]

Weld a solid pulley on John. Someone will confirm but IIRC a 306 one works.

[jgra1]

Thanjs steve

Not having a lot of luck re 306.. anyone know what model? Xud hdi etx

[addo]

Can't bodge up an oversized key or weld up the keyway a smidge?

[charentejohn]

It may affect the balance but would a large washer tagged onto the pulley work, just a couple of quick mig welds. Then bend over the edges of the washer to clamp the nut.
Same system as some locking washers.

Just a thought as it can be done off the car, not perfect solution but that and some loctite on the shaft may do it.
It would probably never come off again but would keep the car going a few more years ?

[jgra1]

thanks for all inputs chaps.
after an impromptu day off and a lot of sun :

got another pulley from a breaker, and the two keys.. (also grabbed two mafs, a new interior door handle (which I left there!) )
fitted cam sprocket to see how it was, and decided not to remove it again (tight fit) so couldn't then do much with key way.. decided not to weld the rubberised pulley on, but added some araldite to the remaining bit of outer keyway, and kinda bonded the pulley to the cam sprocket as well... marked a line across pulley, bolt etc.. did bolt as tight as I could..
fitted new cambelt.. tensioner a bit of a pain as Rich w said..

with the spare maf, and the pulley noise all gone, car sounds and runs better than ever..

the only problem... after a few miles I reckon I can hear the cambelt... maybe just a little to tight... I really don't want to take pulley off again.. but is it possible to detension the cambelt without the lower cover removed?

[addo]

Can you "window" it with a Dremel and cutoff wheel to access the tensioner, and then bond a piece of another cover over the hole?

[jgra1]

I reckon I can get to tensioner from after removing top covers addo.. wont be easy but...

Definitely can hear something after things have warmed up...

[citroenxm]

John,

TRY, if you lock the Crank at TDC with a BLOODY STRONG allen key, then put the pully on.. and tighten the bolt up THEN put some extensions between a breaker bar and socket, AND use a scaffold bar for extension, and tighten the bolt F KIN TIGHT!

Remember the C5 PAS pump does not pulse and cut on/out like the Xantia pumps as its only driving the PAS, and air con/altinator... The tight bolt should be surfice to drive the auxilleries.. once you sort the pully out.