Xantia 1.9 turbo d crank pully help

[WindyMiller]

Hello,

I purchased a Xantia estate 1.9 Turbo D 1997 model back in January.

I am new to PSA/XUD engines, this being the first one I have worked on.

I did a cambelt, water pump and injector pump service back in March and have done around 8/9k miles since. I was last to take off and put back on the Aux crank pulley and its bolt.

The car threw the Aux belt earlier in the week, I inspected the engine and found the lower pully to be rattling around. The crank pulley bolt was set into the washer as the Aux pully had been camming into the back of the washer and the washer and rear face of the bolt head had made a nice smooth dome shape with one an another, like a self-aligning washer set.

I was able to get to the bolt once I cut the washer off, the bolt was still tight but came off with the starter motor trick, on closer inspection the threads of the bolt have taken a bit of a hit but not stripped in their entirety. The rear of the Aux pulley had broken/fatigued/snapped off from the key way around a 1/3rd of the diameter creating a hammer and anvil set up, like an impact driver. This is what has been camming into the back of the washer/bolt.

I have sourced a new aux pulley, this came with a new bolt, this is a Febi part so quality should be good.
I need to source a new washer. Any ideas?
They key way on the crank has taken a bit of a hammering but I think serviceable, the key way on the timing pulley is a bit manky.
The woodruff key is not in a good shape and needs to be replaced.
About 1/3 of the key interfaces with the timing belt crank pulley and the other 2/3rds with the aux belt pulley.
If anyone has seen the woodruff key on this set up before, its a domed key thats been cut flat at each end, I want replace the key with a completely domed key, this extra material on the new fully domed key should pick up more of the timing pully (that 1/3rd ratio I mentioned above) – the point here is this extra depth of key on keyway interaction is in an undamaged section of the timing belt crank pulled key way – so it should be tight. I could replace the crank timing pulley but I am dont want to do the belt again as its an ass of a job even with the tools I made up for it.

Does anyone have a means of finding out the size of the key so I can make sure I get the right key to replace it? I have the old one and have taken some sizes off it but it would be good to cross reference it with a “good” key.

I can take photos of this all, I am new on the forum although I have been reading up on here for a while now.
I wish it wasnt so but this old Xantia has grown on me a fair bit.

Apricate any input.

Jonathan

[xantia_v6]

You may find this topic interesting: viewtopic.php?t=68354 it is about the 2.1 litre version of the engine, but describes an alternate key.

I think that several years ago Citrojim posted a topic about a problem similar to yours where the crankshaft keyway was mangled.

[WindyMiller]

viewtopic.php?p=138605&hilit=woodruff#p138605

The Woodruff keys don't transmit torque. They're purely for location so you can make up some new custom ones using a lump of steel and a file. A bit tedious but less so than swapping a crank! All power is trasmitted through friction between the crank pulley, timing sprocket and the crank shoulder register, hence why the crank bolt has to be tight. I'd replace the crank bolt too.

Seems that so long as the key way is linning things up correctly I should be ok?

[CitroJim]

viewtopic.php?p=138605&hilit=woodruff#p138605

The Woodruff keys don't transmit torque. They're purely for location so you can make up some new custom ones using a lump of steel and a file. A bit tedious but less so than swapping a crank! All power is trasmitted through friction between the crank pulley, timing sprocket and the crank shoulder register, hence why the crank bolt has to be tight. I'd replace the crank bolt too.

Seems that so long as the key way is linning things up correctly I should be ok?

Yes, absolutely!

[WindyMiller]

Cool, any ideas on that washer, is there a part number for it?

[citroenguy]

Cool, any ideas on that washer, is there a part number for it?

Washer has no 0516 A6, bolt 0516 60

[WindyMiller]

Thanks all, all bits on route, will update once I have it in hand.

[WindyMiller]

any ideas on the torque required on the crank bolt? Assume I use the hole for setting the timing on the fly wheel to lock he crank out to torque the bolt against?
Regards Jonathan

[moizeau]

Don't use the locking pin to tighten the bolt. It'll probably work but it it shears, g/box off. On the XUD I always used 5th gear, missus on the brake and 'kin tight. Not the PSA way but....PSA also say don't use impact guns, not known a mechanic with one that doesn't....at your own risk