200TDi crankshaft pulley removal

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Astermagik

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Hi,
I'm in the process of replacing the cambelt on my 110, 200TDi. All the manuals have convinced me that it's a relatively easy process, but I'm stuck and I've hardly started!
I've got as far as stripping out the fan / cowl / water pump and relevant pipes. Now I've got to the dreadded crankshaft pulley. According to everything I've read, the 200TDi has effectively 2 parts to it: first there are 4 bolts which you need to remove and the front part (or the pulley as they refer to it) should come off. Then after that comes the hard part of loosening the 30mm bolt to get the 'damper' off. I'm only as far as loosening the 4 bolts...but nothing is coming off. No-one is more specific than that, but to me it sounds like it should come off in my hand. No? I've tried everything short of putting a puller on it (plastic hammer, screwdriver etc) which I am loathe to do, since I reckon it may break the vees.
Can someone enlighten me? Has the last guy put this back together incorrectly? Should this come off easily?
Cheers, Nick
 
Just undo the 30mm bolt and remove the whole pully at once it is easer.

But even with the 30mm bolt removed sometimes the pully is still a bit stiff to take off the crank ,just take your time and dont damage the V's with the hammer :)
 
Hi,

Thanks for that...but I bought a tool to hold the crank to get the 30mm bolt out and that only fits with the outer pulley off. How else do you stop the shaft moving when loosening it? Doing the 'put-it-in-gear' trick? I had a feeble attempt at that, but it didn't seem kosher so I stopped!
 
put it in gear and get someone to hold there foot on the brake as well that helps the car from roling.
 
Just thought I'd update anyone who is following this.
In the end, I couldn't get the nut loose against the brakes / gearbox - there is too much 'spring' in the drive train. I had to find a way to get the front pulley off - and that was heat! A good going over with a small blow torch got it off - although you've got to be careful you don't damage the damper, since it's part rubber.
Once that came off, I used a locking tool (from Difflock - but you could lash something up) and then a nice big power bar with a pipe and it came off.
 
Hi
Just found this post on google, know its a bit old but will comment anyway.
I was stuck in exacually the same way with the crankshaft pully but i found a really easy way too get the nut off. just get a impact socket that fits and put an air wrench on it. you dont need too hold it or put it in gear or anything. i was pratting around with bars and trying too stop it spining but got it off in seconds with the gun.
Hope this helps anyone else who gets stuck.
 
Very much later than the last comment......... I have found that a 3/4 drive 30mm socket and bar, with the bar resting on top of the nearside chassis and a quick click of the starter works just fine without all the aggro of a breaker bar and scaffold bar
 
Since the 200tdi has so much radiator to crank clearance, I would drop by a shop equipped with an pneumatic impact gun, ask them to back it off, re-tighten with anti seize compound so it can be undone when you get home.

I have a Snap On 900 lbs reverse torque and it backed out my crank bolts on both my 200 and 300tdi engines and the used engines I bought too..easily.
 
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