Peugeot 405 Manual

Crankshaft pulley - removal and refitting
XU petrol engine in-car repair procedures / Crankshaft pulley - removal and refitting


Removal
1 Remove the auxiliary drivebelt (Chapter 1).

16-valve models
2 Undo the four pulley retaining bolts and remove the pulley from the end of the crankshaft, noting which way around it is fitted. If the pulley locating roll pin is a loose fit, remove it and store it with the pulley for safe-keeping. If necessary, the pulley can be prevented from rotating as described in paragraph 3.

All other models
3 To prevent crankshaft turning whilst the pulley retaining bolt is being slackened, select 4th gear and have an assistant apply the brakes firmly. If the engine has been removed from the vehicle, lock the flywheel ring gear using the arrangement shown (see illustration). Do not attempt to lock the pulley by inserting a bolt/drill through the pulley timing hole.

5.3 Use a fabricated tool like this one to lock the
5.3 Use a fabricated tool like this one to lock the flywheel ring gear and prevent crankshaft rotation

4 Unscrew the retaining bolt and washer, then slide the pulley off the end of the crankshaft. If the pulley locating roll pin or Woodruff key (as applicable) is a loose fit, remove it and store it with the pulley for safekeeping.

Refitting
16-valve models
5 Ensure that the locating roll pin is in position in the crankshaft. Offer up the pulley, ensuring that it is the correct way round.

Locate the pulley on the roll pin, then refit the retaining bolts and tighten them to the specified torque. If necessary, prevent the pulley from rotating as described in paragraph 3.

6 Refit and tension the auxiliary drivebelt as described in Chapter 1.

All other models
7 Ensure that the Woodruff key is correctly located in its crankshaft groove, or that the roll pin is in position (as applicable). Refit the pulley to the end of the crankshaft, aligning its locating groove or hole with the Woodruff key or pin.

8 Thoroughly clean the threads of the pulley retaining bolt, then apply a coat of locking compound to the bolt threads.

9 Refit the crankshaft pulley retaining bolt and washer. Tighten the bolt to the specified torque, preventing the crankshaft from turning using the method employed on removal.

10 Refit and tension the auxiliary drivebelt as described in Chapter 1.


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