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[tommycon]

hiya.
 manage to get my new crank pulley and new bolt, tried to undo the one on my 2.2dti and BY ECK its a stubborn sod, had my son press the brake while car in 5th and i cant seem to get enough leverage.
cheers

[JasonH]

I know it's incredibly tight on the V6's. Last one I saw someone undo was done with a 3ft long 1/2" drive breaker bar - but there was a locking tool involved...

[william01]

tis an awkward bugger, had to take mine off the 2.5v6, engine was out,  ended up jumping on the breaker bar with crank pulley locked off with an adapted spanner i had drilled to fit on the pulley. good luck.

[mantagte]

check which way your engine turns over
remove engine cover underneath car if fitted
get 2-3 foot long scaffolding pipe
put socket on crankshaft nut use a t bar or long handled bar slide scaffolding pole onto that so scaffolding pole is either on the ground or against the chassis rail
flick engine over on the key
DO NOT HOLD THE KEY OVER FOR MORE THAN HALF A SECOND
this is how i removed father in laws
hth

[Matchless]

If you use the above technique on a V6 you will be buying a new sprocket and worrying about where the sheared-off keyway went to inside your engine.
Most cambelt sprockets are made by pressing steel and ceramic powders into a mould at high temperature and pressure, they dont like sudden shocks, especially air hammers as favoured by many 'professionals'. You must bolt a restraining tool to the sprocket and counterhold that whilst turning the bolt.
The above relates to the V6 and 2.0/2.2 petrol, I dont know about the 2.2D so can only advise caution.

[tommycon]

i`ll put it on ramps to try and some more leverage
any thoughts on warming the engine up before atempting it? got to be careful tho because the water pump wnt be turning

[tommycon]

well tried again today and snaped 2 wrenches, one was a torque wrench that i`ve had for years and as never let me down and the other was a T-bar, used a length of scafolding tube on them.
anymore sugestions anyone please?

[Kevin Wood]

The key is to solidly lock the crank pulley rather than try to turn it against the slack in the transmission, as the "give" in the drivetrain means you can only apply a fraction of the torque that you could to a rigidly locked bolt.

Even if you have to make up a tool to do so (strap from crank pulley to another bolt on the engine somewhere, for example) it will be worthwhile.

Kevin

[Kevin Wood]

Oh, and liberally apply plus gas a couple of times a day. Victory came on Day 3 when I had to remove the pulley from Mrs. KW's MX 5.

Kevin

[tommycon]

taking up the slack is a big problem with this, i can a quarter turn just doing that, because the pulley as broke in 2 its very difficult to fabricate something,, i`ve bought myself a bit breaker bar and will try tomorrow.
 cheers

[tommycon]

well its off!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
took me ages and every tool and idea i had but in the end it was thanks to mantagtes advice
i put a 3/4" 24mm socket on the bolt with a very strong T bar and turned the key a couple of times and wollop!!!!!
thanks everyone for the help
paul

[mantagte]

glad to hear its off at last

[Andy B]

glad to hear its off at last

Your method has never failed me, but a big lump hammer has usually done the job too. A windy gun made short work of SWMBO's Astra G's crank pulley bolt too.