Table of contents: Removal 🠇 Installation 🠇
Removal
1. Remove the accessory drive belt as described in chapter 1B.
2. To prevent the crankshaft from turning when you loosen the pulley mounting bolt, select a high gear and have an assistant fully depress the brake pedal. Alternatively, the flywheel ring gear can be locked using a suitable tool made from angle steel (figure 5.2). Remove the cover from the base of the front section of the transmission housing and use the bolts to secure the tool to the flywheel housing flange so that it locks the flywheel ring gear. Do not attempt to lock the pulley by inserting a bolt/drill through the mounting hole. If a bolt/drill is inserted into the installation hole, temporarily remove it while loosening the pulley bolt, and then reinsert it after loosening the bolt.
Figure 5.2. Use a homemade tool similar to the one shown to lock the flywheel ring gear and prevent the crankshaft from turning
3. Unscrew the bolt and remove it together with the washer, then remove the pulley from the end of the crankshaft. If the dowel pin or woodruff key for the pulley (whichever is applicable) if the pulley is not secured, remove it and store it in a safe place along with the pulley. If the pulley is a tight fit, it can be removed from the crankshaft using an appropriate puller.
Installation
4. Install the woodruff key into the corresponding groove on the crankshaft or insert the cylindrical pin (whichever is applicable). Install the pulley onto the end of the crankshaft, aligning the locating groove or hole with the woodruff key or pin.
5. Thoroughly clean the pulley mounting bolt threads, then apply locking compound to the bolt threads. Peugeot/Citroen recommends using Loctite (can be purchased from a dealer). If it is not available, any good quality locking compound can be used.
6. Screw in the crankshaft pulley mounting bolt (don't forget to put a washer underneath). Tighten the bolt to the specified torque, then turn it the rest of the way to the specified angle while holding the crankshaft from turning, using the method used during removal.
7. Install and tension the accessory drive belt as described in chapter 1B.