Crank pulley removal 1.6tdci

[1157jonboy]

Hi, I need to replace the crankshaft pulley on my wife’s 2011 mondeo 1.6tdci as it’s vibrating and really noisy. Was just wondering if there’s any special tools needed or is it just a case of undo the centre bolt, pull off the pulley and replace it? Thanks in advance.

[nicam49]

Nooooo! Don't be hasty. If I'm not mistaken,, then this pulley's bolt is threadlocked, and risks being snapped if you just do that. I suggest you read this thread thoroughly before tackling the job. (spoiler alert:it DOES have a happy ending) 

https://talkford.com/community/topic/397879-urgent-help-needed-crank-pulley-bolt-snapped/page-1

[TomsFocus]

1.6 TDCi uses a stretch bolt.  No threadlock needed.  

[nicam49]

But is any threadlock involved on the original factory-fitted bolt... 🤔 Have you had a read of the linked thread? 

I've attached a screen shot of the Ford WSM 

[TomsFocus]

39 minutes ago, nicam49 said:

But is any threadlock involved on the original factory-fitted bolt... 🤔 Have you had a read of the linked thread? 

I've attached a screen shot of the Ford WSM 

Why would it be?  It's a stretch bolt, the tension stops it vibrating loose.  No need for threadlock but it does mean the bolt is only single use and needs replacing whenever it's removed.  New bolts are not to be threadlocked either, just torqued correctly, using the NM figure plus an angle figure.

That thread is about a completely different engine.

[nicam49]

Tom, I'm not about to throw caution to the wind here,  is it still a PSA engine? If it is, then why would it not have the same design foibles? Here's a pic of the bolt as fitted to that pulley in the thread... comes already with threadlock. 

OP, sounds like if I'm right or wrong, you'll need to buy a new bolt anyway. 

If it comes with threadlock, like the upper one in the pic, then I'd get the heat gun out, else you'll end up with the lower one in the pic

[TomsFocus]

The 2.2 is part of the DW engine group, much older design and pretty much full PSA.  The 1.6 TDCi (DV group) is a joint venture between PSA and FoMoCo and can't really be compared.

This is a 1.6 TDCi crank pulley bolt:

I used to work on the 2.0 DW engine in 306s, and yes, crank bolts in those could be a pain lol.  The ones on the 1.6 aren't even that tight tbh.  I tried to find a pic from when I made the DV6 cambelt guide but sadly just showed the pulley on and then off, without a pic of the bolt.

[nicam49]

Tom, thanks for clarifying that for me and OP👍

[TomsFocus]

No worries.  If I ever go on Mastermind, my chosen specialist subject will be DV6 engines from 2004 to 2015...

[nicam49]

Wouldn't miss that episode! 

[1157jonboy]

Thanks for all your replies, the bolt came out no problem, pulley changed and the new bolt installed without any loctite, I couldn’t find the exact torque setting so did it up tight! I did open the link to the broken bolt story but I did notice straight away that was a completely different engine. Anyway all done, no dramas and it wasn’t even the issue after all!! Turned out to be the air con unit being noisy so I bought a drive belt for the same engine without air con and hey presto the annoying rumble has gone 😃