Cologne Crankshaft pulley removal
Discussion
Hello folks,
Does anyone have any advice for removing the crankshaft pulley on the 2.9 Cologne? I need to replace the timing cover and although I've managed to get the front pulley off with a standard 3 leg puller from Halfords, removing the remainder of the pulley has been far less successful.
Admittedly I'm battling 20 odd years of corrosion but it doesn't help that the puller cannot 'grab' behind the pulley and so far I've only succeeded in snapping a piece off (see pic)
Anybody have any recommendations on how to remove or know of any tools up to the job?
Of course, my other question is where I can find a replacement pulley..... and if anyone knows where I can source a replacement timing cover I'd be grateful.
Thanks.
Does anyone have any advice for removing the crankshaft pulley on the 2.9 Cologne? I need to replace the timing cover and although I've managed to get the front pulley off with a standard 3 leg puller from Halfords, removing the remainder of the pulley has been far less successful.
Admittedly I'm battling 20 odd years of corrosion but it doesn't help that the puller cannot 'grab' behind the pulley and so far I've only succeeded in snapping a piece off (see pic)
Anybody have any recommendations on how to remove or know of any tools up to the job?
Of course, my other question is where I can find a replacement pulley..... and if anyone knows where I can source a replacement timing cover I'd be grateful.
Thanks.
looks like you need to find or make a puller that will pick up on those four bolt holes in the pulley?
What's wrong with your timing cover?
Unfortunately I don't think your problems are quite over once the pulley is off, the timing cover sort of locks into the sump. Timing cover goes on before sump and has to come off in reverse order. I think you will need to at least un-bolt the sump and drop it half an inch if possible (won't come right off with engine in car).
I know this because I tried taking the timing cover of a scrap engine to get the cam out to use for an exchange, as it was scrap (sorry, didn't know you'd need a timing cover two years later) I ended up breaking it to get it off with sump still on.
Technically the pulley/damper is balanced with the crank and flywheel, but "when needs must" hopefully replacing just this bit won't cause problems?
Parts supply is getting a bit patchy, maybe keep your eye on Ebay for a complete engine, I don't think they're fetching a lot yet, unlike the earlier Essex engines which are getting valuable.
Good luck
ETA photo of puller from Haynes Granada Manual
What's wrong with your timing cover?
Unfortunately I don't think your problems are quite over once the pulley is off, the timing cover sort of locks into the sump. Timing cover goes on before sump and has to come off in reverse order. I think you will need to at least un-bolt the sump and drop it half an inch if possible (won't come right off with engine in car).
I know this because I tried taking the timing cover of a scrap engine to get the cam out to use for an exchange, as it was scrap (sorry, didn't know you'd need a timing cover two years later) I ended up breaking it to get it off with sump still on.
Technically the pulley/damper is balanced with the crank and flywheel, but "when needs must" hopefully replacing just this bit won't cause problems?
Parts supply is getting a bit patchy, maybe keep your eye on Ebay for a complete engine, I don't think they're fetching a lot yet, unlike the earlier Essex engines which are getting valuable.
Good luck
ETA photo of puller from Haynes Granada Manual
Edited by phillpot on Saturday 4th February 09:41
Not wishing to add to your woes, but, I found that the timing cover,( which on mine the water outlet had cracked off) is obsolete. No longer available from Ford, still in their price catalogue at £76, but all the dealers my chap tried said no stock. So I bought a complete second hand engine from Norman, on here, and have scavenged the cover, and a few other bits from that. Obviously I cannot help with the cover but I may have the same pulley and any other bits needed if that helps.
I can load up photos, or if you are in the area pop in for a look.
I can load up photos, or if you are in the area pop in for a look.
phillpot said:
looks like you need to find or make a puller that will pick up on those four bolt holes in the pulley?
What's wrong with your timing cover?
Unfortunately I don't think your problems are quite over once the pulley is off, the timing cover sort of locks into the sump. Timing cover goes on before sump and has to come off in reverse order. I think you will need to at least un-bolt the sump and drop it half an inch if possible (won't come right off with engine in car).
I know this because I tried taking the timing cover of a scrap engine to get the cam out to use for an exchange, as it was scrap (sorry, didn't know you'd need a timing cover two years later) I ended up breaking it to get it off with sump still on.
Technically the pulley/damper is balanced with the crank and flywheel, but "when needs must" hopefully replacing just this bit won't cause problems?
Parts supply is getting a bit patchy, maybe keep your eye on Ebay for a complete engine, I don't think they're fetching a lot yet, unlike the earlier Essex engines which are getting valuable.
Good luck
ETA photo of puller from Haynes Granada Manual (which also concurs that sump has to come off)
[
Thanks very much for this info - I saw something similar in Halfords so will nip up there later to see if it will do the trick...And yes, I did make the disappointing discovery of 2 (maybe 3?) sump bolts through the timing cover so am prepared for this woe....well as prepared as I can be What's wrong with your timing cover?
Unfortunately I don't think your problems are quite over once the pulley is off, the timing cover sort of locks into the sump. Timing cover goes on before sump and has to come off in reverse order. I think you will need to at least un-bolt the sump and drop it half an inch if possible (won't come right off with engine in car).
I know this because I tried taking the timing cover of a scrap engine to get the cam out to use for an exchange, as it was scrap (sorry, didn't know you'd need a timing cover two years later) I ended up breaking it to get it off with sump still on.
Technically the pulley/damper is balanced with the crank and flywheel, but "when needs must" hopefully replacing just this bit won't cause problems?
Parts supply is getting a bit patchy, maybe keep your eye on Ebay for a complete engine, I don't think they're fetching a lot yet, unlike the earlier Essex engines which are getting valuable.
Good luck
ETA photo of puller from Haynes Granada Manual (which also concurs that sump has to come off)
[
Edited by phillpot on Sunday 10th February 23:03
The reason for needing the new cover is upon return from its service I noticed some water leaking from a hose and in tightening up the jubilee clip managed to sheer off the (considerably corroded) outlet from the cover....you can imagine my joy at releasing it was one solid cast item!
When removing a further hose yesterday the other connection gave way too so it was obviously past its best....
To add to my bad luck one sold on e-bay for £50 at the scond time of asking just 2wks ago...brand new too. So guess I'll just need to keep my eyes open for one...
S2Mike said:
Not wishing to add to your woes, but, I found that the timing cover,( which on mine the water outlet had cracked off) is obsolete. No longer available from Ford, still in their price catalogue at £76, but all the dealers my chap tried said no stock. So I bought a complete second hand engine from Norman, on here, and have scavenged the cover, and a few other bits from that. Obviously I cannot help with the cover but I may have the same pulley and any other bits needed if that helps.
I can load up photos, or if you are in the area pop in for a look.
Thanks for this - looks like I had the same problem. Will have to keep an eye out for a cover but if you still have the pulley I'd be interested as this might be harder to track down.I can load up photos, or if you are in the area pop in for a look.
Also, I managed to shear the head off one of the water pump bolts so don't suppose you have one of these lying about?
I'm going to attempt to get the pulley off tonight so will hopefully be able to get some better pics and see if this matches the one you have...
Cheers
n1ck73 said:
S2Mike said:
Not wishing to add to your woes, but, I found that the timing cover,( which on mine the water outlet had cracked off) is obsolete. No longer available from Ford, still in their price catalogue at £76, but all the dealers my chap tried said no stock. So I bought a complete second hand engine from Norman, on here, and have scavenged the cover, and a few other bits from that. Obviously I cannot help with the cover but I may have the same pulley and any other bits needed if that helps.
I can load up photos, or if you are in the area pop in for a look.
Thanks for this - looks like I had the same problem. Will have to keep an eye out for a cover but if you still have the pulley I'd be interested as this might be harder to track down.I can load up photos, or if you are in the area pop in for a look.
Also, I managed to shear the head off one of the water pump bolts so don't suppose you have one of these lying about?
I'm going to attempt to get the pulley off tonight so will hopefully be able to get some better pics and see if this matches the one you have...
Cheers
No probs, I actually got the job done for me, it was in having the manifold welded when the timing cover problem "showed up" I think they may have nudged it while struggling with the manifolds, which they had to get the heads off to do, which then involved the sump as detailed by Phillpot.
Well, progress has been a little slow....the alternative puller I found in Halfords was far too big so had to wait for one I ordered from e-bay to show up.
However, had a go yesterday and it worked a treat - if only I'd used this tool in the first place I wouldn't need to source a replacement damper....still, applying that type of hindsight logic I wouldn't have tried to tighten the jubilee clip that led to this disaster!
The next problem is that my sump sits right on top of a chassis cross member so can't be lowered at all to allow the timing cover to come off.
Therefore, I'm going to have to get hold of a hoist to lift the engine....
Trying to source parts on the bay and elsewhere - Thanks for the pointers chaps - Not found the Bolton guy yet but will try the guy breaking the engine on here.....
However, had a go yesterday and it worked a treat - if only I'd used this tool in the first place I wouldn't need to source a replacement damper....still, applying that type of hindsight logic I wouldn't have tried to tighten the jubilee clip that led to this disaster!
The next problem is that my sump sits right on top of a chassis cross member so can't be lowered at all to allow the timing cover to come off.
Therefore, I'm going to have to get hold of a hoist to lift the engine....
Trying to source parts on the bay and elsewhere - Thanks for the pointers chaps - Not found the Bolton guy yet but will try the guy breaking the engine on here.....
Phillpot,
You cunning mine of mind information.
Have you fitted some captive nuts ( Rivnuts? ) in the main chassis rails, or welded & threaded plates?
Either way, an elegant solution as usual. Does it allow the sump to be completely removed?
Have you ever seriously considered taking up engineering for a living?
You seem to have a natural gift for it.
Like me & bog snorkelling
You cunning mine of mind information.
Have you fitted some captive nuts ( Rivnuts? ) in the main chassis rails, or welded & threaded plates?
Either way, an elegant solution as usual. Does it allow the sump to be completely removed?
Have you ever seriously considered taking up engineering for a living?
You seem to have a natural gift for it.
Like me & bog snorkelling
Edited by glenrobbo on Wednesday 20th February 20:22
glenrobbo said:
Hi Nick,
If you have no luck with Kevin, the guy in Bolton is Dale,
email: dalesfords@btinternet.com.
Search eBay for sierra diff mount, and also check seller's other items.
He's got a lot of stuff.
HTH
Glen
. If you have no luck with Kevin, the guy in Bolton is Dale,
email: dalesfords@btinternet.com.
Search eBay for sierra diff mount, and also check seller's other items.
He's got a lot of stuff.
HTH
Glen
I have just ordered some brake calipers from dale and his buddy stephan
They have been really helpfull
glenrobbo said:
Hi Nick,
If you have no luck with Kevin, the guy in Bolton is Dale,
email: dalesfords@btinternet.com.
Search eBay for sierra diff mount, and also check seller's other items.
He's got a lot of stuff.
HTH
Glen
. If you have no luck with Kevin, the guy in Bolton is Dale,
email: dalesfords@btinternet.com.
Search eBay for sierra diff mount, and also check seller's other items.
He's got a lot of stuff.
HTH
Glen
I have just ordered some brake calipers from dale and his buddy stephan
They have been really helpfull
mikel003003 said:
I have just ordered some brake calipers from dale and his buddy stephan
They have been really helpfull
Yes they are helpful, better at customer care than some places I can think of.
Is it these connections that are the problem?
.... 
These pictures are of a "spare engine" I sort of forgot I had, would rather keep it complete but if you are really stuck give me shout.
When you are sorted I wouldn't mind having a go at repairing your old one as a spare to keep handy should anyone else get in trouble.
.... These pictures are of a "spare engine" I sort of forgot I had, would rather keep it complete but if you are really stuck give me shout.
When you are sorted I wouldn't mind having a go at repairing your old one as a spare to keep handy should anyone else get in trouble.
It is possible to get the timing cover off without removal of the sump. The locating pins that the sump bolts too and are fitted into the timing cover (and at the other end too) are actually studs with a star (torx I think but am not sure) head and once the nut has been removed from the sump the stud can be withdrawn. This then allows the timing cover to be pulled off the sump gasket and forward over the crankshaft end.
The difficulty will be that you may struggle to reseal the sump gasket on re-assembly and then have to take the sump off anyway to replace the whole seal, but you pays your money and takes your choice - the correct way is definately sump off.
When I replaced my sump recently (with engine out) I didn't refit these studs and used stainless bolts throughout, makes locating the sump slightly more difficult but means the sump can be removed now even with the engine in and a fixed cross member.
HTH
Mark
The difficulty will be that you may struggle to reseal the sump gasket on re-assembly and then have to take the sump off anyway to replace the whole seal, but you pays your money and takes your choice - the correct way is definately sump off.
When I replaced my sump recently (with engine out) I didn't refit these studs and used stainless bolts throughout, makes locating the sump slightly more difficult but means the sump can be removed now even with the engine in and a fixed cross member.
HTH
Mark
glenrobbo said:
mikel003003 said:
I have just ordered some brake calipers from dale and his buddy stephan
They have been really helpfull
Yes they are helpful, better at customer care than some places I can think of.
glenrobbo said:
Hi Nick,
If you have no luck with Kevin, the guy in Bolton is Dale,
email: dalesfords@btinternet.com.
Search eBay for sierra diff mount, and also check seller's other items.
He's got a lot of stuff.
HTH
Glen
Any luck yet Nick?If you have no luck with Kevin, the guy in Bolton is Dale,
email: dalesfords@btinternet.com.
Search eBay for sierra diff mount, and also check seller's other items.
He's got a lot of stuff.
HTH
Glen
I went to those guys yesterday and they were most helpful.
They have many Sierras in, and are currently stripping a couple of 2.9's, so give them a call, I'm sure they can supply the bits you need.
The yard is actually in Chorley.
For anyone on here interested, they have some limited slip diffs, open diffs, and a nice race-prepared 2wd Cossie engine, 2.8 & 2.9 full engines, brake parts and many other bits.
No connection with them, just a happy customer.
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