M8 bolts crankshaft pulley removal - 200tdi

AH-4x4 said:

Hi guys,

The engine is out of the defender the Irwin socket is just to wide to get it on the bolt.

To drill out the bolt heads any tricks of the trade out there? Any special drill bits to use? Not looking forward to it

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Get the smaller irwins first before drilling.
No art in the drilling, just needs to be dead central, normal drill bits, just dont run the drill flat out. you might find if you run a 4 or 5mm drill both the length of the bolt it might come undone.

lynall said:

Mine are snap on, which are just rebranded irwins (I of cousre did not know that at the time!) but they are 3/8 drive, great bits of kit, get me out of trouble all the time.
I always grease my damper, yet still it needs the puller, no effort needed just seems to have to come off dead square.

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So the 3/8 will fit those pulley bolts?
That's probably the best bet then, OP needs to get them as a next step.

Flossie said:

So the 3/8 will fit those pulley bolts?
That's probably the best bet then, OP needs to get them as a next step.

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Cant be 100 percent certain but Iirc the smaller irwins can also take a socket as well as the 3/8 drive, so assuming the od is no larger than the socket it will fit.
I wiil try and remember to check at work later.

Tbh I have always found the std M8 bolts with 10mm head to be real crap quality, 10mm always seems a sloppy fit, yet a 3/8 socket will not fit!

Bit like the def 200tdi pas belt 3/8 to thin, 1/2 to fat, and the real deal is 11.5mm, what tit thought of that idea?

lynall said:

Cant be 100 percent certain but Iirc the smaller irwins can also take a socket as well as the 3/8 drive, so assuming the od is no larger than the socket it will fit.
I wiil try and remember to check at work later.

Tbh I have always found the std M8 bolts with 10mm head to be real crap quality, 10mm always seems a sloppy fit, yet a 3/8 socket will not fit!

Bit like the def 200tdi pas belt 3/8 to thin, 1/2 to fat, and the real deal is 11.5mm, what tit thought of that idea?

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You mean the square drive for tensioning? Filed mine out

@AH-4x4, looking at the condition of your damper and pulley plan on replacing with new, so 1. squarely drill out bolts and do use green cutting paste to cool the drill bits [or rig up a water tube with garden to keep metals cool] - use good quality drill bits, not Screwfix/B&Q specials, tungsten tipped HSS black as a minimum and drill on slow speed. 2. tap out bolt threads, again use cutting paste. 3. fit crank locking tool to newly tapped out threads and undo main bolt. This is the tidy way of completing this task.

Or as above, drain and remove sump, insert large block of wood between lower block and crank web, locking wood to floor...make sure wood is long enough to lock properly; sometimes two pieces are best so not straining single point of crank area. Then crack off main bolt.

Be sure to order all new parts before you start the job; good luck.

Flossie said:

You mean the square drive for tensioning? Filed mine out

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No the actual v belt width, only time I have ever seen that size.

Edit I lied, just dug out piccy and it was the fan belt that was 11.5mm wide, ETC7939?
Iirc the belt sat high is the v of the water pump pulley, but was flush on the alt and crank pulleys, i think I now have a 3/8,10mm belt on there, but and this is why I changed to the genuine 11.5belt, the skinny pos contsantly needs adjusting.

lynall said:

No the actual v belt width, only time I have ever seen that size.

Edit I lied, just dug out piccy and it was the fan belt that was 11.5mm wide, ETC7939?
Iirc the belt sat high is the v of the water pump pulley, but was flush on the alt and crank pulleys, i think I now have a 3/8,10mm belt on there, but and this is why I changed to the genuine 11.5belt, the skinny pos contsantly needs adjusting.

View attachment 215262

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Cool. Explains why I'm always tweaking mine!
Unfortunately I have to use a non standard belt, well, readily available but not Landrover, as I moved the alternator in to fit an intercooler pipe better on my disco conversion.
Also, is a 1/2" extension bar supposed to fit the belt tensioner square hole?
I assumed it would but it didn't until I filed it larger.

Flossie said:

Cool. Explains why I'm always tweaking mine!
Unfortunately I have to use a non standard belt, well, readily available but not Landrover, as I moved the alternator in to fit an intercooler pipe better on my disco conversion.
Also, is a 1/2" extension bar supposed to fit the belt tensioner square hole?
I assumed it would but it didn't until I filed it larger.

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Pretty sure I use a 1/2 ext bar for adjusting pas belt, I do cheat and use a large flat screwdriver on fan belt.

Rigth finally remembered to measure irwin/snap on remover for the 10mm headed bolt.
Flat to flat 18mm, corner of flat to opposite corner 20mm, obviously this is the drive end, the business end is quite a bit thinner.
Standard deep 10mm impact socket 3/8 drive end 18mm, end that actually fits on the bolt head 15mm dia.

So I reckon it will do the job, worst comes to the worst, you can take a grinder to the drive end of the irwin.