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Harmonic Balancer - Crankshaft Pulley: Service and Repair




Crankshaft Pulley

Special Tool(s)






Material(s)






Removal

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Remove the RH (Right Hand) fender splash shield. REFER to Fender Splash Shield .

2. Loosen the 4 retainers and remove the underbody shield.





3. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt from the crankshaft pulley.





4. Remove the brake vacuum pump. REFER to Brake Vacuum Pump .

5. Remove the valve cover. REFER to Valve Cover .

6. Remove the 2 bolts and the rear intake camshaft cap.





7. Using a wrench on the flats of the intake camshaft to prevent cam rotation, remove the brake vacuum pump adapter.





8. NOTE: Turn the engine in the normal direction of rotation only.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the TDC (Top Dead Center) marked tooth on the crankshaft pulley (located on the 20th tooth counterclockwise from the missing tooth) at the 6 o'clock position.





9. Remove the 2 bolts, the 2 nuts and the RH (Right Hand) halfshaft bracket.





10. Remove the engine plug bolt.





11. Install the 303-507.





12. NOTE: The 303-507 will contact the crankshaft and prevent it from turning past TDC (Top Dead Center). However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC (Top Dead Center) position during the crankshaft pulley removal and installation.

NOTE: The engine front cover is shown removed in graphic for clarity.
Rotate the crankshaft slowly clockwise until the crankshaft contacts the 303-507.

- The TDC (Top Dead Center) marked tooth on the crankshaft pulley will align with the center line of the CKP (Crankshaft Position) sensor.






13. NOTICE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

NOTE: The camshaft timing slots are offset. If the 303-1565 cannot be installed, remove the 303-507 and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure.
Install the 303-1565 into the rear of the intake camshaft slot as shown.





14. NOTICE: The crankshaft must remain in the TDC (Top Dead Center) position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

NOTICE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced. Remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.

Use the 303-D055 (D85L-6000-A) to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.

- Remove and discard the crankshaft pulley bolt and washer.
- Remove the crankshaft pulley.
- Remove the diamond washer and discard.






15. If the diamond washer did not come off with the crankshaft pulley, remove the washer from the crankshaft and discard.





Installation

1. Install a new diamond washer.





2. NOTE: Apply clean engine oil on the seal contact area before installing.
Position the crankshaft pulley onto the crankshaft and align the TDC (Top Dead Center) marked tooth on the crankshaft pulley with the center line of the CKP (Crankshaft Position) sensor.





3. Install the 303-1521 onto the TDC (Top Dead Center) marked tooth on the crankshaft pulley.
- Install a new crankshaft pulley bolt and washer.
- Tighten to 20 Nm (177 lb-in).
- Remove the 303-1521.





4. NOTICE: The crankshaft must remain in the TDC (Top Dead Center) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the 303-D055 (D85L-6000-A) and the bolt should be tightened using hand tools only.

Use the 303-D055 (D85L-6000-A) to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm (74 lb-ft).
- Stage 2: Tighten an additional 90 degrees (one-fourth turn).





5. Remove the 303-507.





6. Remove the 303-1565.





7. NOTE: Only turn the engine in the normal direction of rotation.
Turn the crankshaft clockwise one and three-fourths turns.

- Install the 303-507.






8. NOTE: The engine front cover is shown removed in graphic for clarity.
Rotate the crankshaft slowly clockwise until the crankshaft contacts the 303-507.

- The TDC (Top Dead Center) marked tooth on the crankshaft pulley will align with the center line of the CKP (Crankshaft Position) sensor.






9. Install the 303-1565 to check the position of the camshaft.

- If it is not possible to install the 303-1565 , the engine valve timing must be corrected by repeating this procedure.






10. Install the 303-1521. If the 303-1521 does not align with the TDC (Top Dead Center) marked tooth on the crankshaft pulley, loosen the 2 CKP (Crankshaft Position) sensor bolts and adjust the sensor until the tool is installed.
- Tighten the 2 CKP (Crankshaft Position) sensor bolts to 7 Nm (62 lb-in).
- Remove the 303-1521.





11. Remove the 303-1565.





12. Remove the 303-507.





13. Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).





14. Install the RH (Right Hand) halfshaft bracket, the 2 bolts and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).





15. Using a wrench on the flats of the intake camshaft to prevent cam rotation, install the brake vacuum pump adapter.
- Tighten to 63 Nm (46 lb-ft).





16. NOTE: The intake camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.

Apply 1 mm (0.039 in) beads of Gasket Maker to the intake rear camshaft bearing cap mating surface as shown.





17. NOTICE: Wipe off any excess sealer from the vacuum pump sealing surface of the cylinder head and camshaft cap.

Install the rear intake camshaft cap and the 2 bolts.
- Tighten the bolts in 2 stages:
- Stage 1: Tighten to 7 Nm (62 lb-in).
- Stage 2: Tighten to 16 Nm (142 lb-in).





18. Install the valve cover. REFER to Valve Cover .

19. Install the brake vacuum pump. REFER to Brake Vacuum Pump .

20. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt on the crankshaft pulley.





21. Install the underbody shield and tighten the 4 retainers.





22. Install the RH (Right Hand) fender splash shield. REFER to Fender Splash Shield .

23. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.


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