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Crankshaft Pulley




Crankshaft Pulley

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)






Material(s)






Exploded View

NOTE: Early build engines have a 6-rib crankshaft pulley, late build engines have a 4-rib crankshaft pulley.

NOTE: Early built shown, late build similar.









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. With the vehicle in NEUTRAL, position it on a hoist. REFER to Lifting Points .

2. Remove the 8 retainers and the underbody insulator.





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

4. Remove the ACL (Air Cleaner) outlet tube. REFER to Air Cleaner Outlet Pipe - 2.0L GDI .

5. Remove the accessory drive belt. REFER to Front End Accessory Drive (FEAD) - Exploded View .

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

7. Disconnect the CKP (Crankshaft Position) sensor electrical connector.





8. Remove the 2 bolts and the CKP (Crankshaft Position) sensor.





9. Turn the crankshaft until piston No.1 is 45 degrees before TDC (Top Dead Center) by using the guide holes on the engine front cover and the crankshaft pulley.





10. Remove the engine plug bolt.





11. 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.

Install 303-507 and using the crankshaft pulley bolt, turn the crankshaft clockwise slowly until contact is made with 303-507.





12. NOTICE: 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 step of this procedure.
Using 303-1565 , rotate 303-1565 so the tool number faces down and install into the rear of the intake camshaft slot as shown.





13. 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.

NOTE: 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 303-D055 (D85L-6000-A) , and the crankshaft pulley bolt should be removed using an air impact wrench (1/2-in drive minimum).

Use 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.






Installation

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. Install a new diamond washer onto the crankshaft.






2. NOTE: Do not install the crankshaft pulley bolt at this time.

NOTE: Apply clean engine oil on the seal area before installing.

Position the crankshaft pulley onto the crankshaft with the crankshaft pulley TDC (Top Dead Center) guide hole at the 6 o'clock position.





3. NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Install a standard bolt through the crankshaft pulley TDC (Top Dead Center) guide hole and into the engine front cover TDC (Top Dead Center) guide hole.





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 a new bolt should be installed using hand tools only.

NOTE: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. 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.







5. Remove the standard bolt from the crankshaft pulley TDC (Top Dead Center) guide hole.





6. Install the CKP (Crankshaft Position) sensor and the 2 bolts.

- Do not tighten the bolts at this time.






7. Install 303-1521 to set the CKP (Crankshaft Position) sensor position and tighten the 2 bolts.
- Tighten to 7 Nm (62 lb-in).





8. Connect the CKP (Crankshaft Position) sensor electrical connector.





9. Remove 303-507 and install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).





10. Remove 303-1565 from the rear of the intake camshaft slot.





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

12. Install the ACL (Air Cleaner) outlet tube. REFER to Air Cleaner Outlet Pipe - 2.0L GDI .

13. Install the accessory drive belt. REFER to Front End Accessory Drive (FEAD) - Exploded View .

14. Install the RH fender splash shield. REFER to Fender Splash Shield .

15. Install the underbody insulator and the 8 retainers.





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