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Crankshaft Pulley: Installation

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install a new diamond washer.
    2. NOTE: Do not install the crankshaft pulley bolt at this time.
    NOTE: Apply clean engine oil on the seal area before installing.
  2. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
    3. Fig 1: Locating Crankshaft Pulley & Hole
    GF0008924Courtesy of FORD MOTOR CO.
    NOTE: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
  3. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
    4. Fig 2: Locating Crankshaft Pulley Bolt
    GF0008925Courtesy of FORD MOTOR CO.
  4. Assemble the special tools using 4 hardened washers in the locations shown.
    5. Fig 3: Assembling Special Tools (205-126 And 205-072-02)
    GF0008922Courtesy of FORD MOTOR CO.
    NOTE: The crankshaft must remain in the top dead center (TDC) 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 special tool and the bolt should be installed using hand tools only.
    NOTE: Do not reuse the crankshaft pulley bolt.
  5. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
    • Stage 1: Tighten to 100 Nm (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
    6. Fig 4: Using Special Tools (205-126 And 205-072-02)
    GF0024073Courtesy of FORD MOTOR CO.
  6. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    7. Fig 5: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  7. Remove the special tool.
    8. Fig 6: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  8. Remove the special tool.
    9. Fig 7: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    NOTE: Only turn the engine in the normal direction of rotation.
  9. Turn the crankshaft clockwise 1 and 3/4 turns.
  10. Install the special tool.
    11. Fig 8: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
    NOTE: Only turn the engine in the normal direction of rotation.
  11. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
    12. Fig 9: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
    NOTE: Only hand-tighten the bolt or damage to the front cover can occur.
  12. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
    13. Fig 10: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  13. Install the special tool to check the position of the camshafts.
    • If it is not possible to install the special tool, the engine valve timing must be corrected by repeating this procedure.
    14. Fig 11: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  14. Remove the special tool.
    15. Fig 12: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  15. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    16. Fig 13: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  16. Remove the special tool.
    17. Fig 14: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  17. Install the engine plug bolt.
    • Tighten to 20 Nm (15 lb-ft).
  18. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - HYBRID article.
  19. Install the front RH splash shield, the 5 bolts and the pin-type retainer.
    • Tighten to 9 Nm (80 lb-in).
  20. Install the front RH wheel and tire. For additional information, refer to WHEELS AND TIRES article.
  21. Install the valve cover. For additional information, refer to Valve Cover .
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