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Crankshaft Pulley: Installation

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not install the crankshaft pulley bolt at this time.
    NOTE: Apply clean engine oil on the seal area before installing.
    Fig 1: Locating Crankshaft Pulley
    G04618904Courtesy of FORD MOTOR CO.
  1. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
    2. CAUTION: 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.
    Fig 2: Locating Crankshaft Pulley Standard Bolt
    G04618905Courtesy of FORD MOTOR CO.
  2. 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.
  3. Assemble the special tools using 4 hardened washers in the locations shown in Fig 3.
    Fig 3: Assembling Special Tools (205-072-02 And 205-126)
    G04618906Courtesy of FORD MOTOR CO.
    4. CAUTION:
    1. The crankshaft must remain in the 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.
    2. Do not reuse the crankshaft pulley bolt.
  4. 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 N.m (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees (1/4 turn).
      Fig 4: Installing Crankshaft Pulley Bolt Using Special Tools (205-072-02, 205-126)
      G04618907Courtesy of FORD MOTOR CO.
  5. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 5: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  6. Remove the special tool.
    Fig 6: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  7. Remove the special tool.
    Fig 7: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
    8. NOTE: Only turn the engine in the normal direction of rotation.
  8. Turn the crankshaft clockwise 1 and 3/4 turns.
  9. Install the special tool.
    Fig 8: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
    10. NOTE: Only turn the engine in the normal direction of rotation.
    Fig 9: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  10. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
    11. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
  11. 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.
      Fig 10: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
      G03950429Courtesy of FORD MOTOR CO.
  12. Using the special tool, 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.
      Fig 11: Identifying Special Camshaft Tool (303-465)
      G03898006Courtesy of FORD MOTOR CO.
  13. Remove the special tool.
    Fig 12: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  14. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 13: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
    G03950429Courtesy of FORD MOTOR CO.
  15. Remove the special tool.
    Fig 14: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  16. Install the engine plug bolt.
    • Tighten to 20 N.m (15 lb-ft).
  17. Install the accessory drive belt. For additional information, refer to REMOVAL AND INSTALLATION .
  18. Install the valve cover. For additional information, refer to VALVE COVER .
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