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Crankshaft Pulley: Installation

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

    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 Holes In Crankshaft Pulley
    G04679952Courtesy 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 Bolt
    G04679953Courtesy 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.
    Fig 3: Locating Special Tools And Hardened Washers
    G04679954Courtesy of FORD MOTOR CO.
    4. CAUTION: 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.
    CAUTION: Do not reuse the crankshaft pulley bolt.
    • 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).
      Fig 4: Identifying Special Tools And Crankshaft Pulley Bolt
      G04679955Courtesy of FORD MOTOR CO.
  5. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 5: Locating Bolt
    G04679956Courtesy 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.
    • To install, tighten to 20 Nm (15 lb-ft).
      Fig 15: Locating Engine Plug Bolt
      G04319319Courtesy of FORD MOTOR CO.

    17. Automatic transaxle vehicles 

  17. Install the RH halfshaft and the 2 halfshaft carrier bearing bracket bolts.
    • Tighten to 40 Nm (30 lb-ft).

    18. All vehicles 

  18. If equipped, install the underbody cover and the 7 screws.
    Fig 16: Locating Underbody Cover Screws
    G04679967Courtesy of FORD MOTOR CO.
  19. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.3L .
  20. Install the valve cover. For additional information, refer to VALVE COVER .
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