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Crankshaft Pulley: Removal

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.
CAUTION: 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 you loosen the pulley bolt. 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.
CAUTION: 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.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.3L .
  3. If equipped, remove the 7 screws and the underbody cover.
    Fig 1: Locating Underbody Cover Screws
    G04679944Courtesy of FORD MOTOR CO.
  4. Remove the valve cover. For additional information, refer to VALVE COVER .
    5. CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
    • The hole in the crankshaft pulley should be in the 6 o'clock position.
      Fig 2: Locating Hole On Crankshaft Pulley And Turning Crankshaft Clockwise
      G04679945Courtesy of FORD MOTOR CO.
    6. CAUTION: The special tool 303-465 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 special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
    Fig 3: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  6. Install the special tool in the slots on the rear of both camshafts.

    7. Automatic transaxle vehicles 

  7. Remove the 2 half shaft carrier bracket bolts and slide the RH halfshaft 12 mm (0.47 in) out of the transaxle.
    Fig 4: Locating Half Shaft Carrier Bracket Bolts And Sliding Rh Halfshaft Out Of Transaxle
    G04679947Courtesy of FORD MOTOR CO.

    8. All vehicles 

  8. Remove the engine plug bolt.
    Fig 5: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    9. NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.
    Fig 6: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  9. Install the special tool.
  10. Assemble the special tools using 4 hardened washers in the locations shown.
    Fig 7: Locating Special Tools And Hardened Washers
    G04679950Courtesy of FORD MOTOR CO.
    11. CAUTION: The crankshaft must remain in the TDC 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 special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
    CAUTION: If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft.
  11. Using the special tools and an air impact wrench, remove the crankshaft pulley.
    • Remove and discard the crankshaft pulley bolt and washer.
    • Remove the crankshaft pulley.
      Fig 8: Locating Crankshaft Pulley Bolt And Special Tool
      G04679951Courtesy of FORD MOTOR CO.
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