Crankshaft Pulley: Removal

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: 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.

NOTE: 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.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the front RH wheel and tire. For additional information, refer to WHEELS & TIRES .
If equipped, remove the 7 screws and the underbody cover.

Fig 1: Locating Underbody Cover Screws
Courtesy of FORD MOTOR CO.
Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.5L .
Remove the valve cover. For additional information, refer to VALVE COVER .
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
- The hole in the crankshaft pulley should be in the 6 o'clock position.
NOTE: 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.

Fig 2: Locating Crankshaft Pulley Hole
Courtesy of FORD MOTOR CO.
Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
NOTE: The Camshaft Alignment Plate 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 Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

Fig 3: Identifying Camshaft Alignment Plate In Slots On Rear Of Both Camshafts
Courtesy of FORD MOTOR CO.
Remove the engine plug bolt.

Fig 4: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.
Install the Crankshaft TDC Timing Peg.
NOTE: The Crankshaft TDC Timing Peg 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 5: Installing Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Using the Crankshaft Damper Holding Tool and an air impact wrench, remove the crankshaft pulley.
- Remove and discard the crankshaft pulley bolt and washer.
- Remove the crankshaft pulley.
- Remove the diamond washer and discard.
NOTE: The crankshaft must remain in the Top Dead Center (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 Crankshaft Damper Holding Tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

NOTE: 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.

Fig 6: Locating Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.