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Crankshaft Pulley: Removal

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe damage can occur.
  1. Remove the fan and shroud. For additional information, refer to ENGINE COOLING .
  2. Remove the accessory drive belt. For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING .
  3. Remove the valve cover. For additional information, refer to VALVE COVER .
    4. 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.
    Fig 1: Using Crankshaft Pulley Bolt To Turn Crankshaft
    G03273559Courtesy of FORD MOTOR CO.
  4. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
    5. 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 2: Installing Special Tool In Slots On Rear Of Both Camshafts
    G03273560Courtesy of FORD MOTOR CO.
  5. Install the special tool in the slots on the rear of both camshafts.
  6. Remove the plug bolt.
    Fig 3: Removing Plug Bolt
    G03273561Courtesy of FORD MOTOR CO.
    7. NOTE: Only turn the engine in the normal direction of rotation.
    NOTE: Installing the special tool in this step will prevent the engine from being rotated in the clockwise direction. However, the engine can still be rotated in the counterclockwise direction.
    Fig 4: Installing Special Tool Through Plug Bolt Hole
    G03273562Courtesy of FORD MOTOR CO.
  7. Install the special tools.
  8. Install the special tools.
    Fig 5: Installing Special Tool To Crankshaft Pulley
    G03273563Courtesy of FORD MOTOR CO.
    9. CAUTION: Failure to hold the crankshaft pulley in place during bolt loosening can cause damage to the engine.
  9. Remove the crankshaft pulley.
    1. Remove the crankshaft pulley bolt.
    2. Remove the special tools.
    3. Remove the crankshaft pulley.
      Fig 6: Removing Crankshaft Pulley
      G03273564Courtesy of FORD MOTOR CO.
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