Crankshaft Pulley: Removal

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 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 article.
Remove the front RH wheel and tire. For additional information, refer to WHEELS & TIRES article.
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 -- FUSION & MILAN (EXCEPT HYBRID) article in this service information.
Remove the valve cover. For additional information, refer to VALVE COVER in this service information.

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: Turning Crankshaft Pulley So The Hole Is In The 6 O'Clock Position

Courtesy of FORD MOTOR CO.

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: 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

Courtesy of FORD MOTOR CO.

Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
Remove the engine plug bolt.

Fig 4: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.

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: Remove/Install Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

Install the Crankshaft TDC Timing Peg.

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: Removing Crankshaft Pulley Using Crankshaft Damper Holding Tool And Air Impact Wrench

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.