Crankshaft Pulley - Early Build: Removal

WARNING: This page is about a different car, the 2013 Ford Explorer. 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.

Remove the RH fender splash shield. REFER to FENDER SPLASH SHIELD .
Loosen the 4 retainers and remove the underbody shield.
Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt from the crankshaft pulley.
Remove the brake vacuum pump. REFER to BRAKE VACUUM PUMP .
Remove the valve cover. Refer to VALVE COVER .
Remove the 2 bolts and the rear intake camshaft cap.
Using a wrench on the flats of the intake camshaft to prevent cam rotation, remove the brake vacuum pump adapter.
NOTE: Turn the engine in the normal direction of rotation only.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the TDC marked tooth on the crankshaft pulley (located on the 20th tooth counterclockwise from the missing tooth) at the 6 o'clock position.
Remove the 2 bolts, the 2 nuts and the RH halfshaft bracket.
Remove the engine plug bolt.
Install the 303-507.
NOTE: The 303-507 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.

NOTE: The engine front cover is shown in illustration removed in graphic for clarity.

Rotate the crankshaft slowly clockwise until the crankshaft contacts the 303-507.
- The TDC marked tooth on the crankshaft pulley will align with the center line of the CKP sensor.
NOTE: The 303-1565 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 303-1565 cannot be installed, remove the 303-507 and rotate the crankshaft three-fourths of a revolution clockwise and repeat the previous 2 steps of this procedure.

Install the 303-1565 into the rear of the intake camshaft slot as shown in illustration.
NOTE: 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 Strap Wrench 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.

Use the 303-D055 D85L-6000-A to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.
- Remove and discard the crankshaft pulley bolt and washer.
- Remove the crankshaft pulley.
If the diamond washer did not come off with the crankshaft pulley, remove the diamond washer.