Crankshaft Pulley: Installation

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Install a new diamond washer.

Fig 1: Locating Diamond Washer
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil on the seal contact area before installing.

Position the crankshaft pulley onto the crankshaft and align the TDC marked tooth on the crankshaft pulley with the center line of the CKP sensor.

Fig 2: Aligning TDC Marked Tooth On Crankshaft Pulley With Center Line Of CKP Sensor
Courtesy of FORD MOTOR CO.
Install the 303-1521 onto the TDC marked tooth on the crankshaft pulley.
- Install a new crankshaft pulley bolt and washer.
  - Tighten to 20 Nm (177 lb-in).
  - Remove the 303-1521 .
Fig 3: Locating Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the 303-D055 (D85L-6000-A) and the bolt should be tightened using hand tools only.

Use the 303-D055 (D85L-6000-A) to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:
- Stage 1: Tighten to 100 Nm (74 lb-ft).
  - Stage 2: Tighten an additional 90 degrees (one-fourth turn).
Fig 4: Tightening Crankshaft Pulley Bolt Using Strap Wrench
Courtesy of FORD MOTOR CO.
Remove the 303-507 .

Fig 5: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Remove the 303-1565 .

Fig 6: Identifying Camshaft Alignment Tool
Courtesy of FORD MOTOR CO.
NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise one and three-fourths turns.
- Install the 303-507 .
Fig 7: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
NOTE: The engine front cover is shown 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.
Fig 8: Aligning TDC Marked Tooth On Crankshaft Pulley With Center Line Of CKP Sensor
Courtesy of FORD MOTOR CO.
Install the 303-1565 to check the position of the camshaft.
- If it is not possible to install the 303-1565 , the engine valve timing must be corrected by repeating this procedure.
Fig 9: Identifying Camshaft Alignment Tool
Courtesy of FORD MOTOR CO.
Install the 303-1521 . If the 303-1521 does not align with the TDC marked tooth on the crankshaft pulley, loosen the 2 CKP sensor bolts and adjust the sensor until the tool is installed.
- Tighten the 2 CKP sensor bolts to 7 Nm (62 lb-in).
  - Remove the 303-1521 .
Fig 10: Locating CKP Sensor Bolts
Courtesy of FORD MOTOR CO.
Remove the 303-1565 .

Fig 11: Identifying Camshaft Alignment Tool
Courtesy of FORD MOTOR CO.
Remove the 303-507 .

Fig 12: Identifying Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.
Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).
Fig 13: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.
Install the RH halfshaft bracket, the 2 bolts and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).
Fig 14: Locating Halfshaft Bracket Bolts And Nuts
Courtesy of FORD MOTOR CO.
Using a wrench on the flats of the intake camshaft to prevent cam rotation, install the brake vacuum pump adapter.
- Tighten to 63 Nm (46 lb-ft).
Fig 15: Locating Brake Vacuum Pump Adapter
Courtesy of FORD MOTOR CO.
NOTE: The intake camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.

Apply 1 mm (0.039 in) beads of Gasket Maker to the intake rear camshaft bearing cap mating surface as shown in illustration.

Fig 16: Identifying Beads Of Gasket Maker To Intake Rear Camshaft Bearing Cap Mating Surface
Courtesy of FORD MOTOR CO.
NOTE: Wipe off any excess sealer from the vacuum pump sealing surface of the cylinder head and camshaft cap.

Install the rear intake camshaft cap and the 2 bolts.
- Tighten the bolts in 2 stages:
  - Stage 1: Tighten to 7 Nm (62 lb-in).
  - Stage 2: Tighten to 16 Nm (142 lb-in).
Fig 17: Locating Rear Intake Camshaft Cap Bolts
Courtesy of FORD MOTOR CO.
Install the valve cover. REFER to Valve Cover .
Install the brake vacuum pump. REFER to BRAKE VACUUM PUMP .
Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt on the crankshaft pulley.

Fig 18: Rotating Accessory Drive Belt Tensioner Counterclockwise
Courtesy of FORD MOTOR CO.
Install the underbody shield and tighten the 4 retainers.

Fig 19: Locating Underbody Shield Retainers
Courtesy of FORD MOTOR CO.
Install the RH fender splash shield. REFER to FENDER SPLASH SHIELD .
After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.