Crankshaft Pulley - Early Build: Installation

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: Before installation, clean and inspect the diamond washer for any damage. If damaged is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.

Install the diamond washer.
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.

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.

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).
Remove the 303-507.
Remove the 303-1565.
NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft clockwise one and three-fourths turns.
- Install the 303-507.
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.
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.

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.

Remove the 303-1565.
Remove the 303-507.
Install the engine plug bolt.
- Tighten to 20 Nm (177 lb-in).
Install the RH halfshaft bracket, the 2 bolts and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).
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).
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.

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).

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.
Install the underbody shield and tighten the 4 retainers.
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.