Crankshaft Pulley: Installation

NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage 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.

NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

If equipped, install the diamond washer.

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NOTE: Do not install the crankshaft pulley bolt at this time.

Install the crankshaft pulley.

Material: Motorcraft ® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)

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NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.

NOTE: This step will correctly align the crankshaft pulley to the crankshaft

Install a standard M6 x 18 mm bolt through the crankshaft pulley and thread it into the front cover.

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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 Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.

NOTE: Install a new crankshaft pulley bolt.

Using the special tool, install the crankshaft pulley bolt. Tighten in 2 stages. Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.

Torque:

Stage 1: 74 lb.ft (100 Nm)

Stage 2: 90 °

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Remove the M6 bolt.

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Remove the special tool. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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Remove the special tool. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing.

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NOTE: Only rotate the crankshaft clockwise.

Turn the crankshaft clockwise one and three-fourths turns.

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1. Install the special tool. Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
2. Rotate the crankshaft slowly until the crankshaft stops.
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NOTE: The bolt can only be installed if the valve timing is correct.

Install the M6 bolt. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.

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NOTE: The special tool can only be installed if the valve timing is correct.

Install the special tool. If it is not possible to install the tool, the engine valve timing must be corrected by repeating this procedure. Install Special Service Tool: 303-465 Tool, Camshaft Align Timing.

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Remove the special tool. Remove Special Service Tool: 303-465 Tool, Camshaft Align Timing.

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Remove the M6 bolt.

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Remove the special tool. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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Install the engine bolt plug.
Torque: 177 lb.in (20 Nm)

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Install the following items:
1. Remove the fender splash shield. Refer to: Fender Splash Shield .
2. Remove the valve cover. Refer to: Valve Cover .
3. Remove the accessory drive belt. Refer to: Accessory Drive Belt .
If equipped. Install the splash shield and the screws.

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After completing repairs, perform the Misfire Monitor Neutral Profile Correction procedure.