Crankshaft Pulley: Removal

WARNING: This page is about a different variant/trim than selected.

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. 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. All parts must be thoroughly cleaned and 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. Refer to: Jacking and Lifting - Overview .
Remove the RHF wheel and tire. Refer to: Wheel and Tire .
Remove the retainers and the engine undershield.

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Remove the RHF fender splash shield. Refer to: Fender Splash Shield .
Remove the accessory drive belt. Refer to: Accessory Drive Belt .
Remove the valve cover. Refer to: Valve Cover .
NOTE: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
- The hole in the crankshaft pulley should be in the 6 o'clock position.
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Remove the engine plug bolt.

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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.

Install Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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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.

Install Special Service Tool: 303-465 Tool, Camshaft Align Timing.

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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 Crankshaft Damper Holding Tool, and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

NOTE: If equipped, the crankshaft sprocket diamond washer may come off with the crankshaft pulley.

NOTE: Use an air impact wrench to remove the crankshaft pulley bolt.

Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool 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.
  Use Special Service Tool: 303-1416 Tool, Crank Damper Holding.
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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, remove the diamond washer.

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