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 .
Remove the engine front undershield. Refer to: Engine Front Undershield .
Remove the accessory drive belt. Refer to: Accessory Drive Belt .
- Disconnect the CKP sensor electrical connector.
- Remove the bolts and the CKP sensor.
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Turn the crankshaft clockwise until the No. 1 piston is 45 degrees BTDC using the guide holes on the engine front cover and the crankshaft pulley.

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Remove the engine plug bolt.

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

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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.

NOTE: The engine front cover is removed from graphic for clarity.

Rotate the crankshaft clockwise until the contacts the special tool. Use Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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Remove the RH and LH CMP sensors. Refer to: Camshaft Position (CMP) Sensor .
NOTE: Exhaust camshaft shown, intake camshaft similar.

Make sure the camshaft trigger wheels are aligned as shown.

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NOTE: Removing the O-ring seals will aid in the installation of 303-1686.

Remove the O-ring seals from 303-1686. Use Special Service Tool: 303-1686 Holding Tool, Camshaft.

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NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

NOTE: Do not force the camshaft Holding Tool into the valve cover or damage can result to the camshaft trigger wheels.

NOTE: The camshaft trigger wheels are offset. If the Camshaft Holding Tools cannot be installed, remove the TDC Timing Peg and rotate the crankshaft three-fourths of a revolution clockwise and repeat steps 10 and 11 of this removal procedure.

Install Special Service Tool: 303-1686 Holding Tool, Camshaft.

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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 Crank Damper Holding Tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).
- Using the special tool, remove the bolt, washer and the crankshaft pulley. Use Special Service Tool: 303-1689 Holding Tool, Crank Damper.
- NOTE: If necessary, retain the original crankshaft pulley bolt to use for the removal of the crankshaft front seal.
  
  Discard the bolt.

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