Crankshaft Pulley: Installation

All vehicles 

1. Install a new diamond washer.
NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
2. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
Fig 1: Identifying Hole In Crankshaft Pulley At 6 O'Clock Position
Courtesy of FORD MOTOR CO.
NOTE: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
3. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
Fig 2: Identifying Standard 6mm x 18 mm Bolt
Courtesy of FORD MOTOR CO.
4. Assemble the Adapter and Drive Pinion Flange Holding Fixture using 4 hardened washers in the locations shown.
Fig 3: Assembling Special Tools (205-126 And 205-072-02) And Hardened Washers
Courtesy of FORD MOTOR CO.
NOTE: The crankshaft must remain in the Top Dead Center (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 special tool and the bolt should be installed using hand tools only.
NOTE: Do not reuse the crankshaft pulley bolt.
5. • Install a new crankshaft pulley bolt. Using the Adapter and Drive Pinion Flange Holding Fixture to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:
   • Stage 1: Tighten to 100 Nm (74 lb-ft).
   • Stage 2: Tighten an additional 90 degrees (1/4 turn).
Fig 4: Identifying Special Tools (205-126 And 205-072-02) & Crankshaft Pulley Bolt
Courtesy of FORD MOTOR CO.
6. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
Fig 5: Identifying 6 mm x 18 mm Bolt
Courtesy of FORD MOTOR CO.
7. Remove the Crankshaft TDC Timing Peg.
Fig 6: Identifying Special Tool
Courtesy of FORD MOTOR CO.
8. Remove the Camshaft Alignment Plate.
Fig 7: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
NOTE: Only turn the engine in the normal direction of rotation.
9. Turn the crankshaft clockwise 1 and 3/4 turns.
10. Install the Crankshaft TDC Timing Peg.
Fig 8: Identifying Special Tool
Courtesy of FORD MOTOR CO.
NOTE: Only turn the engine in the normal direction of rotation.
11. Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft TDC Timing Peg.
Fig 9: Identifying Special Tool (303-507)
Courtesy of FORD MOTOR CO.
NOTE: Only hand-tighten the bolt or damage to the front cover can occur.
12. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    • If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
Fig 10: Identifying Hole In Crankshaft Pulley In 6 O'Clock Position
Courtesy of FORD MOTOR CO.
13. Install the Camshaft Alignment Plate to check the position of the camshafts.
    • If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected by repeating this procedure.
Fig 11: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
14. Remove the Camshaft Alignment Plate.
Fig 12: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
15. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
Fig 13: Identifying 6 mm x 18 mm Bolt
Courtesy of FORD MOTOR CO.
16. Remove the Crankshaft TDC Timing Peg.
Fig 14: Identifying Special Tool
Courtesy of FORD MOTOR CO.
17. Install the engine plug bolt.
    • To install, tighten to 20 Nm (177 lb-in).
Fig 15: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.

Automatic transaxle vehicles 

18. Install the RH halfshaft and the 2 halfshaft carrier bearing bracket bolts.
    • Tighten to 40 Nm (30 lb-ft).

All vehicles 

19. If equipped, install the underbody cover and the 7 screws.
Fig 16: Locating Splash Shield Bolts
Courtesy of FORD MOTOR CO.
20. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.3L article.
21. Install the valve cover. For additional information, refer to Valve Cover .