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, using diamond washers between the flange faces on each part. 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. 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.

All vehicles

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.3L .
If equipped, remove the 7 screws and the underbody cover.

Fig 1: Locating Splash Shield Bolts

Courtesy of FORD MOTOR CO.

Remove the valve cover. For additional information, refer to Valve Cover .

NOTE: Failure to position the No. 1 piston at Top Dead Center (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 Top Dead Center (TDC).
- The hole in the crankshaft pulley should be in the 6 o'clock position.

Fig 2: Identifying Hole In Crankshaft Pulley In 6 O'Clock Position

Courtesy of FORD MOTOR CO.

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 the Camshaft Alignment Plate in the slots on the rear of both camshafts.

Fig 3: Identifying Special Camshaft Tool (303-465)

Courtesy of FORD MOTOR CO.

Automatic transaxle vehicles

Remove the 2 halfshaft carrier bracket bolts and slide the RH halfshaft 12 mm (0.47 in) out of the transaxle.

Fig 4: Locating Half Shaft Carrier Bracket Bolts And Sliding Rh Halfshaft Out Of Transaxle

Courtesy of FORD MOTOR CO.

All vehicles

Remove the engine plug bolt.

Fig 5: Locating Engine Plug Bolt

Courtesy of FORD MOTOR CO.

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 the Crankshaft TDC Timing Peg.

Fig 6: Identifying Special Tool (303-507)

Courtesy of FORD MOTOR CO.

Assemble the Adapter and Drive Pinion Flange Holding Fixture using 4 hardened washers in the locations shown.

Fig 7: Assembling Special Tools (205-126 And 205-072-02)

Courtesy of FORD MOTOR CO.

NOTE: The crankshaft must remain in the Top Dead Center (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 Adapter and Drive Pinion Flange Holding Fixture and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

NOTE: The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced, remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.

Using the Adapter and Drive Pinion Flange Holding Fixture and an air impact wrench, remove the crankshaft pulley.
- Remove and discard the crankshaft pulley bolt and washer.
- Remove the crankshaft pulley.
- Remove the diamond washer and discard.

Fig 8: Locating Crankshaft Pulley Bolt And Special Tools (205-126, 205-072-02)

Courtesy of FORD MOTOR CO.