Harmonic Balancer - Crankshaft Pulley: Service and Repair

Crankshaft Pulley





Special Tool(s)





Material

Removal

CAUTION: 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.

CAUTION: 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 you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.

1. Remove the fan shroud.
2. Remove the accessory drive belt.
3. Remove the valve cover.





4. CAUTION: 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 TDC.





5. CAUTION: The special tool 303-465 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 special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

Install the special tool in the slots on the rear of both camshafts.





6. Remove the plug bolt.





7. NOTE: Only turn the engine in the normal direction of rotation.

NOTE: Installing the special tool in this step will prevent the engine from being rotated in the clockwise direction. However, the engine can still be rotated in the counterclockwise direction.

Install the special tool.
8. Remove the degas bottle.
9. Remove the battery.





10. Remove the three bolts and the battery tray.





11. Install the special tool.





12. Remove the LH motor mount center nut.





13. Remove the RH upper motor mount nuts.





14. Loosen the lower engine mount nuts.
15. Lower the engine enough to allow for the clearance to install special tools.





16. Install the special tools.





17. CAUTION: Failure to hold the crankshaft pulley in place during bolt loosening can result in damage to the engine.

Remove the crankshaft pulley.
1. Remove the crankshaft pulley bolt.
2. Remove the special tools.
3. Remove the crankshaft pulley.

Installation





1. NOTE: Do not reuse the crankshaft damper bolt.

NOTE: Apply clean engine oil on the seal area before installing.

Install the crankshaft pulley and hand-tighten the bolt.





2. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.

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

Install a standard 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt through the crankshaft pulley and thread it into the front cover.
^ Rotate the pulley as necessary to align the bolt holes.





3. CAUTION: Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.
Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in two stages:
^ Stage 1: Tighten to 100 Nm (74 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees (1/4 turn).





4. Remove the special tools.





5. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





6. Remove the special tool.





7. Remove the special tool.

8. NOTE: Only turn the engine in the normal direction of rotation.

Turn the engine two complete revolutions.

9. NOTE: Only turn the engine in the normal direction of rotation.

Turn the crankshaft until the No. 1 piston is at top dead center (TDC).





10. Install the special tool.





11. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.

Using the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt, check the position of the crankshaft pulley.
If it is not possible to install the bolt, correct the engine timing.





12. Using the special tool, check the position of the camshafts.
If it is not possible to install the special tool, correct the engine timing.





13. Remove the special tool.





14. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.





15. Remove the special tool.





16. Install the plug bolt.
17. Raise the engine.





18. Install the RH motor mount nuts.





19. Install the LH motor mount center nut.





20. Tighten the lower engine mount nuts.
1. Position the lower engine mount.
2. Tighten the lower engine mount nuts.





21. Remove the special tool.





22. Install the battery tray.
23. Install the degas bottle.
24. Install the valve cover.
25. Install the accessory drive belt.
26. Install the fan and shroud.