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Harmonic Balancer - Crankshaft Pulley: Service and Repair



Crankshaft Pulley





Special Tool(s)





Material

Removal

NOTICE: 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 tools, otherwise severe engine damage can occur.

NOTICE: 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.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the fan and shroud.
3. Remove the accessory drive belt.
4. Remove the valve cover. Service and Repair





5. 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.





6. 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.





7. Remove the plug bolt.

8. NOTE: The special tool 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 in the TDC position during the crankshaft puley removal and installation.

Install the special tool.





9. Assemble the special tools using four hardened washers in the Tocations shown.





10. CAUTION: 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 special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

CAUTION:If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft

Using the special tools 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.






Installation

1. NOTE: Do not install the crankshaft pulley bolt at this time.

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

Install the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.





2. NOTICE: Only hand-tighten the 6 mm x 18 mm 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 x 18 mm bolt through the crankshaft pulley and thread it into the front cover.





3. NOTICE: 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 tools and the bolt should be installed using hand tools only.

NOTE: Do not reuse the crankshaft pulley bolt.

Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool 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: Rotate an additional 90 degrees.





4. Remove the 6 mm x 18 mm bolt.





5. Remove the Crankshaft Timing Peg.





6. Remove the Camshaft Alignment Plate.





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

Turn the crankshaft clockwise one and three-fourths turns.

8. Install the special tool.





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

Turn the crankshaft clockwise until the crankshaft contacts the special tool.





10. NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.

Using the 6 mm x 18 mm 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.





11. Install the special tool to check the position of the camshafts.
- If it is not possible to install the special tool, the engine valve timing must be corrected by repeating this procedure.





12. Remove the special tool.





13. Remove the 6 mm x 18 mm bolt.





14. Remove the special tool.





15. Install the timing peg plug.
- Tighten to 20 Nm (15 lb-ft).





16. Install the valve cover. Service and Repair

17. Install the accessory drive belt.
18. Install the fan and shroud.
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