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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
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.
^ The hole in the crankshaft pulley should be in the 6 o'clock position.





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 engine plug bolt.

7. 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 at the TDC position during the crankshaft pulley removal and installation.





Install the special tool.





8. Install the special tools.





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

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

Remove the crankshaft pulley.
^ Remove the crankshaft pulley bolt and washer.
^ 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 2 stages:
^ Stage 1: Tighten to 100 Nm (74 ft. lbs.).
^ Stage 2: Tighten an additional 90° (1/4 turn).





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





5. Remove the special tool.





6. Remove the special tool.

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

Turn the engine 2 complete revolutions.

8. 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).





9. Install the special tool.





10. 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.





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





12. Remove the 6 mm (0.23 inch) x 18 mm (0.7 inch) bolt.
13. Install the engine plug bolt.
^ Tighten to 20 Nm (15 ft. lbs.).
14. Install the accessory drive belt.
15. Install the valve cover.