Crankshaft Pulley: Installation

NOTE: Before installation, clean and inspect the diamond washer for any damage. If damaged is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.
• 1.
  Install the diamond washer.

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• 2.
  
  Apply clean engine oil on the seal contact area before installing.

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• 3.
  
  Install the crankshaft pulley the small hole in the 6 o'clock position.

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NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
• 4.
  Install an M6 bolt

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NOTE: The crankshaft must remain in the 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 303-D055 D85L-6000-A and the bolt should be tightened using hand tools only.
• 5.
  Use a strap wrench to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:
  • Stage 1: Tighten to 100 Nm (74 lb-ft).
  • Stage 2: Tighten an additional 90 degrees (one-fourth turn).

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• 6.
  
  Remove the M6 bolt

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NOTE: Do not tighten the CKP sensor bolts at this time.
• 7.
  Install the CKP sensor and 2 bolts.

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• 8.
  
  Install the Crankshaft Sensor Alignment Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel.
  • Tighten to 7 Nm (62 lb-in).

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• 9.
  
  Connect the CKP sensor.

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• 10.
  
  Remove the 303-507.

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• 11.
  
  Install the engine plug bolt.
  • Tighten to 20 Nm (177 lb-in).

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• 12.
  
  Install the RH halfshaft bracket, the 2 bolts and the 2 nuts.
  • Tighten to 25 Nm (18 lb-ft).

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• 13.
  
  Remove the 303-1565.

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• 14.
  
  Using a wrench on the flats of the intake camshaft to prevent cam rotation, install the brake vacuum pump adapter.
  • Tighten to 63 Nm (46 lb-ft).

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NOTE: The intake camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft ® Metal Surface Prep.
• 15.
  Apply 1 mm (0.039 in) beads of Gasket Maker to the intake rear camshaft bearing cap mating surface as shown.

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NOTE: Wipe off any excess sealer from the vacuum pump sealing surface of the cylinder head and camshaft cap.
• 16.
  Install the rear intake camshaft cap and the 2 bolts.
  • Tighten the bolts in 2 stages:
    • Stage 1: Tighten to 7 Nm (62 lb-in).
    • Stage 2: Tighten to 16 Nm (142 lb-in).

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• 17.
  
  Install the valve cover. Refer to Valve Cover .

• 18.
  
  Install the brake vacuum pump. REFER to Power Brake Actuation .

• 19.
  
  Install the accessory drive belt. REFER to Accessory Drive

• 20.
  
  Install the underbody shield and tighten the 4 retainers.

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• 21.
  
  Install the RH fender splash shield. REFER to Front End Body Panels .

• 22.
  
  After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.