Crankshaft Pulley

Removal & Installation

2.3L Engine

To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Disconnect the negative battery cable.

   CAUTION
   Before loosening or removing the crankshaft pulley bolt you must first install the special tools noted in these instructions. 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. Because of this, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. 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 damage may occur.

   CAUTION
   Cleanliness is very important during any engine repair procedure. Engine failure can be caused by any foreign material that enters the oil passages, coolant passages, or the oil pan. This includes material created while cleaning gasket surfaces. Make sure no foreign material enters these locations.

3. Put the vehicle in neutral and place it on a hoist.
4. Remove the fan and shroud.
5. Remove the accessory drive belt.
6. Remove the valve cover.

   CAUTION
   Failure to position the No. 1 piston at the top dead center may result in damage to the engine. Turn the crankshaft in the normal direction of rotation only.

7. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center. The hole in the crankshaft pulley should be at the 6 o’clock position.

   CAUTION
   The camshaft alignment plate (303-465) is for camshaft alignment only. Using this tool to prevent engine rotation may 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.

8. Install the special tool in the slots on the rear of both camshafts.
9. Remove the plug bolt.

   NOTE: The special tool will contact the crankshaft and prevent it from turning past the top dead center, however, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain in the top dead center position during the crankshaft pulley removal and installation.

10. Install the crankshaft timing peg (303-507).

    Install the crankshaft timing peg (303-507) – 2.3L engine

11. Assemble the drive pinion flange holding fixture (205-126) and the adapter for 205-126 (205-072-02) using four hardened washers in the locations shown below.

    Assemble special tools 205-126 and 205-072-02 using washers (2.3 L)

    CAUTION
    The crankshaft must remain in the top dead center position during removal of the pulley bolt or engine damage may occur. Because of this, 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.

12. Using the drive pinion flange holding fixture (205-126) and the adapter for 205-126 (205-072-02) and an air impact wrench, remove the crankshaft pulley. After removing the crankshaft pulley bolt and washer, discard them.

To Install:

CAUTION
Do not install the crankshaft pulley bolt at this point in the procedure.

NOTE: Apply clean engine oil to the area before installing.

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

   CAUTION
   Only hand-tighten the 6 mm (0.23 in.) bolt or the front cover may get damaged.

   NOTE: The following step will correctly align the crankshaft pulley to the crankshaft.

2. Install a standard 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt through the crankshaft pulley and thread it into the front cover.

   CAUTION
   The crankshaft must remain in the top dead center position during installation of the pulley bolt or engine damage may occur. Because of this, the crankshaft pulley must be held in place with the special tools and the bolt should be installed using hand tools only.

   CAUTION
   Do not reuse the crankshaft pulley bolt.

3. Install a new crankshaft pulley bolt. Using the drive pinion flange holding fixture (205-126) and the adapter for 205-126 (205-072-02) to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in two steps.
   • Step 1: Tighten to 74 ft-lb (100 Nm).
   • Step 2: Rotate an additional 90 degrees (1/4 turn).
4. Remove the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt.
5. Remove the crankshaft timing peg (303-507).

   Remove the crankshaft timing peg (2.3 L)

6. Remove the camshaft alignment plate (303-465).

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

7. Turn the crankshaft clockwise 1 ¾ turns.
8. Install the crankshaft timing peg (303-507).

   Install the crankshaft timing peg (2.3 L)

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

9. Turn the crankshaft clockwise until the crankshaft contacts the crankshaft timing peg (303-507).

   CAUTION
   Only hand-tighten the 6 mm (0.23 in.) bolt or the front cover may get damaged.

10. Using the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt, check the position of the crankshaft pulley. If it is not possible to install this bolt, the engine valve timing must be corrected by repeating this procedure.
11. Using the camshaft alignment plate (303-465), check the position of the camshafts. If it is not possible to install this tool, the engine valve timing must be corrected by repeating this procedure.
12. Remove the camshaft alignment plate (303-465).
13. Remove the 6 mm (0.23 in.) x 18 mm (0.7 in.) bolt.
14. Remove the crankshaft timing peg (303-507).
15. Install the plug bolt.
    • Torque to 15 ft-lb (20 Nm).
16. Install the valve cover.
17. Install the accessory drive belt.
18. Install the fan and shroud.