AutoInc. Magazine
Current Issue
Ad Index
AutoInc. Archive
How to Contribute
Reprint Permission
Subscription Info
Letters to the Editor
Top 10 Web Sites
Software Guide
NACE Online Daily News
How's Your Business?
Ad Opporunities
Media Planner
AutoInc. Mission
Meet Our Staff
  Tech Tips

Reading Before You Wrench
May Save You Time, Money

Posted 2/11/2010
By Jerry Rathman

Nowadays, not taking the time to read before you wrench could end up costing you a lot of time and money. Something as simple as replacing the crankshaft pulley and balancer assembly has turned into a major repair on some Ford engines and now requires a number of special tools.

"Something as simple as replacing the crankshaft pulley and balancer assembly has turned into a major repair on some Ford engines and now requires a number of special tools.”

On some 2001 to the present (2.0L, 2.3L, and 2.5L) cars with four-cylinder engines, the balancer and the lower timing gear are not keyed to the crankshaft, and are only held in time by friction using diamond washers between the flange faces. Because of this, the crankshaft and camshafts must be locked down before the pulley bolt is loosened. Failure to do this will result in the camshafts getting out of time and possible damage to the engine.

The crankshaft is held in place with a timing peg that is threaded into the block, just above the pan rail, behind the crankshaft position (CKP) sensor. This peg contacts a flyweight and prevents the crankshaft from rotating in the clockwise direction. It should be noted that the crankshaft could still rotate counterclockwise and that it must be held against the peg during pulley removal and installation.

The camshafts are held in place with an alignment plate that engages a slot machined into the rear of each camshaft. This plate will prevent the camshafts from turning. The slots are offset, so if the tool cannot be engaged, try rotating the crankshaft one complete revolution.

To remove the pulley, a special tool with pegs to engage the "spokes" of the pulley is used to hold it in place. With the pulley held against the timing peg, remove the bolt. Failure to hold the pulley in place while removing the bolt could cause engine damage. The diamond washers need to be replaced each time the pulley is removed to prevent the pulley from slipping out of alignment. Since the pulley is also the balancer, it must be reinstalled in the proper position to prevent a vibration. This is done during reassembly by threading a 6mm bolt through the hole in the 6 o'clock position of the balancer and into the timing cover.

When the pulley is installed, the crankshaft must remain in the top dead center position. A new pulley bolt should be used, and while supporting the pulley with the special tools, it should be tightened in two steps. First, torque the bolt to 74 ft-lb, then tighten it an additional 90 degrees. Then, remove all of the special tools at this time and rotate the crankshaft by hand two complete revolutions - stop if you feel any resistance. The engine should turn freely. Reinstall the timing peg and rotate the crankshaft until it contacts the peg. At this point, the camshaft alignment plate should slide into the machined slots of the camshaft. If it does, the engine is timed correctly. If it does not, the pulley will need to be removed and the cam timing reset.

All of the tools needed for this job are available from most tool suppliers.

Jerry Rathman Jerry Rathman is an Identifix Ford specialist. He is a Ford master and ASE master with L1 certification.
Experience Identifix This information is provided by IDENTIFIX®. IDENTIFIX® resources cut diagnostic time and provide repair solutions that increase the shop's bottom line. From Repair-Trac pattern failure quick fixes, to Diagram-Online wiring diagrams by fax, to the Repair Hotline staffed by 32 master techs who specialize in diagnosing complex problems by phone or fax, IDENTIFIX® helps techicians fix more cars in less time.

For more information on IDENTIFIX, call (800) 288-6210, 8 a.m. - 6 p.m. Central Time.

© 2011 IDENTIFIX. All Rights Reserved.


  • Fuel Injection Service, Not Just Cleaning
  • The Art of Extraction
  • EGR Systems: Operation and Diagnosis
  • Proactive Target Marketing:_Rethinking Your Business Strategy
  • Engine Performance: HO2S Diagnostics

  • Developing Employee Potential
  • How Critical Thinking Can Help Your Business
  • How to Diagnose the Ford Glow Plug
  • What to Look for When Shopping for the Right Shop Management Software
  • Putting a Price Tag on Complaints
  • AutoInc. Web Site | ASA Web Site | House-Senate Differences Present Challenges for Health Care Reform | Update on Feather, Fill and Block Issue | Do It Right the First Time | Take Back Your Business! | Tech to Tech | Tech Tips | News Briefs | Taking the Hill | Shop Profile | Net Worth | Members' Advantage | Candidates for ASA’s Board of Directors | Chairman's Message | Guest Editorial | ASA Announces Dates, Location for 2010 Business Meeting | Hard-Working Mom Gets Much-Needed Car | ASA to Host 2010 Taking the Hill Fly-In and AMI Leadership Conference

    Copyright (c) 1996-2011. Automotive Service Association®. All rights reserved.
    XML Add RSS headlines.