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Harmonic Balancer - Crankshaft Pulley: Service and Repair



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CRANKSHAFT PULLEY - HYBRID REMOVAL/INSTALLATION

Removal

CAUTION:Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and 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 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 service tools, otherwise severe engine damage can occur.

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.
1. With the vehicle in NEUTRAL, position it on a hoist. See Lifting.

2. Remove the front RH wheel and tire. See Service and Repair.

3. Remove the accessory drive belt. See - Service and Repair.

4. Remove the valve cover. See - Service and Repair.






5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).

- The hole on the crankshaft pulley should be in the 6 o'clock position.

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.






6. Install the special tool in the slots on the rear of both camshafts.

CAUTION:The Camshaft Alignment Plate 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.






7. Remove the engine plug bolt.






8. Install the special tool.

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 pulley removal and installation.






9. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.

- Remove and discard the crankshaft pulley, bolt and washer.
- Remove the crankshaft pulley.
- Remove the diamond washer and discard.

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:The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced. Remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.

Installation

1. Install a new diamond washer.






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

CAUTION:Do not install the crankshaft pulley bolt at this time.
NOTE:Apply clean engine oil on the seal area before installing.






3. 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:Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front cover can occur.
NOTE:This step will correctly align the crankshaft pulley to the crankshaft.






4. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages:

- Stage 1: Tighten to 100 Nm {10.2 kgf-m, 74 ft-lbf}.
- Stage 2: Tighten an additional 90 degrees (one-quarter turn).

CAUTION: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 special tool and the bolt should be installed using hand tools only.

CAUTION:Do not reuse the crankshaft pulley bolt.






5. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.






6. Remove the special tool.






7. Remove the special tool.

8. Turn the crankshaft one and three-quarters turn.

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






9. Install the special tool.






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

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






11. 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 the bolt, the engine valve timing must be corrected by repeating this procedure.

CAUTION:Only hand-tighten the bolt or damage to the front cover can occur.






12. 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.






13. Remove the special tool.






14. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.






15. Remove the special tool.

16. Install the engine plug bolt.

- Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.

17. Install the accessory drive belt. See - Service and Repair.

18. Install the front RH wheel and tire. See Service and Repair.

19. Install the valve cover. See - Service and Repair.

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