Ford CJ5Z-6312-A Crankshaft Pulley

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Take off the drivebelt, and the brake vacuum pump. Remove the valve cover off. Disconnect the rear intake camshaft bearing cap by undoing the bolts and cap; in order to freeze movement of the camshaft, place a wrench on the flats of the camshaft, then, unscrew and remove the brake vacuum pump adapter from the end of the camshaft. Undo the bolts shown in Fig. 6.1 and withdrawal the right driveaxle intermediate shaft bracket. With the help of the camshaft and crankshaft position indicator set the engine at the top dead center. The crankshaft essentially has to be immobilized to check free rotation while the bolt of the crankshaft pulley is loosened; to this effect, a preferable method is to position a strap around the crankshaft pulley and tighten it to grip the crankshaft, then go ahead and use a 1/2 inch drive air or electric impact wrench to remove the crankshaft bolt. Lack of firmly securing the crankshaft pulley can cause the crankshaft to move and the cranking bolt to break leading to the damages of the engine. It is especially important not to lock the crankshaft using timing pin or camshaft alignment tool as these are calibration tools. Loosen the pulley bolt after which the pulley and the back diamond washer can be disconnected. Get a 'new' pulley bolt and a diamond washer. For assembly, replace the existing diamond washer with a new one on the nose of the crankshaft, apply a thin layer of clean engine oil on the crankshaft front seal and finally put on the crankshaft pulley. You should replace the seal if it has been found to show signs of leakage, prior to fitting the crankshaft pulley. Let the intake end of the camshaft be aligned with the help of special tool #303-1565 that should be installed in the mentioned part of the camshaft ; Put the Crankshaft Position (CKP) sensor alignment tool(#303-1521) on the sensor, then put a new crankshaft pulley bolt and washer on hand tighten only and then remove the tool. After that while still using the strap wrench to hold the pulley, tighten the crankshaft pulley bolt in stages reaching the torque required. It is not allowed to tighten the crankshaft pulley bolt with an impact gun. Take out the timing pin from the cylinder block as well as camshaft alignment tool. Depress the spring-loaded brake that holds the crankshaft pulley by placing the fingers between the pulley and the brake and turn the engine clockwise two full turns while observing how the tool interacts with the spark plugs. Should there be any resistance, then this should be investigated immediately, as this may imply wrong timing and an interference between the valves and the pistons. The engine should then be rotated again until it reaches TDC and the rotation should only be made in clockwise direction. After that, screw the timing pin into the cylinder block. Place the crankshaft at TDC and engage the tooth on the crankshaft pulley with the CKP sensor center line, and then fit the camshaft aligning tool to check the camshafts position. If for some reasons the tool cannot be installed it is necessary to correct the engine timing through the TDC. This is done when the camshaft alignment tool is in place, the timing pin is properly in place and also when the crankshaft pulley TDC tooth is aligned with the CKP sensor center line at the same time. After getting the right engine timing, you can then take out every tool used in aligning, the bolts and the timing pin plug. The rest of installation is, therefore, the antithesis of removal.

Remove the camshaft alignment tool. Remove the spark plugs and rotate the engine clockwise two complete revolutions by turning the crankshaft pulley bolt with a wrench or large socket. Rotate the engine again to achieve TDC. Rotate the engine in the clockwise direction only. Install the timing pin into the cylinder block.

Disconnect the cable from the negative battery terminal.

Disconnect the cable from the negative battery terminal.