Vibration Damper and Pulley � Remove and install

Removal Procedure

Pulleys with Split Lock Rings

Remove:

- the Alternator belt. Install Tooling into one of the unused threads in the assembly of the crankshaft pulley, the vibration damper and the crankshaft adapter.

- the setscrews (4).

- the vibration damper (3) and the crankshaft pulley (2) from the crankshaft adapter (1). 

- Tooling from the crankshaft adapter (1). Use a suitable tool in order to prevent the crankshaft from rotating. Use Tooling to remove the three torx screws (5). Hold a wood block against the crankshaft adapter (1). Strike the wood block with a hammer in order to loosen the split lock rings (9).

- the crankshaft adapter (1) from the crankshaft. 

- the thrust block (6) from the crankshaft adapter (1). 

- the O-ring seal (7) from the thrust block (6). Discard the O-ring seal. 

- the split lock rings (9) and the spacer (8) from the crankshaft adapter (1). Note the position and orientation of the split lock rings and the spacer.

Pulleys without Split Lock Rings

Remove:

- the alternator belt. The weight of the assembly of the crankshaft pulley, the vibration damper and the crankshaft adapter is approximately 22 kg (48 lb).

- Remove the vibration damper and the crankshaft pulley before the crankshaft adapter is removed from the engine.

- one of the setscrews (4). Install Tooling into the assembly of the crankshaft pulley, the vibration damper and the crankshaft adapter.

- the five remaining setscrews (4).

- the vibration damper (3) and the crankshaft pulley (2) from the crankshaft adapter (1). 

- Tooling from the crankshaft adapter (1). Use a suitable tool in order to prevent the crankshaft from rotating. Use Tooling to remove the three torx screws (5).

- the crankshaft adapter (1) from the crankshaft.

Installation Procedure

Pulleys with Split Lock Rings

Ensure that the crankshaft adapter, the split lock rings, the spacer and the thrust block are clean and free from damage. Replace any components that are damaged.

Install: 

- a new O-ring seal (7) to the thrust block (6).

- the spacer (8) to the crankshaft adapter (1).

- both pairs of split lock rings (9) to the crankshaft adapter (1). There is an internal split lock ring and an external lock ring. Ensure that the split lock rings are installed in the correct position. Refer to Illustration. Position the gap in the split lock rings at 180 degrees away from each other. Ensure that the front of the crankshaft is clean and free from damage. 

- the crankshaft adapter (1) onto the crankshaft. Align the holes in the thrust block with the holes in the crankshaft. 

- the thrust block (6) into the crankshaft adapter (1).

- the three torx screws (5) to the thrust block (6). Use a suitable tool in order to prevent the crankshaft from rotating. Use Tooling to tighten the torx screws to a torque of 200 N�m (147 lb ft). Repeat Step two more times in order to ensure correct torque.

- Tooling to the crankshaft adapter (1). Align the crankshaft pulley (2) with Tooling. 

- the crankshaft pulley to the crankshaft adapter (1). Inspect the vibration damper for damage. If necessary, replace the vibration damper. Align the vibration damper (3) with Tooling. 

- the vibration damper to the crankshaft adapter (1).

- the four setscrews (4) to the assembly of the crankshaft pulley, the vibration damper and the crankshaft adapter. The setscrews should be evenly spaced. Remove Tooling. Use a suitable tool in order to prevent the crankshaft from rotating. Tighten the setscrews (4) to a torque of 115 N�m (85 lb ft).

- the alternator belt.

Pulleys without Split Lock Rings

Ensure that the crankshaft adapter and the front of the crankshaft are clean and free from damage. Install the crankshaft adapter (1) to the crankshaft.

Install: 

- the three torx screws (3) to the crankshaft adapter (1). Use a suitable tool in order to prevent the crankshaft from rotating. Use Tooling to tighten the torx screws to a torque of 200 N�m (147 lb ft). Repeat Step two more times in order to ensure correct torque.

- Tooling to the crankshaft adapter (1). Align the crankshaft pulley (2) with Tooling. Install the crankshaft pulley to the crankshaft adapter (1). Inspect the vibration damper for damage. If necessary, replace the vibration damper.

Align the vibration damper (3) with Tooling. 

- the vibration damper to the crankshaft adapter (1).

- the setscrews (4) to the assembly of the crankshaft pulley, the vibration damper and the crankshaft adapter. Remove Tooling. 

- the remaining setscrew (4). The setscrews should be evenly spaced. Use a suitable tool in order to prevent the crankshaft from rotating. Tighten the setscrews (4) to a torque of 115 N�m (85 lb ft).

- the alternator belt.