Series 55 – Section 1.11 Crankshaft Pulley

Section 1.11
Crankshaft Pulley

Eight bolts secure the crankshaft pulley to the crankshaft. See Figure "Crankshaft Pulley Installation" .‪

Note: Do not substitute any other bolts. Crankshaft pulley bolts are unique parts.

1.Viscous Vibration Damper‪	3.Bolt‪
2.Crankshaft Pulley‪	‪

Figure 1. Crankshaft Pulley Installation

The crankshaft pulley is rigid-designed. Crankshaft pulley bolts are equally spaced. A relief area, machined around each bolt hole, acts as a seating surface. See Figure "Crankshaft Pulley Cross-Section" .‪

Figure 2. Crankshaft Pulley Cross-Section

The crankshaft pulley drives two poly-vee belts. A 3/4 in. square drive hole in the center of the pulley allows a breaker bar or ratchet to be used to bar the engine over. See Figure "Barring Engine Over" .‪

1.Long Handled Breaker‪

2.Crankshaft Pulley‪

Figure 3. Barring Engine Over

Section 1.11.1
Repair or Replacement of Crankshaft Pulley

To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure "Repair or Replacement of Crankshaft Pulley Flowchart" .‪

Figure 4. Repair or Replacement of Crankshaft Pulley Flowchart

Section 1.11.2
Removal of Crankshaft Pulley

Pre-cleaning is not necessary.‪

Remove the crankshaft pulley as follows:‪

1. Remove the drive belts from the crankshaft pulley. Refer to "13.4.7 Drive Belts" .
2. Remove the front engine mount. Refer to "1.1.2 Cleaning and Removal of Cylinder Block" .
3. Remove the inspection plug in the bottom of the flywheel housing.
4. Install the flywheel lock, J 36375-A. See Figure "Flywheel Lock Installation" .
   

   1.Ring Gear‪	3.Flywheel Housing‪
   2.Crankshaft Pulley‪	‪

   Figure 5. Flywheel Lock Installation

5. Thread the center screw of the tool until the top of the tool rests between two teeth of the flywheel ring gear.

   Note: It may be necessary to bar the engine over to position the center screw of the tool between two teeth.

6. Tighten the knurled knob finger-tight.
7. Remove two of the eight crankshaft pulley retaining bolts. (Choose two bolts 180 ° apart).
8. Install two guide studs, J 34691-A, into the empty bolt holes.

   NOTICE:
   Carefully remove the crankshaft pulley. The vibration damper may come off with it. If the damper falls, it may be damaged internally.‪

9. Remove the remaining bolts.
10. Remove the crankshaft pulley by sliding it off the guide studs.

    Note: Leave the guide studs in position to keep the vibration damper in place.

Section 1.11.2.1
Inspection of Crankshaft Pulley

Inspect the crankshaft pulley as follows:‪

1. Inspect the crankshaft pulley.
   1. Determine if the crankshaft pulley is bent, or has broken or cracked edges.
   2. If damage is detected, replace the crankshaft pulley.
2. Inspect the drive belt seat grooves.
   1. Check drive belt seat grooves for bent flanges or a rough belt seating area.
   2. Minor rough seating surfaces can be smoothed with an emery cloth or a stone.
   3. If flanges are bent, replace the crankshaft pulley.
3. Inspect the retaining bolt seat areas.
   1. Check seat area for stress cracks.
   2. If stress cracks are discovered, replace the pulley.
4. Inspect the pulley and vibration damper inner contact surfaces.
   1. Check for galling or burrs.
   2. Minor galls or burrs may be smoothed with an emery cloth.

   NOTICE:
   If the crankshaft pulley is badly damaged, also inspect the vibration damper. Refer to "1.10.2.1 Inspection of Crankshaft Vibration Damper" . A loose or bent crankshaft pulley may also cause a cracked crankshaft. The crankshaft must be inspected. Refer to "1.6.3.1 Inspection of Crankshaft" .‪

   3. If galls or burrs are major, replace the crankshaft pulley.

Section 1.11.3
Installation of Crankshaft Pulley

Install the crankshaft pulley as follows:‪

1. Install the flywheel lock J 36375-A, to the inspection plug hole in the bottom of the flywheel housing. See Figure "Flywheel Lock Installation" .
   

   1.Flywheel‪

   2.Flywheel Housing‪

   Figure 6. Flywheel Lock Installation

   Note: It may be necessary to bar the engine over so that the center screw of the tool is exactly between two teeth. Use tool J 36375-A for this procedure.

2. Thread the center screw of the tool until the tip of the tool rests between two teeth of the flywheel ring gear.
3. Tighten the knurled knob finger-tight.
4. Install two guide studs, J 34691-A, in crankshaft pulley bolt holes 180 ° apart. Apply a light coat of anti-seize compound to the pilot diameter (not the crankshaft face) to ease future removal.
5. Install the crankshaft pulley to the crankshaft. The bolt holes are evenly spaced, so the pulley may be installed in any position.
6. Install four bolts through the pulley and damper, into the crankshaft. Tighten the bolts finger-tight.
7. Remove the guide studs.
8. Install the remaining bolts.
9. Torque the bolts to 200-220 N · m (148-162 lb · ft) torque, proceeding in a clockwise direction.
10. Remove the flywheel lock tool.
11. Install the pipe plug into the flywheel housing inspection hole.
12. Install the drive belts to the crankshaft pulley. Adjust belt tensions to the proper specifications. Refer to "13.4.7 Drive Belts" .
13. Install the front engine mount.
14. Install any other components removed for this operation.