4010

Ford 2.3 / 2.5L SOHC

Power Pulley Installation

Remove old pulley.

Install new pulley and torque bolt to 100-120 lbs/ft.

Install your pointer.

Mark pulley in line with pointer at absolute TDC.

Check cam and ignition timing.

Find absolute TDC, using a degree wheel.

With head on:

1. Mark and remove rockers to prevent valves from touching pistons.

2. Install a piston stop, into the number 1 spark plug hole.

3. Adjust stop so that piston will be stopped slightly down in bore.

4. Slowly rotate engine until piston hits stop. Do this softly.

5. Set pointer on degree wheel to zero, rotate engine back until piston hits stop.

6. Read number of degrees between pointer and zero, divide by 2.

7. Add to degrees shown at pointer, subtract from zero.

8. Remove piston stop, bring piston up till the pointer is at calculated degree mark.

9. Mark the new power pulley for TDC using the edge of a small fine file.

10. Make the mark approximately 1/16” wide.

With head off:

1. Install a piston stop on the number 1 cylinder.

2. Follow steps # 3 thru 10.

Find absolute TDC, w/o a degree wheel.

Follow steps 1 thru 4 as above.

5. Make a temporary mark on pulley.

6. Slowly rotate engine back until piston hits stop.

7. Make another temporary mark on pulley.

8. Split the distance between marks, this will be TDC.

9. Mark the new power pulley for TDC using the edge of a small fine file.

10. Make the mark approximately 1/16” wide.

11/28/2011