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Old 06-23-2006, 11:41 AM   #9
CFM Focus
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Join Date: Jun 2002
Location: www.c-f-m.com
Posts: 1,481

Default Re: Duratec UDPs - We need your input!

Thanks for the input so far! Here is a rough draft on the instructions:

PLEASE FOLLOW THE FOLLOWING INSTRUCTIONS VERY CAREFULLY OR SEVERE ENGINE DAMAGE WILL OCCUR.
  1. Remove accessory drive belt
  2. Remove valve cover
  3. Remove spark plugs
  4. Rotate crankshaft CLOCKWISE until you start to feel pressure building up
  5. Continue to rotate until you can insert the supplied camshaft alignment plate on the rear slots of the camshafts
  6. Remove plug bolt from side of engine block and insert supplied timing peg which keeps the crankshaft from turning clockwise.
  7. Insert supplied M6 bolt through factory crankshaft pulley and into threaded hole in timing cover. Rotate the pulley as necessary to align holes. HAND TIGHTEN ONLY AS DAMAGE TO TIMING COVER CAN OCCUR OTHERWISE!
  8. Using the supplied plate, hold the crankshaft pulley in place while removing the crankshaft pulley bolt
  9. Remove plate and M6 bolt and then remove pulley
  10. Install new pulley and new bolt. Hand tighten bolt only. DO NOT USE ORIGINAL BOLT!
  11. Insert supplied M6 bolt through factory crankshaft pulley and into threaded hole in timing cover. Rotate the pulley as necessary to align holes.

    WARNING: Failure to hold crankshaft pulley in place during CRANKSHAFT PULLEY BOLT tightening will result in engine damage!
  12. Using the supplied plate, hold the crankshaft pulley in place while tightening the crankshaft pulley bolt in TWO stages:

    1. Tighten to 74ft/lb
    2. Tighten an additional 90 degrees
  13. Remove plate and M6 bolt from pulley
  14. Remove timing peg from block
  15. Remove camshaft alignment plates
  16. Turn the engine CLOCKWISE two complete revolutions
  17. Insert supplied M6 bolt through factory crankshaft pulley and into threaded hole in timing cover. Rotate the pulley as necessary to align holes.
  18. Install timing peg on block
  19. Insert camshaft alignment plates

    If it is not possible to accomplish ALL of the 3 steps above after rotating the crankshaft two revolutions then camshaft timing is off and MUST be fixed before starting engine!
  20. Install factory plug bolt on block
  21. Install spark plugs
  22. Install valve cover
  23. Install accessory drive belt
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