Wednesday, March 14, 2012

How to Replace Crankshaft Damper on Ford Escape and Mercury Mariner?


The procedure is similar for both Ford and Mercury car models:----

The details to replace Crankshaft Damper is as follows:----

Crankshaft Damper
REMOVAL & INSTALLATION:---

2.3L Engine
Specific to:
Ford Escape 2008
Mercury Mariner 2008

NOTE
The following special tools, or their equivalents, are required for this procedure. Camshaft Alignment Plate 303-465 (T94P-6256-CH), Crankshaft Timing Peg 303-057, Drive Pinion Flange Holding Fixture 205-126 (T78P-4851-A), Adapter for 205-126 (205-072-02).


image 

Fig. Special tools required

WARNING
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, which enters the oil passages, coolant passages or the oil pan can cause engine failure.


WARNING
The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Raise and safely support the vehicle.
  3. Remove the front RH wheel and tire.
  4. Remove the accessory drive belt.
  5. Remove the valve cover, as outlined in this section.
    WARNING
    Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  6. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.
    WARNING
    The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.


    NOTE
    The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.



    Click image to see an enlarged view
    Fig. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position
  7. Install camshaft alignment plate 303-465, or equivalent special tool in the slots on the rear of both camshafts.

    Click image to see an enlarged view
    Fig. Install the camshaft alignment plate special tool in the slots on the rear of both camshafts
  8. Remove the engine plug bolt.
    NOTE
    The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.
  9. Install Crankshaft Timing Peg 303-057 or equivalent special tool.

    Click image to see an enlarged view
    Fig. Install Crankshaft Timing Peg 303-057 or equivalent special tool
  10. Install Drive Pinion Flange Holding Fixture 205-126 (T78P-4851-A) and Adapter for 205-126 (205-072-02) or equivalent special tools.
    WARNING
    Failure to hold the crankshaft pulley in place while loosening the bolt can result in damage to the engine.


    WARNING
    If the crankshaft sprocket diamond washer comes off with the crankshaft pulley it must be installed back onto the crankshaft.



    Click image to see an enlarged view
    Fig. Install Drive Pinion Flange Holding Fixture and Adapter special tools
  11. Remove the crankshaft pulley bolt and washer. Discard the bolt.
  12. Remove the crankshaft pulley.
To install:

NOTE
Do not reuse the crankshaft pulley bolt.


NOTE
Apply clean engine oil on the seal area before installing.

  1. Install the crankshaft pulley and hand-tighten the bolt.
    WARNING
    Only hand-tighten the bolt or damage to the front cover can occur.


    NOTE
    The following 2 steps will correctly align the crankshaft pulley to the crankshaft.
  2. Install a standard 6-mm (0.23-in.) x 18-mm (0.7-in.) bolt through the crankshaft pulley and thread it into the front cover.
  3. Rotate the pulley as necessary to align the bolt holes.
    WARNING
    Failure to hold the crankshaft pulley in place while tightening the bolt can cause damage to the engine front cover.
  4. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:

    Stage 1: Tighten to 74 ft. lbs. (100 Nm).
    Stage 2: Tighten an additional 90 degrees (1/4 turn).
  5. Remove the 6-mm (0.23-in.) x 18-mm (0.7-in.) bolt.
  6. Remove the special tools.
    NOTE
    Only turn the engine in the normal direction of rotation.
  7. Turn the engine 2 complete revolutions.
    NOTE
    Only turn the engine in the normal direction of rotation.
  8. Turn the crankshaft until the No. 1 piston is at TDC.
  9. Install the special crankshaft timing peg tool.
    WARNING
    Only hand-tighten the bolt or damage to the front cover can occur. Using the 6-mm (0.23-in.) x 18-mm (0.7-in.) bolt, check the position of the crankshaft pulley. If it is not possible to install the bolt, correct the engine timing.
  10. Using the camshaft alignment plate special tool, check the position of the camshafts. If it is not possible to install the special tool, correct the engine timing.
  11. Remove the 6-mm (0.23-in.) x 18-mm (0.7-in.) bolt.
  12. Install the engine plug bolt and tighten to 15 ft. lbs. (20 Nm).
  13. Install the accessory drive belt.
  14. Install the valve cover.
2.5L Model, Except Hybrid
Specific to:
Ford Escape 2009
Mercury Mariner 2009
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.


    NOTE
    During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure.



    Click image to see an enlarged view
    Fig. Special tool required
  2. With the vehicle in NEUTRAL, position it on a hoist.
  3. Remove the front RH wheel and tire.
  4. Remove the accessory drive belt.
  5. Remove the valve cover.
    NOTE
    Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.


    NOTE
    Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.


    NOTE
    The camshaft alignment plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.


    NOTE
    The camshaft timing slots are offset. If the camshaft alignment plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.



    Click image to see an enlarged view
    Fig. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position
  6. Install the camshaft alignment plate in the slots on the rear of both camshafts.

    Click image to see an enlarged view
    Fig. Install the camshaft alignment plate special tool in the slots on the rear of both camshafts
  7. Remove the engine plug bolt.
    NOTE
    The crankshaft TDC timing peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.
  8. Install the crankshaft TDC timing peg.
    NOTE
    The crankshaft must remain in the Top Dead Center (TDC) position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the crankshaft damper holding tool, and the bolt should be removed using an air impact wrench (1/2-in drive minimum).


    NOTE
    The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced. Remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.



    Click image to see an enlarged view
    Fig. Install Crankshaft Timing Peg 303-057 or equivalent special tool
  9. Use the crankshaft damper holding tool and a suitable 1 / 2 inch drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. 

    Click image to see an enlarged view
    Fig. Crankshaft damper holding tool installed
  10. Remove and discard the crankshaft pulley bolt and washer.
  11. Remove the crankshaft pulley.
  12. Remove the diamond washer and discard.
To install:
  1. Install a new diamond washer.
    NOTE
    Do not install the crankshaft pulley bolt at this time.


    NOTE
    Apply clean engine oil on the seal area before installing.
  2. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
    NOTE
    This step will correctly align the crankshaft pulley to the crankshaft.
  3. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover. Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.
    WARNING
    The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.
  4. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1 / 2 inch drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: 

    Stage 1: Tighten to 100 Nm (74 lb-ft).
    Stage 2: Tighten an additional 90 degrees.
  5. Remove the 6 mm x 18 mm bolt.
  6. Remove the crankshaft TDC timing peg.
  7. Remove the camshaft alignment plate.
    NOTE
    Only turn the engine in the normal direction of rotation.
  8. Turn the crankshaft clockwise one and three-fourths turns.
  9. Install the crankshaft TDC Timing Peg.
  10. Turn the crankshaft clockwise until the crankshaft contacts the crankshaft TDC timing peg.
  11. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
  12. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
  13. Install the camshaft alignment plate to check the position of the camshafts.
  14. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected by repeating this procedure.
  15. Remove the Camshaft Alignment Plate.
  16. Remove the 6 mm x 18 mm bolt.
  17. Remove the Crankshaft TDC Timing Peg.
  18. Install the engine plug bolt and tighten to 15 ft. lbs. (20 Nm).
  19. Install the accessory drive belt.
  20. Install the front RH wheel and tire.
  21. Install the valve cover.
  22. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
3.0L Engine
Specific to:
Ford Escape 2008
Mercury Mariner 2008
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the accessory drive belt.
  3. Remove the splash shield.
  4. Install the Strap Wrench 303-D055 (D85L-6000-A), or equivalent special tool.

    Click image to see an enlarged view
    Fig. Install the strap wrench to hold the crankshaft pulley stationary
  5. Remove the crankshaft pulley bolt and washer.
  6. Using the Crankshaft Vibration Damper Remover 303-009 (T58P-6316-D) or equivalent special tool, remove the crankshaft pulley.

    Click image to see an enlarged view
    Fig. Using the Crankshaft Vibration Damper Remover tool to remove the crankshaft pulley
To install:

NOTE
Clean the keyway and slot using metal surface cleaner before applying silicone gasket and sealer.


NOTE
The crankshaft pulley must be installed and the bolt tightened within four minutes of applying the silicone gasket and sealer.

  1. Apply silicone gasket and sealant to the end of the keyway slot.
    NOTE
    Lubricate the outside diameter sealing surface of the crankshaft pulley with clean engine oil.



    Click image to see an enlarged view
    Fig. Apply silicone gasket and sealant to the end of the keyway slot
  2. Using Crankshaft Vibration Damper Installer 303-102 (T74P-6316-B) or equivalent special tool, install the crankshaft pulley.
    NOTE
    Use an appropriate strap wrench to hold the crankshaft pulley.



    Click image to see an enlarged view
    Fig. Using Crankshaft Vibration Damper Installer 303-102 (T74P-6316-B) or equivalent special tool, install the crankshaft pulley
  3. Install the bolt and the washer and tighten in four stages:

    Stage 1: Tighten to 89 ft. lbs. (120 Nm).
    Stage 2: Loosen 360 degrees.
    Stage 3: Tighten to 37 ft. lbs. (50 Nm).
    Stage 4: Tighten an additional 90 degrees.
  4. Install RH front inner splash shield. Tighten the retainers to 80 inch lbs. (9 Nm).
  5. Install the accessory drive belt.
Specific to:
Ford Escape 2009
Mercury Mariner 2009
  1. Before servicing the vehicle, refer to the Precautions Section
  2. With the vehicle in NEUTRAL, position it on a hoist.
  3. Remove the accessory drive belt.
  4. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
  5. Using the 3 Jaw Puller, remove the crankshaft pulley.

    Click image to see an enlarged view
    Fig. 3 Jaw puller shown installed
To install:
  1. Lubricate the crankshaft front seal inner lip with clean engine oil.
    NOTE
    Clean the keyway and slot using metal surface prep before applying silicone gasket and sealant. The crankshaft pulley must be installed and the bolt tightened within 4 minutes of applying the silicone gasket and sealant.
  2. Apply silicone gasket and sealant to the end of the keyway slot.
  3. Lubricate the outside diameter sealing surface with clean engine oil.
  4. Using the crankshaft vibration damper installer, install the crankshaft pulley.

    Click image to see an enlarged view
    Fig. Crankshaft vibration damper shown installed
  5. Install the bolt and washer.
  6. Tighten the bolt in 4 stages:

    Stage 1: Tighten to 120 Nm (89 lb-ft).
    Stage 2: Loosen one full turn.
    Stage 3: Tighten to 50 Nm (37 lb-ft).
    Stage 4: Tighten an additional 90 degrees.
  7. Install the accessory drive belt.
Hybrid Model
Specific to:
Ford Escape 2009
Mercury Mariner 2009

CAUTION
Before proceeding, read and observe all of the High Voltage System Precautions.


WARNING
Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.


NOTE
During engine repair procedures, cleanliness is extremely important. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages, coolant passages or the oil pan can cause engine failure.



Click image to see an enlarged view
Fig. Special tool required
  1. With the vehicle in NEUTRAL, position it on a hoist.
  2. Remove the front RH wheel and tire.
  3. Remove the accessory drive belt.
  4. Remove the valve cover.
    NOTE
    Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.


    NOTE
    Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.


    NOTE
    The camshaft alignment plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.


    NOTE
    The camshaft timing slots are offset. If the camshaft alignment plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.



    Click image to see an enlarged view
    Fig. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC. The hole in the crankshaft pulley should be in the 6 o'clock position
  5. Install the camshaft alignment plate in the slots on the rear of both camshafts.

    Click image to see an enlarged view
    Fig. Install the camshaft alignment plate special tool in the slots on the rear of both camshafts
  6. Remove the engine plug bolt.
    NOTE
    The crankshaft TDC timing peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.
  7. Install the crankshaft TDC timing peg.
    NOTE
    The crankshaft must remain in the Top Dead Center (TDC) position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the crankshaft damper holding tool, and the bolt should be removed using an air impact wrench (1/2-in drive minimum).


    NOTE
    The crankshaft sprocket diamond washer may come off with the crankshaft pulley. The diamond washer must be replaced. Remove and discard the diamond washer. If the diamond washer is not installed, engine damage may occur.



    Click image to see an enlarged view
    Fig. Install Crankshaft Timing Peg 303-057 or equivalent special tool
  8. Use the crankshaft damper holding tool and a suitable 1 / 2 inch drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt. 

    Click image to see an enlarged view
    Fig. Crankshaft damper holding tool installed
  9. Remove and discard the crankshaft pulley bolt and washer.
  10. Remove the crankshaft pulley.
  11. Remove the diamond washer and discard.
To install:
  1. Install a new diamond washer.
    NOTE
    Do not install the crankshaft pulley bolt at this time.


    NOTE
    Apply clean engine oil on the seal area before installing.
  2. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
    NOTE
    This step will correctly align the crankshaft pulley to the crankshaft.
  3. Install a 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover. Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.
    WARNING
    The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.
  4. Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding Tool and a suitable 1 / 2 inch drive hand tool to hold the crankshaft pulley, tighten the crankshaft pulley bolt in 2 stages: 

    Stage 1: Tighten to 100 Nm (74 lb-ft).
    Stage 2: Tighten an additional 90 degrees.
  5. Remove the 6 mm x 18 mm bolt.
  6. Remove the crankshaft TDC timing peg.
  7. Remove the camshaft alignment plate.
    NOTE
    Only turn the engine in the normal direction of rotation.
  8. Turn the crankshaft clockwise one and three-fourths turns.
  9. Install the crankshaft TDC Timing Peg.
  10. Turn the crankshaft clockwise until the crankshaft contacts the crankshaft TDC timing peg.
  11. Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
  12. If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
  13. Install the camshaft alignment plate to check the position of the camshafts.
  14. If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected by repeating this procedure.
  15. Remove the Camshaft Alignment Plate.
  16. Remove the 6 mm x 18 mm bolt.
  17. Remove the Crankshaft TDC Timing Peg.
  18. Install the engine plug bolt and tighten to 177 inch lbs. (20 Nm).
  19. Install the accessory drive belt.
  20. Install the front RH wheel and tire.
  21. Install the valve cover.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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