Wednesday, March 14, 2012

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


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

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

Crankshaft Damper (Balancer)
REMOVAL & INSTALLATION:-----
2.3L Engine
Specific to:
Ford Escape 2006-2008
Mercury Mariner 2006-2008

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).


WARNING
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.


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. Raise and safely support the vehicle.
  2. Remove the accessory drive belt.
  3. 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.
  4. 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.



    image
    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 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
  6. 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.
  7. 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
  8. 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
  9. Remove the crankshaft pulley bolt and washer. Discard the bolt.
  10. 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:
    1. Stage 1: Tighten to 74 ft. lbs. (100 Nm).
    2. 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.
    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).
  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.
3.0L Engine
Specific to:
Ford Escape 2006-2008
Mercury Mariner 2006-2008
  1. Remove the accessory drive belt.
  2. Remove the splash shield.
  3. 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
  4. Remove the crankshaft pulley bolt and washer.
  5. 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.
    1. Stage 1: Tighten to 89 ft. lbs. (120 Nm).
    2. Stage 2: Loosen 360 degrees.
    3. Stage 3: Tighten to 37 ft. lbs. (50 Nm).
    4. 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.



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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