Lincoln Corsair: Engine - 2.0L EcoBoost (177kW/240PS) – MI4 / Removal and Installation - Crankshaft Pulley
Special Tool(s) /
General Equipment
|
303-1521 Alignment Tool, Crankshaft Position Sensor TKIT-2010C-FLM |
|
303-1686 Holding Tool, Camshaft |
|
303-1689 Holding Tool, Crank Damper |
|
303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW |
Removal
LHD AWD/LHD FWD
NOTICE:
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. 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.
NOTICE:
During engine repair procedures, cleanliness is
extremely important. All parts must be thoroughly cleaned and 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.
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With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
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Remove the retainers and the underbody shield.
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Remove the RH fender splash shield.
Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
LHD AWD
-
Remove the AWD RH halfshaft.
Refer to: Front Halfshaft RH - AWD (205-04 Front Drive Halfshafts, Removal and Installation).
-
Remove the bolts and the transfer case support bracket.
LHD FWD
-
Remove the FWD RH halfshaft.
Refer to: Front Halfshaft RH - 2.0L EcoBoost (177kW/240PS) – MI4, FWD
(205-04 Front Drive Halfshafts, Removal and Installation).
-
Remove the bolts and the halfshaft support bracket.
LHD AWD/LHD FWD
-
Remove the accessory drive belt.
Refer to: Accessory Drive Belt (303-05B Accessory Drive - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
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If equipped, release the tabs and remove the crankshaft pulley cover.
-
If equipped, inspect the 3 crankshaft pulley cover
tabs for damage, if damaged replace the crankshaft pulley cover.
-
-
Disconnect the CKP sensor electrical connector.
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Remove the bolts and the CKP sensor.
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Turn the crankshaft clockwise until the No.1 piston is 45 degrees BTDC
using the guide holes on the engine front cover and the crankshaft
pulley.
-
Remove the engine plug bolt.
-
Install Special Service Tool: 303-507
Timing Peg, Crankshaft TDC.
-
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.
NOTE:
The engine front cover is removed from graphic for clarity.
Rotate the crankshaft clockwise until the contacts the special tool.
Use Special Service Tool: 303-507
Timing Peg, Crankshaft TDC.
-
Remove the RH and LH CMP sensors.
Refer to: Camshaft Position (CMP) Sensor (303-14A Electronic Engine
Controls - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
-
NOTE:
Exhaust camshaft shown, intake camshaft similar.
Make sure the camshaft trigger wheels are aligned as shown.
-
NOTE:
Removing the O-ring seals will aid in the installation of 303-1686.
Remove the O-ring seals from 303-1686.
-
NOTICE:
The Camshaft Alignment Tool is for camshaft
alignment only. Using this tool to prevent engine rotation can result in
engine damage.
NOTICE:
Do not force the camshaft holding tool into the
valve cover or damage can result to the camshaft trigger wheels.
NOTE:
The camshaft trigger wheels are offset. If the Camshaft Holding Tools cannot be installed, remove the TDC
Timing Peg and rotate the crankshaft three-fourths of a revolution
clockwise and repeat steps 10 and 11 of this removal procedure.
Install Special Service Tool: 303-1686
Holding Tool, Camshaft.
-
NOTICE:
The crankshaft must remain in the 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
Crank Damper Holding Tool and the bolt should be removed using an air
impact wrench (1/2-in drive minimum).
-
Using the special tool, remove the bolt, washer and the crankshaft pulley.
Use Special Service Tool: 303-1689
Holding Tool, Crank Damper.
Installation
LHD AWD/LHD FWD
-
Lubricate the crankshaft pulley with clean engine oil.
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Position the crankshaft pulley onto the crankshaft with the access hole at the 6 o'clock position.
-
NOTE:
This step will correctly align the crankshaft pulley to the crankshaft.
Install an M6 bolt.
-
NOTICE:
The crankshaft must remain in the 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 Crank Damper Holding Tool and the bolt should be installed
using hand tools only.
Using the special tool, install the new crankshaft bolt and washer and tighten.
Use Special Service Tool: 303-1689
Holding Tool, Crank Damper.
Torque:
Stage 1:
74 lb.ft (100 Nm)
Stage 2:
90°
-
Remove the M6 bolt.
-
NOTE:
Do not tighten the CKP sensor bolts at this time.
Install the CKP sensor and the bolts finger tight.
-
Install the special tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel.
Use Special Service Tool: 303-1521
Alignment Tool, Crankshaft Position Sensor.
Torque:
97 lb.in (11 Nm)
-
Remove Special Service Tool: 303-1521
Alignment Tool, Crankshaft Position Sensor.
-
Connect the CKP sensor electrical connector.
-
NOTICE:
Do not rotate the crankshaft until the special tools 303-1686 are removed from the valve cover.
Remove Special Service Tool: 303-507
Timing Peg, Crankshaft TDC.
-
Install the engine plug bolt.
Torque:
177 lb.in (20 Nm)
-
If equipped.
-
Align and insert 2 tabs of the crankshaft pulley
cover into the open spaces between the ribs of the crankcase pulley.
-
Press the third tab firmly into position until a snap is heard or felt.
-
Verify that the crankshaft pulley cover is securely in place.
-
Remove Special Service Tool: 303-1686
Holding Tool, Camshaft.
-
Install the O-ring seals on 303-1686.
-
Install the following items:
-
Install the RH and LH CMP sensors.
Refer to: Camshaft Position (CMP) Sensor (303-14A Electronic Engine
Controls - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
-
Install the accessory drive belt.
Refer to: Accessory Drive Belt (303-05B Accessory Drive - 2.3L EcoBoost (199kW/270PS), Removal and Installation).
LHD FWD
-
Install the halfshaft support bracket and the bolts.
Torque:
35 lb.ft (48 Nm)
-
Install the FWD RH halfshaft.
Refer to: Front Halfshaft RH - 2.0L EcoBoost (177kW/240PS) – MI4, FWD
(205-04 Front Drive Halfshafts, Removal and Installation).
LHD AWD
-
Install the transfer case support bracket and the bolts.
Torque:
35 lb.ft (48 Nm)
-
Install the AWD RH halfshaft.
Refer to: Front Halfshaft RH - AWD (205-04 Front Drive Halfshafts, Removal and Installation).
LHD AWD/LHD FWD
-
Install the RH fender splash shield.
Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
-
Install the underbody shield and the retainers.
Torque:
13 lb.in (1.5 Nm)
-
Use the Powertrain Control Module (PCM) Misfire
Monitor Profile Correction routine in the diagnostic scan tool.
Special Tool(s) /
General Equipment
303-096
(T74P-6150-A)
Installer, Camshaft Front Oil SealTKIT-2009TC-F
303-409
(T92C-6700-CH)
Remover, Crankshaft SealTKIT-1992-FH/FMH/FLMHTKIT-1993-LMH/MH
Removal
NOTICE:
During engine repair procedures, cleanliness is extremely
important...
Special Tool(s) /
General Equipment
303-328
(T88P-6701-B1)
Replacer, Rear SealTKIT-1988-FLMTKIT-1988-FTKIT-1988-LM
Oil Drain Equipment
Materials
Name
Specification
Motorcraft® High Performance Engine RTV SiliconeTA-357
WSE-M4G323-A6
Removal
Remove the flexplate...
Other information:
System Operation
Emergency Locking Retractor (ELR)
All
retractors have an Emergency Locking Retractor (ELR) mode, which is a
vehicle-sensitive feature designed to activate and lock the seatbelt
webbing during hard braking, cornering, or an impact of approximately 24
km/h (15 mph)...
Removal
WARNING:
The following procedure prescribes critical repair steps
required for correct restraint system operation during a crash. Follow
all notes and steps carefully. Failure to follow step instructions may
result in incorrect operation of the restraint system and increases the
risk of serious personal injury or death in a crash...