Ford Explorer: Engine - 2.3L EcoBoost (201kW/273PS) / 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 |
Materials
Name |
Specification |
Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound XG-3-A |
ESE-M1C171-A
|
Removal
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.
-
With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
-
Remove the bolts and the suspension support bar.
-
NOTICE:
Do not pull the engine appearance cover forward or
sideways to remove. Failure to press straight upward on the underside of
the cover at the attachment points may result in damage to the cover or
engine components.
-
Remove the engine appearance cover nuts.
-
Place your hand under the engine appearance cover at
the grommet location and push straight up to release the grommet from
the stud.
-
After the grommet has been released from the stud, remove the appearance cover from the engine.
-
Remove the following items:
-
Remove the cowl panel.
Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
-
Remove the air cleaner.
Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
-
Remove the accessory drive belt.
Refer to: Accessory Drive Belt (303-05A Accessory Drive - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
-
Remove the air cleaner inlet tube.
-
-
Detach the EVAP canister tube retainer.
-
Detach the coolant hose and wiring harness retainers.
-
Remove the bolts and the air cleaner bracket.
-
-
Remove pin-type retainer.
-
Remove the bolts and the underbody shield.
-
-
Disconnect the CKP sensor electrical connector.
-
Remove the bolts and the CKP sensor.
-
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 - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
-
NOTE:
Exhaust camshaft shown, intake camshaft similar.
NOTE:
The camshaft trigger wheels are offset. If the
camshaft trigger wheels are not correctly aligned, the camshaft holding
tools will not be able to be installed in the next step.
Make sure the camshaft trigger wheels are correctly
aligned as shown. If the trigger wheels are not correctly aligned,
remove the TDC Timing Peg and rotate the crankshaft three-fourths of a
revolution clockwise and repeat steps 11 and 12 of this removal
procedure.
-
NOTE:
Removing the O-ring seals will aid in the installation of 303-1686.
Remove the O-ring seals from 303-1686.
Use Special Service Tool: 303-1686
Holding Tool, Camshaft.
-
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
-
Lubricate the crankshaft pulley with clean engine oil.
-
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 finger tight.
-
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.
With the aid of an assistant and 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 and tighten the bolts.
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)
-
Remove Special Service Tool: 303-1686
Holding Tool, Camshaft.
-
Install the O-ring seals on 303-1686.
-
Install the RH and LH CMP sensors.
Refer to: Camshaft Position (CMP) Sensor (303-14A Electronic Engine Controls - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
-
-
Install the underbody shield and the bolts.
Torque:
22 lb.in (2.5 Nm)
-
Install pin-type retainer.
-
-
Install the air cleaner bracket and the bolts.
Torque:
59 lb.ft (80 Nm)
-
Attach the coolant hose and wiring harness retainers.
-
Attach the EVAP canister tube retainer.
-
Install the air cleaner inlet tube.
-
Install the following items:
-
Install the accessory drive belt.
Refer to: Accessory Drive Belt (303-05A Accessory Drive - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
-
Install the air cleaner.
Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
-
Install the cowl panel.
Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
-
-
NOTE:
Lubricating the grommets with silicone grease
will aid in the installation of the engine appearance cover, and any
future removal and installation of the cover.
Lubricate each grommet with silicone grease.
Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound
/ XG-3-A
(ESE-M1C171-A)
-
Position the engine appearance cover onto engine with the grommet aligned with the stud.
-
Press down on the engine appearance cover at the
grommet location to attach the grommet onto the stud and install the
nuts.
Torque:
44 lb.in (5 Nm)
-
Install the suspension support bar and the bolts.
Torque:
22 lb.ft (30 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-199..
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
Motorcraf..
Other information:
Special Tool(s) /
General Equipment
Interior Trim Remover
Removal
NOTE:
Removal steps in this procedure may contain installation details.
Remove the upper instrument trim panel.
Remove the screws.
Torque:
22 lb.in (2...
2.3L EcoBoost (201kW/273PS)
Item
Specification
Fuel Pressure
58.0
–75.4
psi (
400
–520
kPa)
Fuel Tank Capacity
17.90
gal (
67...
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