Ford Escape: Engine / Removal and Installation - Crankshaft Pulley

Special Tool(s) / General Equipment

	303-1416 Tool, Crank Damper Holding TKIT-2008ET-FLM
	303-1699 Tool, Crank Sensor Alignment
	303-465 Tool, Camshaft Align Timing TKIT-1994-LMH/MH2 TKIT-1994-FH/FMH/FLMH
	303-507 Timing Peg, Crankshaft TDC TKIT-2001N-FLM TKIT-2001N-ROW
Trolley Jack
Wooden Block

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.

1. Remove the RHF fender splash shield.
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the valve cover.
   Refer to: Valve Cover (303-01C Engine, Removal and Installation).
   

1. Remove the bolts and the CKP sensor.
   

1. Release the tabs and remove the crankshaft pulley cover.
   

1. NOTE: Failure to position the No. 1 piston at TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.

   
   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.
     

1. Remove the engine plug bolt.
   

1. 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 disassembly.

   • Install Special Service Tool: 303-507  Timing Peg, Crankshaft TDC.
   • Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC .
     

1. Remove the bolts and position the EGR cooler inlet tube aside.
   

1. Remove and discard the EGR cooler inlet tube gasket.
   

1. Remove the bolts and position the EGR cooler aside.
   

1. 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.

   Install Special Service Tool: 303-465  Tool, Camshaft Align Timing.

1. Position the jack and wooden block under the front of the oil pan to support the engine.
   Use the General Equipment: Trolley Jack
   Use the General Equipment: Wooden Block

1. Remove and discard the engine mount nuts.
   

1. Lower the engine 88.9 mm ( 3.5 inches ).
   

1. Install Suggested Tool: 303-1416  Tool, Crank Damper Holding. Tool shown or a commercially available equivalent can be used.
   Use Special Service Tool: 303-507  Timing Peg, Crankshaft TDC.

1. NOTE: 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 Crankshaft Damper Holding Tool, and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

   NOTE: If equipped, the crankshaft sprocket diamond washer may come off with the crankshaft pulley.

   NOTE: Use an air impact wrench to remove the crankshaft pulley bolt.

   
   Use the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley. Use an air impact wrench to remove the crankshaft pulley bolt.
   
   • Remove and discard the crankshaft pulley bolt and washer.
     
   • Remove the crankshaft pulley.
     Use Special Service Tool: 303-1416  Tool, Crank Damper Holding.

Installation

1. NOTE: Do not install the crankshaft pulley bolt at this time.

   NOTE: Component(s) must be lubricated with clean engine oil.

   Lubricate the crankshaft pulley oil sealing surface with clean engine oil and install the crankshaft pulley.
   Refer to: Specifications (303-01C Engine, Specifications).
   

1. NOTE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover can occur.

   NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

   Install an M6 bolt.
   

1. NOTE: 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 Crankshaft Damper Holding Tool and the bolt should be installed using hand tools only.

   NOTE: Install a new crankshaft pulley bolt.

   • Install a new crankshaft pulley bolt. Use the Crankshaft Damper Holding tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley.
     
   • Tighten the crankshaft pulley bolt in 2 stages.
     Use Special Service Tool: 303-1416  Tool, Crank Damper Holding.
     Torque:
       Stage 1:  74 lb.ft (100 Nm)
       Stage 2:  90 °

1. Remove the M6 bolt.
   

1. Remove Special Service Tool: 303-507  Timing Peg, Crankshaft TDC.

1. Remove Special Service Tool: 303-465  Tool, Camshaft Align Timing.

1. NOTE: Only turn the engine in the normal direction of rotation.

   Turn the crankshaft clockwise one and three-fourth turns.
   

1. NOTE: Only turn the engine in the normal direction of rotation.

   Install Special Service Tool: 303-507  Timing Peg, Crankshaft TDC.

1. NOTE: Only hand-tighten the bolt or damage to the front cover can occur.

   
   Install an M6 bolt, check the position of the crankshaft pulley.
   
   • If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this procedure.
     

1. NOTE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

   NOTE: If it is not possible to install the Camshaft Alignment Plate, the engine valve timing must be corrected.

   Install Special Service Tool: 303-465  Tool, Camshaft Align Timing.

1. Remove Special Service Tool: 303-465  Tool, Camshaft Align Timing.

1. Remove the M6 bolt.
   

1. NOTE: Only tighten the bolts finger tight at this stage.

   Install the CKP sensor and the bolts.
   

1. If the special service tool mark does not align with the TDC marked tooth on the crankshaft pulley, loosen the CKP sensor bolts and adjust the sensor until the tool is installed then tighten.
   Use Suggested Tool: 303-1699  Tool, Crank Sensor Alignment. Tool shown or a commercially available equivalent can be used.
   Torque: 62 lb.in (7 Nm)

1. Remove Special Service Tool: 303-1699  Tool, Crank Sensor Alignment.

1. Remove Special Service Tool: 303-507  Timing Peg, Crankshaft TDC.

1. Install the engine plug bolt.
   Torque: 177 lb.in (20 Nm)

1. Inspect the crankshaft pulley cover tabs for damage replace if necessary.
   

1. Install the crankshaft pulley cover.
   

1. Raise the engine.
   

1. Install the new engine mount nuts.
   Torque: 81 lb.ft (110 Nm)

1. Remove the jack and wooden block from under the engine.
   Use the General Equipment: Trolley Jack
   Use the General Equipment: Wooden Block

1. Inspect the EGR cooler O-ring seal replace if necessary.
   

1. NOTE: Component(s) must be lubricated with clean engine oil.

   Lubricate the new EGR cooler O-ring with a small amount of engine oil.
   

1. Position back the EGR cooler.
   Torque: 89 lb.in (10 Nm)

1. Install the EGR assembly bolt and hand tighten the bolt at this stage.
   

1. Install the EGR assembly mounting bolt.
   Torque: 89 lb.in (10 Nm)

1. Install the EGR assembly bolts and hand tighten the bolts at this stage.
   

1. Tighten in the sequence shown.
   Torque:
      1:   89 lb.in (10 Nm)
      2:   89 lb.in (10 Nm)
      3:   18 lb.ft (25 Nm)

1. This step only necessary if the water outlet housing was removed or loosened.
   Tighten in the sequence shown.
   Torque:
     Stage 1:  89 lb.in (10 Nm)
     Stage 2:  45°

1. Install the new EGR cooler inlet tube gasket.
   

1. Position back the EGR cooler inlet tube and install the bolts hand tight. Torque: 22 lb.ft (30 Nm)

1. Tighten in the sequence shown.
   Torque:
      1:   89 lb.in (10 Nm)
      2:   18 lb.ft (24 Nm)
      1:   18 lb.ft (24 Nm)

1. Install the valve cover.
   Refer to: Valve Cover (303-01C Engine, Removal and Installation).
   

1. Install the RHF fender splash shield.
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. After completing repairs, perform the Misfire Monitor Neutral Profile Correction procedure using a diagnostic scan tool.