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Saturday, October 29, 2011

How to Replace Harmonic balancer on 2003 Ford Focus?

A harmonic balancer (also called crank pulley damper, crankshaft damper, torsional damper, or vibration damper) is a device connected to the crankshaft.



Crankshaft Damper (HARMONIC Balancer)









Removal & Installation



2.0L (VIN 3 & VIN 5) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  3. Remove the accessory drive belt.
  4. Raise and support the vehicle.
  5. Detach the drive belt splash shield.
  6. Hold the crankshaft pulley with a suitable pulley holding device and remove the bolt.
  7. Remove the pulley.
To install:
  1. Clean the pulley/damper mounting bore and crankshaft snout.
  2. Install or connect the following:

    Pulley/damper with hand pressure and tighten the bolt to 85 ft. lbs. (115 Nm)
    Accessory drive belt
    Accessory drive belt splash shield
    Negative battery cable
2.0L (VIN N) & 2.3L (VIN Z) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    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.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  3. Remove or disconnect the following:

    Accessory drive belt
    Valve cover
  4. Position the engine so that the number 1 piston is at top dead center (TDC).
    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.
  5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
  6. Install special tool 303-465 (or a suitable DOHC camshaft alignment tool) to maintain alignment between the two camshafts.
    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.
  7. Remove the plug bolt.
  8. Install special tool 303-507 or a suitable peg to prevent engine rotation.
    NOTE
    Special tool 303-507 will prevent the engine from being rotated in the clockwise direction. However, the engine can still be rotated in the counterclockwise direction.


    WARNING
    Failure to hold the crankshaft pulley in place during bolt loosening can result in damage to the engine.
  9. Install special tools 205-126 and 205-072-02 or a suitable crankshaft pulley holder to prevent the engine from turning.
  10. Remove the crankshaft pulley bolt.
  11. Remove the special tools.
  12. Remove the crankshaft pulley.

    Click image to see an enlarged view
    Fig. Location of crankshaft plug bolt.


    Click image to see an enlarged view
    Fig. Use of special tool 303-507, camshaft holding tool.
To install:

NOTE
Do not reuse the crankshaft damper bolt.

  1. Apply clean engine oil on the seal area before installing.
  2. Install the crankshaft pulley and hand-tighten the bolt.
    WARNING
    Only hand-tighten the bolt or damage to the front cover can occur.


    NOTE
    This step will correctly align the crankshaft pulley to the crankshaft.
  3. 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.
  4. Rotate the pulley as necessary to align the bolt holes.
    WARNING
    Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.
  5. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in two stages:

    Stage 1: Tighten to 74 ft. lbs. (100 Nm)
    Stage 2: Tighten an additional 90 degrees (1/4 turn)
  6. Remove the special tools.
  7. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
  8. Remove special tool 303-507, camshaft holder.
    NOTE
    Only turn the engine in the normal direction of rotation.
  9. Turn the engine two complete revolutions.
  10. Turn the crankshaft until the No. 1 piston is at top dead center (TDC).
  11. Install the plug bolt and tighten to 15 ft. lbs. (20 Nm)
  12. Install the valve cover.
  13. Install the accessory drive belt.
  14. Reconnect the negative battery cable.
2.3L (VIN Z) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    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.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  3. Remove or disconnect the following:

    Accessory drive belt
    Valve cover
  4. Position the engine so that the number 1 piston is at top dead center (TDC).
    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.
  5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
  6. Install special tool 303-465 (or a suitable DOHC camshaft alignment tool) to maintain alignment between the two camshafts.
    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.
  7. Remove the plug bolt.
  8. Install special tool 303-507 or a suitable peg to prevent engine rotation.
    NOTE
    Special tool 303-507 will prevent the engine from being rotated in the clockwise direction. However, the engine can still be rotated in the counterclockwise direction.


    WARNING
    Failure to hold the crankshaft pulley in place during bolt loosening can result in damage to the engine.
  9. Install special tools 205-126 and 205-072-02 or a suitable crankshaft pulley holder to prevent the engine from turning.
  10. Remove the crankshaft pulley bolt.
  11. Remove the special tools.
  12. Remove the crankshaft pulley.

    Click image to see an enlarged view
    Fig. Location of crankshaft plug bolt.


    Click image to see an enlarged view
    Fig. Use of special tool 303-507, camshaft holding tool.
To install:

NOTE
Do not reuse the crankshaft damper bolt.

  1. Apply clean engine oil on the seal area before installing.
  2. Install the crankshaft pulley and hand-tighten the bolt.
    WARNING
    Only hand-tighten the bolt or damage to the front cover can occur.


    NOTE
    This step will correctly align the crankshaft pulley to the crankshaft.
  3. 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.
  4. Rotate the pulley as necessary to align the bolt holes.
    WARNING
    Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.
  5. Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in two stages:

    Stage 1: Tighten to 74 ft. lbs. (100 Nm)
    Stage 2: Tighten an additional 90 degrees (1/4 turn).
  6. Remove the special tools.
  7. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
  8. Remove special tool 303-507, camshaft holder.
    NOTE
    Only turn the engine in the normal direction of rotation.
  9. Turn the engine two complete revolutions.
  10. Turn the crankshaft until the No. 1 piston is at top dead center (TDC).
  11. Install the plug bolt and tighten to 15 ft. lbs. (20 Nm)
  12. Install the valve cover.
  13. Install the accessory drive belt.
  14. Reconnect the negative battery cable.

-----------
For more car related problem troubleshooting:---

This are the sections, you can go through and click the link to read its troubleshooting.

---------

The car will not start?

http://schematicsdiagram.blogspot.com/2011/06/car-will-not-start.html
-----------------

Car will not crank?

http://schematicsdiagram.blogspot.com/2011/06/car-will-not-crank.html

-----------

Car has no spark?

http://schematicsdiagram.blogspot.com/2011/06/car-has-no-spark.html

-------------

How to troubleshoot car battery?

http://schematicsdiagram.blogspot.com/2011/06/how-to-troubleshoot-car-battery.html
-----------------

How to test starter solenoid?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-starter-solenoid.html

--------------------

How to test cars starter?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-cars-starter.html

How to replace starter in car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-replace-starter-in-car.html


-----------

car will turn over but will not start?


http://technoanswers.blogspot.com/2011/05/car-will-turn-over-but-will-not-start.html

-----------------

Car wont start?

http://howtobyme.blogspot.com/2011/10/car-wont-start.html

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Posted by Hemant somaiya at 8:02 PM
Labels: balancer diagrams for ford focus, FORD crankshaft damper removal, Harmonic balancer on 2003 Ford Focus, harmonic balancer removal on ford focus, removing ford harmonic balancer

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