Engine Crankshaft - Pulley Bolt Service Precautions
TSB 06-21-410/30/06
2.3L/2.0L DURATEC - NO START/POSSIBLE ENGINE
DAMAGE - INSTALL SPECIAL SERVICE TOOLS
PRIOR TO REMOVING CRANKSHAFT PULLEY BOLT
FORD:
2003-2007 Focus
2006-2007 Fusion
2001-2007 Ranger
2005-2007 Escape Hybrid, Escape
MERCURY:
2006-2007 Milan
2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 06-16-6 to include symptoms, labor operations, and parts.
ISSUE
Some 2001-2007 MY vehicles equipped with a 2.0L or 2.3L Duratec Engine may exhibit no start, loss of engine timing or scraping noise at crankshaft pulley at front of engine. These engines, (excludes 2.0L SPI and Zetec engines) may experience engine damage if the crankshaft pulley bolt is loosened during service WITHOUT FIRST INSTALLING THE SPECIAL SERVICE TOOLS PER THE WORKSHOP MANUAL PROCEDURE. The crankshaft pulley bolt also retains the crankshaft cam drive sprocket which is NOT keyed to the crankshaft, so valve timing may shift if the crankshaft pulley bolt is loosened. If this occurs, the pistons may contact and damage the valves.
ACTION
Before ANY repair requiring loosening or removal of the crankshafl pulley bolt, engine valve timing MUST be locked by the Special Service Tools identified in the online Workshop Manual, Section 303-01 (In-Vehicle Repair: Crankshaft Pulley). Do not attempt to start the engine without verifying engine cam timing.
SERVICE PROCEDURE
CAUTION
FAILURE TO FOLLOW THE PROCEDURE EXACTLY CAN RESULT IN SERIOUS ENGINE DAMAGE.
SERVICE TOOLS REQUIRED ARE:
1. Crankshaft Timing Peg ESST Number 303-507 is 2-1/8" (54 mm).
2. Camshaft Alignment Plate ESST Number 303-465.
3. Holding Fixture ESST Number 205-126.
4. Adaptor 205-072-02.
Inspect the crankshaft pulley for rubber protruding from the pulley (Figure 1), loose pulse wheel, or bent tabs on pulse wheel touching engine front cover. Replace crankshafl pulley with service kit for respective vehicle line.
NOTE
ESCAPE! MARINER HYBRID 2.3L ATK HEV ENGINE DOES REQUIRE THE SERVICE TOOLS BUT NO SERVICE KIT WAS RELEASED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
062104A 2003-2007 Focus 2.3L 1.5 Hrs.
PZEV 2005-2007 Focus
2.0L: Replace Crankshaft
Pulley, Includes Time To
Lock Engine Valve Timing
Using Special Tools (Do
Not Use With 6312A)
062104A 2006-2007 Fusion/Milan 1.6 Hrs.
2.3L: Replace Crankshaft
Pulley, Includes Time To
Lock Engine Valve Timing
Using Special Tools (Do
Not Use With 6312A)
062104A 2005-2007 Escape/Mariner 1.6 Hrs.
2005-2007 Escape Hybrid,
2006-2007 Mariner Hybrid
2.3L: Replace Crankshaft
Pulley, Includes Time To
Lock Engine Valve Timing
Using Special Tools (Do
Not Use With 6312A)
062104A Operation A: 2001-2007 2.0 Hrs.
Ranger 2.3L: Replace
Crankshaft Pulley, Includes
Time To Lock Engine
Valve Timing Using
Special Tools (Do Not Use
With 6312A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6312 D4
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