Harmonic Balancer - Crankshaft Pulley: Service and Repair

Adapter 303-191-02:

Special Service tools

Crankshaft Damper

Removal
1. Open the engine compartment and fit paintwork protection sheets.
2. Set the engine compartment cover to the service access position.
3. Remove the drive belt from the front accessory drive.
4. Remove the twin fan and motor assembly for access.





5. CAUTION: Under no circumstances should the crankshaft setting peg 303-531 be used in the following operations, to lock the crankshaft.

NOTE: If extra locking of the crankshaft is required, use a lever against one torque converter boss.

Remove the plastic mesh cover from the torque converter housing for access.
Install the crankshaft locking tool to the damper.
Install adapter 303-191-02 to the main locking tool 303-191.
Reposition the crankshaft/damper to align the mounting holes and install the locking tool to the damper using the bolts provided with the tool.
Loosen, but do not remove the damper securing bolt from the crankshaft.

6. Remove the locking tool from the damper.
Remove the damper securing bolt.





7. NOTE: If extra locking of the crankshaft is required due to the crank turning inside the damper, use a lever against one torque converter boss.

Remove the plastic mesh cover from the torque converter housing for access.
Remove the damper from the crankshaft.
Transfer the adapter 303-191-02 from the crankshaft locking tool to the damper extractor tool 303-588.
Locate the thrust button into the end of the crankshaft, the O-ring holds it in place.
Assemble the puller to the damper, use the socket head screws supplied with the puller.
Extract the damper from the crankshaft.

8. Remove the puller components from the damper.
Remove the thrust button from the end of the crankshaft.





9. Where installed, remove the split locking ring from the damper.





10. On dampers which use the split locking ring, remove the internal O-ring seal.





11. Remove the crankshaft front seal.
Install and tighten the removal tool 303-541 to the crankshaft front seal.
Tighten the center bolt of the tool to extract the seal.
Remove the tool and seal assembly.
Separate the seal from the tool.

12. Very carefully clean the threads of the crankshaft, using a plug tap M16x2, to remove all old cured sealant.
Keep the tap horizontal. Do not enlarge the crankshaft thread - remove sealant only.

13. Wrap a clean piece of cloth around the front seal area to prevent the ingress of old sealant.
Use a soft scraper and compressed air to remove old sealant from the crankshaft.
Remove the cloth.

14. Clean all relevant parts and faces.

Installation





1. Locate the new oil seal into the timing cover.
Remove the transit ring from the oil seal.
Position the seal to the timing cover.





2. Install the new oil seal to the timing cover.
Install oil seal replacer tool 303-542 to the oil seal.
Use the nut and bolt provided with the tool, to fully seat the seal to the timing cover.
Only tighten the nut sufficiently to locate the seal and no more, or the timing cover could become distorted.
Allow the tool to stay in position against the seal for at least five seconds.
Remove the special tool from the seal.

3. If the damper is not to be installed immediately, the transit ring should be installed temporarily to the seal.
4. The following instructions (until stated otherwise) refer to installing a damper which DOES NOT utilize a spit locking ring.
5. Apply a thin, even coating of Loctite 648 to the damper bore. Do not apply it to the end faces or to the crankshaft.





6. Install the crankshaft damper.
Install the damper onto the crankshaft.
Wipe off any Loctite which has squeezed out from the front of the damper.
Install, but do not tighten, a new damper securing bolt.
It must be fully tightened within seven minutes of the Loctite being applied.





7. CAUTION: Under no circumstances should the crankshaft setting peg 303-531 be used in the following operations, to lock the crankshaft.
Tighten the damper securing bolt.
Reposition the damper to allow access to the bolt holes for installing the locking tool.
Install the locking tool to the damper using the bolts provided.
Fully tighten the damper securing bolt to the threshold torque value of 80 Nm, then tighten a further 80°.
A suitable angle gauge is Snap On TA-360.

8. The following instructions (until stated otherwise) refer to installing a damper which utilizes a spit locking ring.





9. Install a new O-ring seal to the damper.





10. Install the crankshaft damper.
Apply petroleum jelly to the damper bore and O-ring seal.
Install the damper onto the crankshaft.
Install the split locking ring onto the crankshaft, inside the center bore of the damper.
Install, but do not tighten, a new damper securing bolt.





11. CAUTION: Under no circumstances should the crankshaft setting peg 303-531 be used in the following operations, to lock the crankshaft.
Tighten the damper securing bolt.
Reposition the damper to allow access to the bolt holes for installing the locking tool.
Install the locking tool to the damper using the bolts provided.
Fully tighten the damper securing bolt to 364 - 386 Nm.

12. The instructions which follow are relevant to both conditions of damper.
13. Remove the locking tool from the damper.
14. Install the drive belt to the front accessory drive.
15. Install the twin fan and motor assembly.
16. Install the plastic mesh cover to the torque converter housing; if removed for access to lock the crankshaft.
17. Reset the engine compartment cover to the normal position and connect the gas struts.
18. Remove the paintwork protection sheets and close the engine compartment.