Engine - 2.3L: Component Locations Mercury Milan I

Special Tool(s)

SPECIAL TOOLS Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) Timing Peg, Crankshaft TDC 303-507

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC). (Scheme 30): Installing Crankshaft TDC Timing Peg
2. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC. (Scheme 31): Locating Balancer Unit And Shafts Mark
3. NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. Remove the 4 bolts and the balancer unit. (Scheme 32): Locating Balancer Unit Bolts
4. Remove the adjustment shims from the seat faces of the balancer unit.
5. NOTE: Visually inspect the balancer unit gear for damage and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
6. With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear. (Scheme 33): Locating Balancer Unit And Shafts Reference Mark
7. Install the balancer unit bolts. Tighten in the sequence shown in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft). (Scheme 34): Identifying Balancer Unit Bolts Tightening Sequence
8. Remove the Crankshaft TDC Timing Peg. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear. (Scheme 35): Installing Crankshaft TDC Timing Peg
9. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. Remove the Crankshaft TDC Timing Peg. (Scheme 36): Installing Crankshaft TDC Timing Peg
10. NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown. Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. (Scheme 37): Measuring Gear Backlash
11. NOTE: If maximum backlash exceeds 0.101 mm (0.003 in), install a new balancer unit. Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table. Remove the balancer unit from the cylinder block. Install the selected adjustment shims on the seat faces of the balancer unit. (Scheme 38): Adjustment Shim Selection Chart
12. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC. (Scheme 39): Installing Crankshaft TDC Timing Peg
13. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear. (Scheme 40): Locating Balancer Unit And Shafts Reference Mark
14. Install the balancer unit bolts. Tighten in the sequence shown in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 50 Nm (37 lb-ft). see scheme 13: Identifying Balancer Unit Bolts Tightening Sequence
15. NOTE: Remeasure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the Dial Indicator Gauge with Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown. Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash. Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. If the backlash exceeds the specified range of 0.005 to 0.101 mm (0.00019 to 0.0039 in), install a new balancer unit and repeat the procedure.

Measuring Gear Backlash. Scheme 41

Scheme 42

Scheme 43

Scheme 44