timing FORD MUSTANG 2003 Workshop Manual

noise—
normally
accompanied by
vibration Powertrain/Drivetrain Mount Neutralizing in this
section.
z Damaged or
misaligned exhaust
system. z
INSPECT the exhaust
system for loose or broken
clamps and brackets.
CARRY OUT Exhaust System Neutralizing in this
section.
z Whistling noise—
normally
accompanied
with poor idle
condition z
Air intake system. zCHECK the air intake
ducts, air cleaner, throttle
body and vacuum hoses for
leaks and correct fit.
REPAIR or ADJUST as
necessary. REFER to
Section 303 - 12
z
Clunking noise zWater pump has
excessive end play or
imbalance. z
CHECK the water pump for
excessive end play.
INSPECT the water pump
with the drive belt off for
imbalance. INSTALL a new
water pump as necessary.
REFER to Section 303 -
03A .
z Generator has
excessive end play. z
CHECK the generator for
excessive end play.
REPAIR or INSTALL a new
generator. REFER to
Section 414 - 02 .
z Pinging noise zExhaust system leak. zINSPECT the exhaust
system for leaks. REPAIR
as necessary.
z Gasoline octane too
low. z
VERIFY with customer the
type of gasoline used.
CORRECT as necessary.
z Knock sensor
operation. z
CHECK the knock sensor.
INSTALL a new knock
sensor as necessary.
REFER to Section 303 - 14 .
z Incorrect spark
timing. z
CHECK the spark timing.
REPAIR as necessary.
z High operating
temperature. z
INSPECT cooling system
for leaks. CHECK the
coolant level. REFILL as
necessary. CHECK the
coolant for the correct mix
ratio. DRAIN and REFILL
as needed. CHECK engine
operating temperature is
within specifications.
REPAIR as necessary.
z Foul- out spark plug. zCHECK the spark plugs.
REPAIR or INSTALL new
spark plugs as necessary.
z Catalytic converter. zAcceptable noise.
z Knocking noise—
light knocking
noise, also z
Excessive clearance
between the piston
and the cylinder wall. z
Engine cold and at high
idle. Using an EngineEAR,
pull a spark plug or fuel Klj . 24 ba
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(PC/ED) manual.
z Damaged valve
tappet or lash
adjuster. z
INSTALL a new valve tappet or
lash adjuster.
z Damaged valve
tappet guide or
valve tappet. z
INSTALL a new valve tappet
guide or valve tappet.
z Burnt or sticking
valve. z
REPAIR or INSTALL a new
valve.
z Weak or broken
valve spring. z
INSTALL a new valve spring.
z Carbon
accumulation in
combustion
chamber. z
ELIMINATE carbon buildup.
z Excessive oil
consumption z
Leaking oil. zREPAIR oil leakage.
z Malfunctioning PCV
system. z
REPAIR or INSTALL new
necessary components.
z Worn valve stem
seal. z
INSTALL a new valve stem seal.
z Worn valve stem or
valve guide. z
INSTALL a new valve and valve
guide.
z Sticking piston
rings. z
REPAIR or INSTALL new piston
rings.
z Worn piston ring
groove. z
INSTALL a new piston and
piston pin.
z Worn piston or
cylinder. z
REPAIR or INSTALL a new
piston or cylinder block.
z Engine noise zLeaking exhaust
system. z
REPAIR exhaust leakage.
z Incorrect drive belt
tension. z
REFER to Section 303 - 05 .
z Malfunctioning
generator bearing. z
Refer to the appropriate section
in Group 414 for the procedure.
z Malfunctioning
water pump
bearing. z
REFER to Section 303 - 03A .
z Malfunctioning or
damaged cooling
system. z
REFER to Section 303 - 03A .
z Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Loose timing
chain/belt (6268). z
ADJUST or INSTALL a new
timing chain/belt.
z Damaged timing
chain tensioner
(6L266). z
INSTALL a new timing chain
tensioner.
z Excessive main
bearing clearance. z
ADJUST clearance or INSTALL
a new crankshaft main bearing
(6333). Klj . 4 ba
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4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle
drops to 0 kPa (0 in- Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in- Hg).
5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum but occasionally flicks (sharp, fast movement) down and back about 13 kPa (4 in- Hg), one or more
valves may be sticking.
6. BURNED OR WARPED VALVES: A regular, evenly- spaced, downscale flicking of the needle
indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or hydraulic
lash adjuster (HLA) clearance will also cause this reaction.
7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are not seating.
8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in- Hg) range at idle
speed, the valve guides could be worn. As engine speed increases, the needle will become
steady if guides are responsible.
9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is increased, weak valve springs are indicated. The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady but somewhat low reading.
12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket leak.
14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or warped cylinder head- to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may be normal, but as the engine rpm is increased, the back pressure caused by a clogged
muffler (5230), kinked tail pipe or other concerns will cause the needle to slowly drop to 0 kPa
(0 in-Hg). The needle then may slowly rise. Excessive exhaust clogging will cause the needle to
drop to a low point even if the engine is only idling.
16. When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system will upset the fuel mixture and cause concerns such as rough idle, missing on
acceleration or burned valves. If the leak exists in an accessory unit such as the power brake
booster (2005), the unit will not function correctly. Always fix vacuum leaks.
Excessive Engine Oil Consumption
The amount of oil an engine uses will vary with the way the vehicle is driven in addition to normal
engine- to-engine variation. This is especially true during the first 16,100 km (10,000 miles) when a new
engine is being broken in or until certain internal engine components become conditioned. Vehicles
used in heavy- duty operation may use more oil. The following are examples of heavy- duty operation:
z trailer towing applications
z severe loading applications
z sustained high speed operation Klj . 12 ba
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GENERAL PROCEDURES
Sprockets
1. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do
not operate the engine with the hood open until the fan blade has been examined for
possible cracks and separation.
NOTE: Specifications show the expected minimum or maximum condition. Refer to the
appropriate section in Group 303 for the procedure.
NOTE: If a component fails to meet the specifications, it is necessary to install a new
component or refinish. If the component can be refinished, wear limits are provided as an aid to
making a decision. A new component must be installed for any component that fails to meet
specifications and cannot be refinished.
Inspect the timing chain/belt and the sprockets.
zInstall new components as necessary. Refer to the appropriate section in Group 303 for
the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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4. Inspect for normal burning.
zCheck for light tan or gray deposits on the firing tip.
5. Inspect for pre- ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect
ignition timing, wrong type of fuel or the unauthorized installation of a heli- coil insert in place of
the spark plug threads.
zInstall a new spark plug.
6. Inspect for overheating, identified by a white or light gray spots and with bluish- burnt
appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark
plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition
timing.
zInstall a new spark plug. Klj . 2 ba
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a
20- 200 seconds to leakdown 3.18 mm (0.125 in) with 225 Newtons (50 pounds) load and tappet filled
with leak- down fluid. —
desired Connecting rod bearing-
to-crankshaft clearance
— allowable 0.022-
0.069 mm (0.00086- 0.0027 in) Connecting rod side clearance 0.11-
0.49 mm (0.0047- 0.0193 in) Balance Shaft
Journal diameter 52.108-
52.082 mm (2.0515- 2.0505 in) Bore inside diameter 55.689-
55.664 mm (2.192- 2.191 in) Maximum runout 0.025 mm (0.001 in)
End play 0.075-
0.200 mm (0.003- 0.008 in)
Torque Specifications Description Nm lb-
ft lb-
in EGR transducer bracket-
to-intake manifold bolts 10 — 89
Ignition coil-
to-intake manifold bolts 6 — 53
Water outlet tube-
to-intake manifold stud bolt 10 — 89
EGR tube-
to-EGR valve nut 40 30 —
Water outlet tube-
to-front water pump bolt 10 — 89
Fuel supply manifold bolts 10 — 89
LH valve cover-
to-cylinder head bolts 10 — 89
LH valve cover-
to-cylinder head stud bolts 10 — 89
EGR tube-
to-exhaust manifold nut 40 30 —
RH valve cover-
to-cylinder head bolts 10 — 89
RH valve cover-
to-cylinder head stud bolts 10 — 89
Coolant recovery reservoir-
to-cylinder head stud bolts 10 — 89
Coolant recovery reservoir-
to-bracket bolts 5 — 44
Crankshaft pulley bolt 160 118 —
Camshaft position sensor bolts 3 — 27
Camshaft synchronizer-
to-front cover bolt 25 18 —
Front cover-
to-cylinder block bolts 25 18 —
Radiator fan shroud-
to-radiator bolts 9 — 80
Camshaft thrust plate-
to-cylinder block bolts 12 9 —
Camshaft synchronizer drive gear-
to-camshaft bolt 45 33 —
Timing chain tensioner-
to-cylinder block bolts 12 9 —
Exhaust manifold-
to-cylinder head nuts 33 24 —
Power steering pump bracket-
to-water pump nuts 20 15 —
Power steering pump bracket-
to-generator bracket bolts 20 15 —
Generator bracket-
to-cylinder head bolts 40 30 —
Exhaust manifold studs 8 — 71
A/C compressor bracket-
to-cylinder head bolts 48 35 —
A/C compressor bracket-
to-cylinder head nut 48 35 — Klj . 4 ba
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Item Part Number Description
1 6255 Distributor drive gear
2 6268 Timing chain
3 6A303 Engine balance shaft drive gear
4 6A304 Engine balance shaft driven gear
5 6C341 Balance shaft thrust plate
6 6A311 Engine dynamic balance shaft
7 W705934 Woodruff key
8 6261 Camshaft bearing Klj . 6 ba
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9 6A333 Balance shaft front and rear bearing
10 6010 Cylinder block
11 6K564 Tappet guide plate and retainer —
RH 12 6K564 Tappet guide plate and retainer —
LH 13 6500 Valve tappet
14 376958 Balance shaft cover plug
15 6337 Crankshaft thrust main bearing
16 6701 Crankshaft rear oil seal
17 6A338 Crankshaft main bearing (lower)
18 6A339 Crankshaft thrust main bearing
19 6325 Rear main bearing cap
20 6327 Main bearing cap
21 6687 Oil pan baffle
22 6622 Oil pump screen cover and tube
23 6625 Oil pump inlet tube gasket
24 6334 Main bearing cap
25 6329 Main bearing cap
26 6303 Crankshaft
27 388907 Woodruff key
28 6333 Crankshaft main bearing (upper)
29 6284 Timing chain vibration damper
30 6263 Camshaft rear bearing
31 6262 Camshaft center bearing
32 6250 Camshaft
33 6265 Camshaft sprocket spacer
34 6269 Camshaft thrust plate
35 6256 Camshaft sprocket
36 6303 Crankshaft sprocket
37 6150 Piston ring
38 6152 Piston ring
39 6161 Piston ring
40 6159 Piston ring
41 6135 Piston pin
42 6200 Connecting rod
43 6211 Connecting rod bearing
44 6210 Connecting rod cap
45 6200 Connecting rod assembly
46 6100 Piston and connecting rod assembly
47 6108 Piston Klj . 7 ba
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IN-
VEHICLE REPAIR
Camshaft
Removal 1. Remove the valve tappets. For additional information, refer to Valve Tappets in this section.
2. Remove the timing chain. For additional information, refer to Timing Chain in this section.
3. Position the wire harness aside.
4. Remove the radiator fan and shroud assembly.
5. Remove the engine balance shaft drive gear from the camshaft. 1. Remove the camshaft key.
2. Remove the engine balance shaft drive gear.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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IN-
VEHICLE REPAIR
Engine Dynamic Balance Shaft
Removal 1. Remove the timing chain (6268). For additional information, refer to Timing Chain in this
section.
2. Disconnect and position the wire harness aside.
3. Remove the radiator fan and shroud assembly (8146).
4. Remove the engine dynamic balance shaft (6A311). zRemove the bolts.
z Remove the balance shaft driver gear, thrust plate and engine dynamic balance shaft as
an assembly. Installation SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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