FORD MUSTANG 2003 Workshop Manual

39. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock
position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12
o'clock position.
40. CAUTION: Unless otherwise instructed, do not rotate either the crankshaft or the
camshafts, when the timing chains are removed and the cylinder heads are installed.
Severe piston and valve damage will occur.
CAUTION: When instructed to do so, rotate the crankshaft counterclockwise only.
Do not rotate past the position shown or severe piston and valve damage can occur.
NOTE: The number one cylinder is at top dead center (TDC) when the stud on the engine block
fits into the slot in the handle of the special tool.
Using the special tool, position the crankshaft so the number one cylinder is at TDC. Klj . 17 ba
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41. Remove the special tool.
42. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked)
link with the timing mark on the sprocket.
43. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
44. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain
tensioner.
45. Remove the retaining clip from the LH timing chain tensioner. Klj . 18 ba
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46. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked)
link with the timing mark on the sprocket.
47. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
48. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
49. Remove the retaining clip from the RH timing chain tensioner. Klj . 19 ba
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50. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft
sprockets and the camshaft sprocket.
51. NOTE: Sensor ring teeth must face forward.
Position the crankshaft sensor ring on the crankshaft.
52. NOTE: The front cover must be installed within four minutes of applying sealant.
Apply silicone gasket and sealant in the locations shown. Klj . 20 ba
362003 Mustang Workshop Manual
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53. Install a new engine front cover gasket on the engine front cover.
54. Install the engine front cover.
Item Part
Number Description
1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
6 W706508 Stud, Hex Shldr Pilot, M8 x 1.25 x 50 —
M6 x 1 x
10 7 N808586 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 60
—
M6 x 1 x 26 Klj . 21 ba
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55. Tighten the four oil pan bolts in the sequence shown in three stages.
zStage 1: Tighten to 2 Nm (18 lb- in).
z Stage 2: Tighten to 20 Nm (15 lb- ft).
z Stage 3: Tighten an additional 60 degrees.
56. Install the belt idler pulleys. 57. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil. 8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
11 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 12 W706560 Stud and Washer, Hex-
Head Pilot, M8 x 1.25 x 65
— M8 x 1.25 x 16 13 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 14 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 15 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 Klj . 22 ba
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58. Using the special tool, install the front oil seal.
59. Install the water pump pulley and bolts.
60.
NOTE: The crankshaft pulley must be installed within four minutes of applying sealant.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
61. Using the special tool, install the crankshaft pulley. Klj . 23 ba
362003 Mustang Workshop Manual
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62.
NOTE: Use special tool 303- 009 or a suitable strap wrench to hold the crankshaft pulley.
Install the washer and the bolt. Tighten the bolt in four stages. zStage 1: Tighten to 90 Nm (66 lb- ft).
z Stage 2: Loosen one full turn.
z Stage 3: Tighten to 50 Nm (37 lb- ft).
z Stage 4: Tighten an additional 90 degrees.
63. Install the LH engine mount.
64. Install the RH engine mount. Klj . 24 ba
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65.
NOTE: Only three bolts are required for installation.
Install the power steering pump. zPosition the power steering pump.
z Install the bolts.
66. Lubricate the O- ring seal with PAG compressor oil, YN-12C, F7AZ-19589- DA or equivalent
meeting Ford specification WSH- M1C231-B.
Install the A/C compressor.
67. Install the oil filter adapter. Klj . 25 ba
362003 Mustang Workshop Manual
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68. Install the camshaft roller followers.
1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft follower.
69. NOTE: One spark plug shown, others similar.
Install spark plugs.
70. NOTE: The RH side is shown, the LH side is similar. Klj . 26 ba
362003 Mustang Workshop Manual
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