timing FORD MUSTANG 2003 User Guide

1. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic
balance shaft assembly into the cylinder block (6010). Turn the engine balance shaft driven
gear so that the timing mark lines up with the timing mark on the engine balance shaft drive
gear (6A303).
2. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and
the camshaft keyway will be at 6 o'clock on the camshaft.
Install the bolts.
3. Install the radiator fan and shroud assembly.
4. Connect the connector and install the pin- type retainer. Klj . 2 ba
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5. Install the timing chain. For additional information, refer to
Timing Chain in this section. Klj . 3 ba
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IN-
VEHICLE REPAIR
Timing Chain
Removal 1. Remove the timing cover. For additional information, refer to Engine Front Cover in this section.
2. Remove the camshaft position sensor drive gear. 1. Remove the bolt.
2. Remove the camshaft position sensor drive gear.
3. Rotate the crankshaft (6303) until the timing marks and keyways align.
4. Compress and install a retaining pin to hold the timing chain tensioner (6L266).
5. Remove the camshaft sprocket (6256), the crankshaft sprocket (6306) and the timing chain/belt (6268) as an assembly.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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6. Remove the timing chain tensioner.
1. Remove the bolts.
2. Remove the timing chain tensioner.
Installation 1. Install the timing chain tensioner. 1. Position the timing chain tensioner.
2. Install the bolts.
2. Rotate the crankshaft so the number one piston (6108) is at top dead center (TDC) and the key is at the 12 o'clock position. Klj . 2 ba
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3. If necessary, retract the tensioner pad retracting mechanism.
1. Compress the tensioner pad retracting mechanism.
2. Insert a retaining pin.
4. Turn the camshaft sprocket so that the timing mark is on the bottom of the balance shaft (6250).
5. Install the timing chain, the camshaft sprocket and the crankshaft sprocket.
6. Make sure that the timing marks and the keyways are aligned. Klj . 3 ba
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52. Remove the camshaft position sensor drive gear.
1. Remove the bolt.
2. Remove the camshaft position sensor drive gear.
53. Compress and install a retaining pin to hold the timing chain tensioner.
54. Remove the camshaft sprocket, the crankshaft sprocket and the timing chain as an assembly.
55. Remove the timing chain tensioner. 1. Remove the bolts.
2. Remove the timing chain tensioner. Klj . 15 ba
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7. Install the camshaft thrust plate.
1. Position the camshaft thrust plate.
2. Install the bolts.
8. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic balance shaft assembly into the cylinder block. Turn the engine balance shaft driven gear so
that the timing mark aligns up with the timing mark on the engine balance shaft drive gear.
9. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and
the camshaft keyway will be at 6 o'clock on the camshaft.
Install the bolts.
10. CAUTION: Make sure the components are installed in the correct location.
NOTE: Lubricate the crankshaft main bearings prior to installation.
Install the crankshaft upper main bearings and the crankshaft upper thrust main bearing. Klj . 4 ba
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19. Install the oil pan bridge and baffle assembly.
20. Using a new gasket, install the oil pump screen cover and tube.
21. Install the timing chain tensioner.
1. Position the timing chain tensioner.
2. Install the bolts.
22. Retract the tensioner pad retracting mechanism. 1. Compress the tensioner pad retracting mechanism.
2. Insert a retaining pin. Klj . 8 ba
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23. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at
the 12 o'clock position.
24. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.
25. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
26. Make sure the timing marks and the keyways are aligned.
27. Install the camshaft position sensor drive gear and retaining bolt. Klj . 9 ba
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a
Refer to the procedure in this section. Power steering reservoir bolts 10 — 89
Water outlet connector bolts 25 18 —
Camshaft cap cluster to cylinder head bolts 10 — 89
Torque converter nuts 25 18 —
Timing chain tensioner bolts 25 18 —
Transmission filler tube bolt 47 35 —
A/C compressor bolts 25 18 —
Ignition coil bolts 6 — 53
Generator brace bolts 10 — 89
Primary timing chain guide-
to-engine bolts 10 — 89
Accelerator cable bracket bolts 10 — 89
Rear seal retainer bolts 10 — 89
Pressure plate bolts 2 — 47
Spark plugs 18 13 —
Crankshaft timing bolt sensor assembly 10 — 89
Camshaft timing bolt sensor assembly 10 — 89
Fuel rail studs 10 — 89
Engine coolant sensor 15 11 —
Exhaust manifold—
stud to cylinder head 10-
13 7-10 —
Throttle body adaptor bolts
a — — —
Throttle body bolts 10 — 89
Idle air control valve 10 — 89
RFI capacitor nut 10 — 89
Generator bolts 25 18 —
Oil pan drain plug 14 10 —
Water bypass tube bracket bolt 25 18 —
Subframe bolts 115 85 —
Battery lead to generator 10 — 89
EGR vacuum regulator solenoid bracket 10 — 89
Pipe plug—
water drain 20 15 —
Screen and cover assembly to main bearing cap stud spacer 25 18 —
Wiring harness retainer nut 10 — 89
Oil pressure switch
a — — —
A/C muffler stud to cylinder head 10 — 89
EGR tube to exhaust manifold connector 50 37 — Klj . 5 ba
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