Friday, March 16, 2012

Timing Chain, Sprockets, Front Cover & Seal removal for Ford Mustang?

2010 Ford Mustang timing chain removal.
The procedure is also for other years ford Mustang.

It has details for 4.0L engine, 4.6L engine, 5.4L engine models.



Timing Chain, Sprockets, Front Cover & Seal
REMOVAL & INSTALLATION Details are as follows:-----

4.0L Engine
Specific to:
Ford Mustang 2009-2010
  1. Drain the cooling system and the engine oil.
  2. Disconnect the negative battery cable.
  3. Remove the intake manifold.
  4. Remove the crankshaft pulley bolt and the crankshaft damper using a puller.
  5. Remove the crankshaft front oil seal using a puller.
  6. Disconnect the upper and lower radiator hoses.
  7. Disconnect the heater hose from the water pump.
  8. Remove the accessory drive belt.
  9. Remove the drive belt idler pulley.
  10. Disconnect the crankshaft position sensor connector and retainer.
  11. Disconnect the coolant bypass hose from the water pump.
  12. Remove 5 engine front cover to engine block cradle bolts.
  13. Remove 5 bolts and 4 stud bolts and remove the front cover. 

    image
    Fig. Exploded view of the timing drive components-4.0L engine
  14. Remove the camshaft roller followers.
  15. Rotate the crankshaft so that the No. 1 cylinder is at Top Dead Center (TDC) of the compression stroke.
  16. Remove the right side chain tensioner.
  17. Install the special tools and remove the right camshaft sprocket bolt. See the procedure under Camshaft.
  18. Hold the crankshaft from turning and remove the jackshaft sprocket bolt.
  19. Remove the primary chain tensioner.
  20. Remove the primary chain and sprockets as an assembly.
  21. Remove the right side cassette upper and lower bolts and remove the cassette.
  22. Remove the left side chain tensioner.
  23. Install the special tools and remove the left camshaft sprocket bolt. See the procedure under Camshaft.
  24. Remove the left side cassette upper and lower bolts and remove the cassette.
  25. Remove the timing chains.
To install:
  1. Install the timing chains.
  2. Install the left side cassette lower bolt and tighten to 9 ft. lbs. (12 Nm).
  3. Install the left side cassette upper bolt and tighten to 14 ft. lbs. (19 Nm).
  4. Install the right side cassette lower bolt and tighten to 9 ft. lbs. (12 Nm).
  5. Install the right side cassette upper bolt and tighten to 14 ft. lbs. (19 Nm).
  6. Install the primary chain and sprockets as an assembly.
  7. Install the primary chain tensioner and tighten to 80 inch lbs. (10 Nm).
  8. Hold the crankshaft from turning and tighten the jackshaft sprocket bolt to 33 ft. lbs. (45 Nm), plus an additional 90°.
  9. Loosely install the camshaft sprocket bolts.
  10. Perform the camshaft timing procedure. See the procedure under Camshaft.
  11. Install the camshaft roller followers.
  12. Apply sealant to the front cover in 2 spots near the top center of the cover.
  13. Apply thread sealant to the front cover stud bolts.
  14. Install the front cover and loosely tighten the bolts and stud bolts.
  15. Use front cover alignment tool and align the front cover.
  16. Tighten the front cover bolts to 14 ft. lbs. (19 Nm).
  17. Install the front cover to engine cradle bolts and tighten to 80 inch lbs. (10 Nm).
  18. Connect the coolant bypass to from the water pump.
  19. Connect the crankshaft position sensor connector and retainer.
  20. Install the drive belt idler pulley and tighten to 35 ft. (47 Nm).
  21. Install the accessory drive belt.
  22. Connect the heater hose to the water pump.
  23. Connect the upper and lower radiator hoses.
  24. Install the crankshaft front oil seal using a seal installer.
  25. Install the crankshaft damper and the pulley bolt. Tighten the pulley bolt to 33 ft. lbs. (45 Nm), plus an additional 85°.
  26. Install the intake manifold.
  27. Connect the negative battery cable.
  28. Fill the cooling system.
  29. Fill the crankcase with clean engine oil.
  30. Run the engine. Check for leaks and proper operation.
4.6L Engine
Specific to:
Ford Mustang 2009-2010
  1. Remove the engine front cover.
  2. Remove the crankshaft sensor ring from the crankshaft.
  3. Position the crankshaft keyway at the 12 o-clock position.
    NOTE
    If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.
The No. 1 cylinder must be coming up on the exhaust stroke with the crankshaft keyway at the 12 o'clock position. Verify by noting the position of the 2 intake lobes and the exhaust lobe on the No. 1 cylinder.

NOTE
If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.

  1. Remove only the 3 roller followers shown from the RH cylinder head.
    NOTE
    Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.


    NOTE
    It may be necessary to push the valve down while compressing the spring.



    Click image to see an enlarged view
    Fig. Removing the 3 roller followers from the RH cylinder head
  2. Using the Valve Spring Compressor, remove the 3 roller followers designated in the previous step from the RH cylinder head.
    NOTE
    If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  3. Remove only the 3 roller followers shown from the LH cylinder head.
    NOTE
    Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.


    NOTE
    It may be necessary to push the valve down while compressing the spring.



    Click image to see an enlarged view
    Fig. Removing the 3 roller followers from the LH cylinder head
  4. Using the Valve Spring Compressor, remove the 3 roller followers designated in the previous step from the LH cylinder head.
    NOTE
    The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.
  5. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
  6. Remove the bolts, the LH timing chain tensioner and tensioner arm.
  7. Remove the bolts, the RH timing chain tensioner and tensioner arm.
  8. Remove the bolts, the RH timing chain tensioner and tensioner arm.
  9. Remove the RH and LH timing chains and the crankshaft sprocket.
    1. Remove the RH timing chain from the camshaft sprocket.
    2. Remove the RH timing chain from the crankshaft sprocket.
    3. Remove the LH timing chain from the camshaft sprocket.
    4. Remove the LH timing chain and crankshaft sprocket.

      Click image to see an enlarged view
      Fig. Removing the timing chains and sprocket
  10. Remove the LH and RH timing chain guides. Remove the bolts. Remove both timing chain guides.
    NOTE
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


    NOTE
    Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
  11. Using the Cam Phaser Locking Tool, remove the bolt and the RH camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
    NOTE
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


    NOTE
    Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
  12. Using the Cam Phaser Locking Tool, remove the bolt and the LH camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
    NOTE
    Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.
  13. Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
    NOTE
    The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage.
  14. Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.

    Click image to see an enlarged view
    Fig. Identifying the RH bearing cap bolt removal sequence
  15. Clean and inspect the RH camshaft bearing caps. Make sure the groove is free of foreign material.
  16. Remove the RH camshaft.
    NOTE
    Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.
  17. Remove the 2 bolts and the LH cylinder head camshaft front bearing cap.

    Click image to see an enlarged view
    Fig. Identifying the LH bearing cap bolt removal sequence
  18. Clean and inspect the LH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
  19. Remove the LH camshaft.
    NOTE
    If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
  20. Remove all of the remaining roller followers from the cylinder heads.
To install:
  1. Install the LH and RH camshafts. Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
  2. Install the LH and RH camshaft bearing caps in their original locations.
    1. Lubricate the camshaft bearing caps with clean engine oil.
    2. Position the front camshaft bearing cap.
    3. Position the remaining camshaft bearing caps.
    4. Install the bolts loosely.
    5. Tighten to 89 inch lbs. (10 Nm) in the sequence shown.
      NOTE
      Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.



      Click image to see an enlarged view
      Fig. Identifying the bearing cap installation sequence
  3. Install the camshaft phaser sprockets and new camshaft phaser bolts finger-tight.
    NOTE
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


    NOTE
    Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.
  4. Using the Cam Phaser Locking Tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages.
    1. Stage 1: Tighten to 30 ft. lbs. (40 Nm).
    2. Stage 2: Tighten an additional 90°.
  5. Install the crankshaft sprocket, making sure the flange faces forward.
  6. Rotate the crankshaft to position the crankshaft sprocket timing mark in the 6 o-clock position.
    NOTE
    If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur.
  7. Inspect the RH and LH timing chain tensioners. Install new tensioners as necessary.
    NOTE
    Timing chain procedures must be followed exactly or damage to valves and pistons will result.
  8. Compress the tensioner plunger, using a vise.
  9. Install a retaining clip on the tensioner to hold the plunger in during installation.
  10. Remove the tensioner from the vise.
  11. If the colored links are not visible, mark one link on one end and one link on the other end and use as timing marks.
  12. Install the 4 bolts and the LH and RH timing chain guides. Tighten to 89 inch lbs. (10 Nm).
  13. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single colored (marked) link on the chain.
    NOTE
    Make sure the upper half of the timing chain is below the tensioner arm dowel.
  14. Position the LH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the colored (marked) chain link.
    NOTE
    The LH timing chain tensioner arm has a bump near the dowel hole for identification.
  15. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts. Tighten to 18 ft. lbs. (25 Nm).
  16. Remove the retaining clip from the LH timing chain tensioner.
  17. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single colored (marked) chain link.
    NOTE
    The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.


    NOTE
    The lower half of the timing chain must be positioned above the tensioner arm dowel.
  18. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is aligned with the colored (marked) chain link.

    Click image to see an enlarged view
    Fig. Verifying the camshaft sprocket timing mark is aligned with the colored (marked) chain link
  19. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts. Tighten to 18 ft. lbs. (25 Nm).
  20. Remove the retaining clip from the RH timing chain tensioner.
    NOTE
    The RH and LH camshaft phaser sprockets are similar. Refer to the single timing mark to identify the RH camshaft phaser sprocket and the L timing mark to identify the LH camshaft phaser sprocket.
  21. As a post-check, verify correct alignment of all timing marks. Make sure the timing marks on the sprockets correspond to the above note.

    Click image to see an enlarged view
    Fig. Verifying the correct alignment of all timing marks
  22. Install the crankshaft sensor ring on the crankshaft.
    NOTE
    It is necessary to rotate the engine to position the camshaft lobes at base circle to install the roller followers.
  23. Using the Valve Spring Compressor, install all of the camshaft roller followers. Lubricate the roller followers with clean engine oil prior to installation.
  24. Install the engine front cover.
5.4L Engine
Specific to:
Ford Mustang 2009-2010

CAUTION
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

  1. Remove the camshaft roller followers.
  2. Remove the engine front cover.
  3. Remove the crankshaft sensor ring.

    Click image to see an enlarged view
    Fig. Removing the crankshaft sensor ring
  4. Remove the crankshaft washer.
  5. Remove the 2 bolts and the RH primary timing chain tensioner.

    Click image to see an enlarged view
    Fig. Removing the RH primary timing chain tensioner (5.4L engine)
  6. Remove the RH primary timing chain tensioner arm.
  7. Remove the RH primary timing chain.
  8. Remove the 2 bolts and the RH primary timing chain guide.

    Click image to see an enlarged view
    Fig. Removing the RH primary timing chain guide
  9. Remove the 2 bolts and the LH primary timing chain tensioner.
  10. Remove the LH primary timing chain tensioner arm.
  11. Remove the LH primary timing chain.
  12. Remove the 2 bolts and the LH primary timing chain guide.
  13. Remove the crankshaft sprocket.

    Click image to see an enlarged view
    Fig. Removing the crankshaft sprocket
To install:

NOTE
Do not compress the ratchet assembly. This will damage the ratchet assembly.

  1. Compress each tensioner plunger, using an edge of a vise.
  2. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
  3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

    Click image to see an enlarged view
    Fig. Pushing ratchet arm back into the tensioner housing
  4. Install a suitable pin into the hole of each tensioner housing to hold the ratchet assembly and plunger in place during installation. Remove the tensioner from the vise.
  5. If the colored links are not visible, mark one link on one end and 2 links on the other end, and use as timing marks.
  6. Using the Crankshaft Holding Tool, position the crankshaft.
  7. Install the crankshaft sprocket with the flange facing forward.
  8. Install the LH primary timing chain guide and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  9. Position the camshaft sprocket timing marks as shown.

    Click image to see an enlarged view
    Fig. Positioning the camshaft sprocket
  10. Position the LH (inner) timing chain onto the crankshaft sprocket, aligning the one colored link on the timing chain with the slot on the crankshaft sprocket.
  11. Install the LH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.
  12. Install the LH primary timing chain tensioner arm.
  13. Install the LH primary timing chain tensioner and the 2 bolts. Tighten to 18 ft. lbs. (25 Nm). Remove the pin from the tensioner.
  14. Install the RH primary timing chain guide and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  15. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the colored link with the timing marks on the sprocket.
  16. Install the RH timing chain on the camshaft sprocket, aligning the 2 colored links with the timing mark on the sprocket.
  17. Install the RH primary timing chain tensioner arm.
  18. Install the RH primary timing chain tensioner and the 2 bolts. Tighten to 18 ft. lbs. (25 Nm). Remove the pin from the tensioner.
  19. As a post-check, verify correct alignment of all timing marks. Make sure that the colored links are lined up with the marks on the crankshaft sprocket and the camshaft sprockets.

    Click image to see an enlarged view
    Fig. Verifying the correct alignment of all timing marks
  20. Install the crankshaft washer.
  21. Install the crankshaft sensor ring.
  22. Install the engine front cover.
  23. Install the camshaft roller followers.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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