Sep 212011
 

Need help figuring out how to tell when the cams are both on TDC. Its for an 05′ mustang V6 4.0 dohc

  One Response to “05′ 4.0 dohc timing”

  1. If you would like pictures as well follow the “Auto Repair Manuals” tab to your left.

    Timing Chain
    Removal & Installation
    4.0L Engine
    Left Timing Chain
    Relieve the fuel system pressure.
    Disconnect the negative battery cable.
    Remove the intake manifold.
    Remove the engine front cover.
    Remove all of the camshaft roller followers.
    NOTE: The camshafts will need to be retimed if the timing of either camshaft is disturbed.

    Turn the crankshaft clockwise to position the No. 1 cylinder at top dead center (TDC).
    Remove the left hydraulic chain tensioner.
    Install the camshaft sprocket holding tool (303-564) or equivalent on the left camshaft and remove the camshaft sprocket bolt.
    Using the crankshaft holding tool (303-674) or equivalent to prevent the crankshaft from turning, remove the jackshaft sprocket bolt.
    Remove the bolts and the primary chain tensioner.
    Remove the primary chain and sprockets as an assembly.
    Remove the suction hose bracket bolt.
    Remove the pressure tube bracket.
    Remove the power steering pump pulley.
    Remove position the power steering pump out of the way.
    Remove the left cassette upper and lower bolts.
    Remove the left cassette.
    To Install:

    Install the left timing chain cassette. Tighten the lower bolt to 9 ft-lb (12 Nm) and the upper bolt to 14 ft-lb (19 Nm).
    Install the power steering pump and pulley.
    Install the pressure tube and suction hose brackets.
    Install the primary chain and sprockets as an assembly.
    Install the primary chain tensioner. Tighten the bolts to 80 in-lb (9 Nm).
    Use the special socket to prevent the crankshaft from turning, and tighten the jackshaft sprocket bolt in 2 steps as follows;
    Step 1: Tighten to 33 ft-lb (45 Nm)
    Step 2: Tighten an additional 90 degrees
    Loosely install the camshaft sprocket bolt.
    NOTE: The LH hydraulic chain tensioner will be installed during camshaft timing.

    Retime the camshafts as described in this section.
    Install the camshaft roller followers.
    Install the engine front cover.
    Install the intake manifold.
    4.6L Engine
    To Remove:

    Remove the engine front cover.
    Remove the crankshaft sensor ring from the crankshaft.
    Position the crankshaft keyway at the 12 o’clock position.

    Rotate the crankshaft pulley to the position shown (1st 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.

    Make sure the camshaft lobes are positioned as shown (right camshaft)

    Remove only the three roller followers shown from the right cylinder head

    Use the valve spring compressor when removing the roller followers

    WARNING
    Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.

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

    Using a spring compressor, remove the 3 roller followers shown from the right cylinder head. Keep the parts in order so they can be installed in their original positions.
    Remove only the 3 roller followers shown in the illustration from the left cylinder head.

    Remove only the three roller followers shown from the left cylinder head

    CAUTION
    The crankshaft cannot be moved past the 6 o’clock position once set.

    Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o’clock position.

    Rotate the crankshaft to the position shown (2nd position)

    Remove the left timing chain tensioner and tensioner arm.
    Remove the right timing chain tensioner and tensioner arm.
    Remove the timing chains and the crankshaft sprocket.
    CAUTION
    Be careful not the damage the camshaft phaser sprocket assemblies. Use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.

    Using the camshaft sprocket holding tool, remove the left and right camshaft phaser sprocket assemblies. Discard the sprocket bolts.
    To Install:

    Install the camshaft phaser sprockets and new camshaft phaser bolts finger tight.
    CAUTION
    Be careful not the damage the camshaft phaser sprocket assemblies. Use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.

    Using the camshaft sprocket holding tool, tighten the camshaft phaser sprocket bolts in 2 steps;
    Step 1: Tighten to 30 ft-lb (40 Nm)
    Step 2: Tighten an additional 90 degrees
    Install the crankshaft sprocket, making sure the flange faces forward.
    Rotate the crankshaft to position the crankshaft sprocket timing mark in the 6 o’clock position.
    Inspect the timing chain tensioners. Install new tensioners as necessary.
    Compress the tensioner plunger, using a vise.
    Install a retaining clip on the tensioner to hold the plunger in during installation.
    Remove the tensioner from the vise.
    If the copper links are not visible, mark one link on one end and one link on the other end and use as timing marks.

    Examine the chain for copper links or mark two links on the chain as shown

    Install the timing chain guides. Tighten the bolts to 89 in-lbs (10 Nm).
    Install the lower end of the left (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the crankshaft sprocket with the single copper (marked) link on the chain.
    NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.

    Install the left timing chain on the camshaft sprocket. Make sure the timing mark on the sprocket is aligned with the marked chain link.
    NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

    Install the left timing chain tensioner arm on the dowel pin and install the chain tensioner. Tighten the bolts to 18 ft-lb (25 Nm).
    Remove the retaining clip from the left timing chain tensioner.
    Install the right timing chain on the crankshaft and camshaft sprockets. Make sure the marks are aligned. The right camshaft sprocket will be stamped with one of the timing marks shown.

    The right camshaft sprocket will be stamped with one of the marks shown

    Install the right timing chain tensioner arm on the dowel pin and install the chain tensioner. Tighten the bolts to 18 ft-lb (25 Nm).
    Remove the retaining clip from the right timing chain tensioner.
    Verify correct alignment of all timing marks.
    Install the crankshaft sensor ring on the crankshaft.
    NOTE: It will be necessary to rotate the engine to position the camshaft lobes at base circle to install the roller followers.

    Using the spring compressor, install all of the camshaft roller followers. Lubricate the roller followers with clean engine oil prior to installation.
    Install the engine front cover.

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