303-01A-1 303-01A-1Engine — 4.6L (2V)

IN-VEHICLE REPAIR

Timing Drive Components

Special Tool(s)

Compressor, Valve Spring303-581 (T97T-6565-A)

Holding Tool, Crankshaft303-448 (T93P-6303-A)

3. Disconnect the eight ignition coil electricalconnectors.

Aligner, Camshaft Position303-557 (T96T-6256-B)

Compressor Spacer, ValveSpring303-382 (T91P-6565-AH)

4. Remove the bolts and the eight ignition coils.

Material

Item Specification

Hydraulic Chain Tensioner 1L3Z-6P250-AARetaining Clip

Removal

CAUTION: Since the engine is notfree-wheeling, timing procedures must befollowed exactly or piston and valve damage canoccur.

1. Remove the engine front cover. For additionalinformation, refer to Engine Front Cover in thissection.

2. Remove the crankshaft sensor ring from thecrankshaft.

Copyright 2002, Ford Motor CompanyLast updated: 1/28/2005 2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-2 303-01A-2Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

5. NOTE: Use compressed air to remove any 8. NOTE: The roller followers are positional.foreign material from the spark plug wells Mark the followers for installation in theirbefore removing the spark plugs. original locations.

Remove the spark plugs. Use the special tool to compress the valvespring and remove the camshaft rollerfollowers.

6. Position the lobe of the camshaft up.

9. Position the crankshaft with the keyway at the12 o’clock position.

7. Install the special tool between the valve springcoils to prevent valve stem seal damage.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-3 303-01A-3Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

10. Remove the timing chain tensioning system 11. Remove the LH and RH timing chains and thefrom both timing chains. crankshaft sprocket.

1 Remove the bolts. • Remove the RH timing chain from thecamshaft sprocket.2 Remove the timing chain tensioners.

• Remove the RH timing chain from the3 Remove the timing chain tensioner arms.crankshaft sprocket.

• Repeat for the LH timing chain andcrankshaft sprocket.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-4 303-01A-4Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

12. Remove the timing chain guides.

1 Remove the bolts.

2 Remove the LH timing chain guide.

3 Remove the bolts.

4 Remove the RH timing chain guide.

13. NOTE: RH shown, LH similar. 14. NOTE: RH shown, LH similar.

Install the special tool. Remove the bolt and the camshaft gear.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-5 303-01A-5Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

Installation

Engines with ratcheting timing chaintensioners

1. CAUTION: Timing chain proceduremust be followed exactly or damage to valvesand pistons will result.

CAUTION: Do not compress theratchet assembly. This will damage theratchet assembly.

NOTE: LH shown, RH similar.4. Install a paper clip into the hole of each

Compress each tensioner plunger, using an edge tensioner housing to hold the ratchet assemblyof a vise. and plunger in during installation.

• Remove the tensioner from the vise.

2. Using a small screwdriver or pick, push backand hold the ratchet mechanism. Engines with non-ratcheting timing chain

tensioners

5. CAUTION: If one or both tensionermounting bolts are loosened or removed, thetensioner-sealing bead must be inspected forseal integrity. Any cracks, tears, cuts orseparation from the tensioner body orpermanent compression of the seal bead, willrequire replacement of the tensioner.

Inspect the RH and LH timing chain tensioners.

• Install new tensioners as necessary.

3. While holding the ratchet mechanism, push theratchet arm back into the tensioner housing.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-6 303-01A-6Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

6. CAUTION: The timing chainprocedure must be followed exactly ordamage to valves and pistons will result

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using a vise.

9. Install the camshaft sprockets and new bolts.Tighten the bolts in two stages.

• Stage 1: Tighten the bolt to 40 Nm (30lb-ft).

• Stage 2: Tighten the bolt an additional 90degrees (1/4 turn).

7. Install a retaining clip on each tensioner to holdthe plunger in during installation.

10. Using the special tool, position the crankshaftso the number one cylinder is at top dead

All engines center (TDC).

8. If the copper links are not visible, mark onelink on one end and one link on the other end,and use as timing marks.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-7 303-01A-7Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

11. Install the crankshaft sprocket, making sure the 12. Install the timing chain guide.flange faces forward. 1 Position the LH timing chain guide.

2 Install and tighten the LH bolts.

3 Position the RH timing chain guide.

4 Install and tighten the RH bolts.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-8 303-01A-8Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

13. Rotate the RH camshaft sprocket until thetiming mark is approximately at the 11 o’clockposition. Rotate the LH camshaft sprocket untilthe timing mark is approximately at the 12o’clock position.

14. Position the LH (inner) timing chain on the 15. Install the LH timing chain on the sprocket,crankshaft sprocket, aligning the copper aligning the copper (marked) link with the(marked) link with the timing mark on the timing marks on the sprocket.sprocket.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-9 303-01A-9Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

16. NOTE: The LH timing chain tensioner arm hasa bump near the dowel hole for identification.

Position the LH timing chain tensioner arm onthe dowel pin and install the LH timing chaintensioner.

All engines

19. Position the RH (outer) timing chain on thecrankshaft sprocket, aligning the copper(marked) link with the timing mark on thesprocket.

Engines with ratcheting timing chaintensioners

17. Remove the retaining clip from the LH timingchain tensioner.

20. Install the RH timing chain on the camshaftsprocket, aligning the copper (marked) link withthe timing marks on the sprocket.

Engines with non-ratcheting timing chaintensioners

18. Remove the retaining clip from the LH timingchain tensioner.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-10 303-01A-10Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

21. Position the RH timing chain tensioner arm onthe dowel pin and install the RH timing chaintensioner.

All engines

24. Make sure that the copper (marked) chain linksare lined up with the dots on the crankshaft

Engines with ratcheting timing chain sprocket and the camshaft sprockets.tensioners

22. Remove the retaining clip from the RH timingchain tensioner.

25. Rotate the camshaft until the lobe is in the upposition.

Engines with non-ratcheting timing chaintensioners

23. Remove the retaining clip from the RH timingchain tensioner.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-11 303-01A-11Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

26. Install the special tool between the valve spring 29. Install the eight ignition coils and bolts.coils to prevent valve stem seal damage.

30. Connect the eight ignition coil electrical27. NOTE: Lubricate the camshaft roller followers connectors.

using clean engine oil.

Install the camshaft roller followers.

1 Install the special tool.

2 Compress the valve spring.

3 Install the camshaft roller followers in theiroriginal locations.

31. Install the crankshaft sensor ring on thecrankshaft.

28. Install the eight spark plugs.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002

303-01A-12 303-01A-12Engine — 4.6L (2V)

IN-VEHICLE REPAIR (Continued)

32. Install the engine front cover. For additionalinformation, refer to Engine Front Cover in thissection.

2003 Crown Victoria/Grand Marquis/Marauder, 7/2002