2003 Ford Windstar BaseFACTORY OEM SERVICE PROCEDURE

Timing Chain: Installation

  1. Install the timing chain tensioner.
    1. Position the timing chain tensioner.
    2. Install the bolts.
      Fig 1: Timing Chain Tensioner Bolt Tightening Torque
      G01307758Courtesy of FORD MOTOR CO.
  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.
    Fig 2: Positioning Crankshaft
    G01307759Courtesy of FORD MOTOR CO.
  3. If necessary, retract the tensioner pad retracting mechanism.
    1. Compress the tensioner pad retracting mechanism.
    2. Insert a retaining pin.
      Fig 3: Identifying Tensioner Retaining Pin
      G01307760Courtesy of FORD MOTOR CO.
  4. Turn the camshaft sprocket so that the timing mark is on the bottom of the balance shaft (6250).
    Fig 4: Aligning Camshaft Sprocket Timing Mark
    G01307761Courtesy of FORD MOTOR CO.
  5. Install the timing chain, the camshaft sprocket and the crankshaft sprocket.
    Fig 5: Installing Timing Chain, Camshaft Sprocket & Crankshaft Sprocket
    G01307762Courtesy of FORD MOTOR CO.
  6. Make sure that the timing marks and the keyways are aligned.
    Fig 6: Aligning Crankshaft (6303) Timing Marks & Keyways
    G01307763Courtesy of FORD MOTOR CO.
  7. Install the camshaft position sensor drive gear.
    Fig 7: Camshaft Position Sensor Drive Gear Bolt Tightening Torque
    G01307764Courtesy of FORD MOTOR CO.
  8. Remove the retaining pin.
    Fig 8: Removing Retaining Pin
    G01307765Courtesy of FORD MOTOR CO.
  9. Install the engine front cover. For additional information, refer to ENGINE FRONT COVER .
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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