Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

download
1. Disconnect the battery negative cable. 2. Drain the engine cooling system. 3. Remove the crankshaft pulley. 4. Remove the water pump pulley. 5. Remove the power steering pump and bracket. 6. Disconnect the Exhaust Gas Recirculation (EGR) tube. 7. Disconnect the coolant hoses. 8. Remove the Camshaft Position Sensor (CMP). 9. Remove the heater water outlet tube. 1999 Ford Mustang V6-3.8L VIN 4 10. Remove the camshaft synchronizer assembly. 11. Disconnect the lower radiator hose. 12. Disconnect the crankshaft position sensor. 13. Remove the wiring harness pin-type retainer. 14. NOTE: Record the location, type, and size of the fasteners. Remove the engine front cover. – Remove and discard the engine front cover gasket. Installation 1. Clean the mounting surfaces of the engine front cover, oil pan and cylinder block of sealant, dirt or other contaminants. 2. Apply a small amount of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 as shown. 3. Install the engine front cover gasket and apply Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4 as shown. 4. NOTE: Refer to the notation made during the removal procedure for the location, size and type of fastener. Install the engine front cover and tighten the fasteners in the sequence shown.

download
1. CAUTION: At no time, when the timing chain(s) are removed and the cylinder heads (6049) are installed, may the crankshaft (6303) and camshafts (6250) be rotated. Failure to follow these directions will result in valve and/or piston damage. NOTE: Because this is not a free-wheeling engine, if it has jumped time, there will be damage to the valves and pistons (6108) and will require the removal of the cylinder heads . The camshaft sprockets (6256) should only be disassembled from the camshafts when one of the components is to be replaced. Remove valve covers (6582) , oil pan (6675) and engine front cover (6019) as described. 2. Remove crankshaft position sensor pulse wheel. 3. Rotate engine to No. 1 top dead center (TDC). 4. NOTE: Cam Positioning Tool Adapters 303-413 (T92P-6256-A) and Cam Positioning Tool 303-380 (T91P-6256-A) MUST be installed on camshaft to prevent camshaft from rotating. Install Cam Positioning Tool Adapters 303-413 (T92P-6256-A) and Cam Positioning Tool 303-380 (T91P-6256-A) on flats of camshafts . 5. Remove two bolts retaining RH timing chain tensioner (6L266) to cylinder head and remove timing chain tensioner . 6. Remove RH timing chain tensioner arm (6L253) . 7. Remove two bolts retaining RH timing chain guide (6K297) to cylinder head and remove timing chain guide . 8. Remove RH timing chain from camshaft sprocket and crankshaft sprockets (6306) . 9. NOTE: Cam Positioning Tool Adapters 303-413 (T92P-6256-A) and Cam Positioning Tool 303-380 (T91P-6256-A) MUST be installed on camshaft to prevent camshaft from rotating. Remove two bolts retaining LH timing chain tensioner to cylinder head and remove timing chain tensioner . 10. Remove LH timing chain tensioner arm . 11. Remove two bolts retaining LH timing chain guide to cylinder head and remove timing chain guide . 12. Remove LH timing chain from camshaft sprocket and crankshaft sprocket . 13. If necessary, remove camshaft sprockets and crankshaft sprockets as described. 14. CAUTION: Do not rotate crankshaft and/or camshafts . Engine damage may occur. Inspect the plastic running face on timing chain tensioner arms and timing chain guides . If worn or damaged, remove and clean oil pan and oil pump screen cover and tube (6622) . Installation

download
SERVICE INFORMATION A revised service procedure for the engine front cover/timing chain has been adopted for the GA16DE. It is no longer recommended to remove the cylinder head when removing the timing chain/front cover(s). Utilize the following steps when servicing the front cover, timing chain, guides or tensioner(s) PARTS INFORMATION Caution ^ After removing the timing chain, do not turn the crankshaft and camshaft separately or the valves will strike the piston heads. ^ When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new engine oil. ^ Apply new engine oil to bolt threads and seat surfaces when installing the camshaft sprockets and the crankshaft pulley. ^ Do not spill engine coolant on the drive belts. ^ Please refer to the Service Manual for the correct tightening torque. Removal 1. Set # 1 piston at TDC on its compression stroke. 2. Remove the spark plug wires. 3. 4. Remove the rocker cover (see Figure 1). Remove the coolant reservoir tank with bracket and reposition it for clearance. 5. Support the engine with a suitable jack. 6. Remove cylinder head front mounting bracket. 7. Remove engine front mounting, then the engine front mounting bracket. 8. Remove cylinder head front cover. 9. Remove the upper chain tensioner (see Figure 2). 10. Wipe off the links of the upper timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the cam sprockets and idler sprocket (see Figure 3) 11. Remove the four (4) front cover to cylinder head bolts. 12. Remove side and lower engine compartment splash covers. 13. Remove the accessory drive belts. 14. Remove the crankshaft pulley. 15. Drain coolant by removing the cylinder block drain plug and opening the radiator drain cock (Refer to MA section of the Service Manual). 16. Drain engine oil. 17. Remove intake manifold support of engine front side. 18. Remove power steering pump, pump bracket and tension rod. Position pump aside for clearance.

download
Install the crankshaft sprocket, making sure the mating marks face the front of the engine. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process. CAUTION: Be careful not to tear or damage the cylinder head gasket. Install the lower chain guides. Front cover installation: a. Using a scraper or other suitable tool remove all traces of liquid gasket from the cylinder block and front cover mating surfaces. b. Install new crankshaft seal in front cover. c. Install new oil passage O-rings and apply a continuous bead of RTV sealant to the front cover (see Figure 1). NOTE: Use Genuine Nissan RTV silicone sealant P/N 999MP-A7007, Three Bond P/N TB1207D or equivalent. d. Install the front cover to the engine. CAUTION: Be careful not to tear or damage the cylinder head gasket or oil seal. Align oil pump drive spacer with the oil pump, and install. Install the oil strainer. Install oil pan, referring to “Installation” in the “OIL PAN” section of the Service Manual. Install upper timing chain and sprockets, using the painted reference marks made during removal. Install upper chain tensioner. 1996 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) a. b. Before installing the chain tensioner, insert a suitable pin into the pin hole of the chain tensioner (see Figure 2) to hold the tensioner in. Once the tensioner is installed, remove the pin. 10. Install the lower chain tensioner (See Figure 3). NOTE: Make sure the gasket is facing the proper direction before installing the tensioner. CAUTION: Now rotate the crankshaft by hand. Check that no binding or interference problems occur when the engine is rotated. 11. Install the thermostat housing. a. Use a scraper to remove all traces of liquid gasket from the mating surfaces of the engine front cover and the thermostat housing.

download
Remove mount from upper front end of engine, allowing engine to rest on wood block. Remove accessory drive belt and tensioner. Remove accessory belt idler. Remove cylinder head cover. 3. Replace silicone isolators on cylinder head cover screws if deteriorated. Remove power steering pump (leave hoses attached). Remove A/C compressor (leave hoses attached). Raise and support vehicle. Drain engine oil. Remove right front wheel and splash shield. 4. Remove support bracket between intake manifold and engine block. Remove front balancer/pulley using a 3-jaw puller. Disconnect exhaust pipe from exhaust manifold. Install Crankshaft Gear Retainer (SA9104E) onto end of crankshaft, with flat side toward crankshaft gear (sprocket). Crankshaft gear retainer holds crankshaft gear in place during removal of front cover. CAUTION: If crankshaft gear is not held in place, timing chain guide will be damaged.