FORD MUSTANG 2003 Workshop Manual

11. Install the vertical main bearing cap fasteners and tighten in the sequence shown.
zTighten to 40 Nm (30 lb- ft).
z Tighten an additional 85- 95 degrees.
12. Back out the jackscrews against the cylinder block in sequence shown. zTighten to 5 Nm (44 lb- in).
z Tighten to 10 Nm (89 lb- in). Klj . 7 ba
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13. Install the side bolts and tighten them in the sequence shown.
14. Check the crankshaft end play. For additional information, refer to Section 303
- 00 .
15. Check the piston to cylinder block and piston ring clearances. For additional information, refer to Section 303 - 00 .
16. Install the piston rings. Klj . 8 ba
362003 Mustang Workshop Manual
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17. Make sure the ring gaps (oil spacer [A], oil ring [B], and compression ring [C]) are properly
spaced around the circumference of the piston.
18. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the
connecting rod.
NOTE: Only one piston and connecting rod shown, others similar.
NOTE: Make sure the crankshaft is facing forward.
NOTE: Lubricate the piston rings, cylinder walls and connecting rod bearings with clean engine
oil.
Install the upper bearings in the connecting rod as shown. Klj . 9 ba
362003 Mustang Workshop Manual
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19.
NOTE: The piston grade number will face the rear of the engine.
Check that the piston/connecting rod assembly is oriented with the identification marks facing
the front of the engine.
20. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the
connecting rod.
NOTE: Make sure the crankshaft is at TDC. Klj . 10 ba
362003 Mustang Workshop Manual
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NOTE:
Only one connecting rod assembly shown, others similar.
Using the special tool install the piston and connecting rod assembly by pushing the pistons
through the top of the cylinder block.
21. NOTE: These bolts are torque- to-yield. Install new bolts each time they are serviced.
Install the connecting rod bearing caps and bolts and tighten in three stages. zStage 1: Tighten to 25Nm (18 lb- ft).
z Stage 2: Tighten to 40Nm (30 lb- ft).
z Stage 3: Tighten an additional 90 degrees.
22. Rotate the crankshaft and install the remaining piston and connecting rod assemblies.
23. Check the connecting rod bearing clearance. For additional information, refer to Section 303 -
00 .
24. Install the oil pump and tighten the bolts. 25. NOTE: Install a new O - ring if necessary. Klj . 11 ba
362003 Mustang Workshop Manual
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Install the oil pump screen cover and tube.
26. NOTE: If not secured within four minutes, sealant must be removed and sealing area cleaned
with metal surface cleaner. Allow to dry until there are no signs of wetness, or four minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.
If the retainer plate was removed, apply a 4 mm (0.16 in) bead of silicone gasket and sealant
around the rear oil seal retainer sealing surface.
27. Install the rear main seal retainer plate. Tighten the bolts in the sequence shown. zTighten bolts 1- 6 to 10 Nm (89 lb- in).
z Hand- tighten bolts 7 and 8.
z Tighten bolts 7 and 8 to 20 Nm (15 lb- ft).
z Tighten bolts 7 and 8 an additional 60 degrees.
28. Install the oil pan and gasket and loosely install the bolts. Klj . 12 ba
362003 Mustang Workshop Manual
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29. Tighten the bolts in the sequence shown.
zTighten to 20 Nm (15 lb- ft).
z Rotate an additional 60 degrees.
30. Install the cylinder head gaskets.
31. CAUTION: Cylinder head to cylinder block pre- assembly must be followed exactly
or damage to valves and pistons can result. Klj . 13 ba
362003 Mustang Workshop Manual
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CAUTION: Camshaft keyways must maintain a 90 degree clocked position relative
to the valve cover rail.
CAUTION: To prevent piston crown and valve damage the crankshaft keyway must
be clocked at 270° (45° BTDC) before the installation of the cylinder head assembly.
NOTE: Crankshaft must be rotated clockwise only.
Align the keyways as shown.
32. NOTE: Position the RH and the LH cylinder heads over the dowels on the cylinder head
gaskets.
NOTE: The LH is shown the RH is similar.
Tighten the bolts in six stages in the sequence shown. zStage 1: Tighten to 40 Nm (30 lb- ft).
z Stage 2: Tighten an additional 90 degrees.
z Stage 3: Loosen the bolts a minimum of one full turn.
z Stage 4: Tighten to 40 Nm (30 lb- ft).
z Stage 5: Tighten an additional 90 degrees.
z Stage 6: Tighten an additional 90 degrees. Klj . 14 ba
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33.
CAUTION: Timing chain procedures must be followed exactly or damage to valves
and pistons will result.
Using a vise, compress the tensioner plunger.
34. Install a retaining clip on the tensioner to hold the plunger in during installation.
35. Remove the tensioner from the vise. Klj . 15 ba
362003 Mustang Workshop Manual
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36.
NOTE: There are 58 links in each timing chain.
If the copper links are not visible, mark one link on one end and one link on the other end to use
as timing marks.
37. Install the timing chain guides. 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.
38. Install the crankshaft sprocket, making sure the flange faces forward. Klj . 16 ba
362003 Mustang Workshop Manual
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