FORD MUSTANG 2003 Workshop Manual

a
With installation of a new filter. Head gasket surface flatness 0.15 mm (0.006 in) max. overall
Crankshaft
Main bearing journal diameter 67.493 mm
Main bearing journal maximum taper 0.05 mm
Main bearing journal maximum out-
of round 0.05 mm
Main bearing journal-
to-cylinder block clearance 0.023-
0.055 mm Connecting rod journal diameter 56.866-
56.886 mm Connecting rod journal maximum taper 0.004 mm (0.0002 in)
Connecting rod journal maximum out-of-
round 0.004 mm (0.0002 in)
Crankshaft maximum end play 0.130-
0.301 mm Thrust bearing journal diameter 67.493 mm
Thrust bearing journal maximum out-
of round 0.05 mm
Thrust bearing journal maximum taper 0.05 mm
Thrust bearing journal length 17.725-
17.775 mm Piston and Connecting Rod
Piston diameter 90.180-
90.191 mm Piston-
to-cylinder bore clearance -
0.010/+0.026 mm Piston ring end gap —
compression (top) 0.30 mm
Piston ring end gap —
compression (bottom) 0.50 mm
Piston ring end gap —
compression (oil ring) 0.65 mm
Piston ring groove width —
compression (top) 1.53-1.549 mm
Piston ring groove width —
compression (bottom) 1.519-
1.539 mm Piston ring groove width —
oil ring 3.031-
3.055 mm Piston ring width —
compression (top) 1.47-
1.49 mm Piston ring width —
compression (bottom) 1.47-
1.49 mm Piston ring width —
oil ring 2.854-
2.984 mm Piston ring-
to groove clearance — compression (top) 0.04-0.079 mm
Piston ring-
to groove clearance — compression (bottom) 0.029-
0.069 mm Piston ring-
to groove clearance — oil ring 0.047-
0.201 mm Piston pin bore diameter 22.0042-
21.998 mm Piston pin diameter 21.991-
29.994 mm Piston pin length 61.60-
62.03 mm Piston pin-
to-piston fit 0.0058-
0.0132 mm Connecting rod-
to-pin clearance 0.018-
0.033 mm Connecting rod pin bore diameter 22.012-
22.024 mm Connecting rod length 150.7 mm
Connecting rod maximum allowed bend 0.038 mm per 25 mm
Connecting rod maximum allowed twist 0.050 mm per 25 mm
Connecting rod bearing bore diameter 56.866-
56.886 mm Connecting rod bearing-
to-crankshaft clearance 0.027-
0.069 mm Connecting rod side clearance 0.15-
0.45 mm Klj . 3 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

b
P=Primary, S=Secondary, E=Exhaust
c Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in
tappet.
Torque Specifications Description Nm lb-
ft lb-
in A/C compressor bolts 25 18 —
A/C peanut fittings 8 — 71
A/C muffler nut 25 18 —
Accelerator bracket bolts 10 — 89
Battery tray bolts 11 8 —
Belt idler support bracket assembly fasteners 25 18 —
Camshaft sprocket bolt 115 85 —
Coolant bypass tube studs 25 18 —
Coolant bypass tube bolts 25 18 —
Coolant hose and tube assembly bolt 25 18 —
Cooling fan motor and shroud bolts 10 — 89
Connecting rod bolt
a — — —
Engine front cover bolt a a a
Drive belt tensioner bolts 25 18 —
Cylinder head bolt
a — — —
Idler pulley bracket 25 18 —
Power steering pump bolts 25 18 —
Power steering hose fitting 65 48 —
Power steering hose bracket bolt 10 — 89
Pulley to crankshaft bolt
a — — —
EGR valve to intake manifold
a — — —
Engine coolant degas bottle bolts 10 — 89
Exhaust manifold studs 25 18 —
Generator bolts 25 18 —
Generator support bracket bolts 25 18 —
Hood prop bolt 10 — 89
Hood mounting nuts 12 9 —
Heater water inlet tube 10 — 89
Heater water outlet tube 24 18 —
Lower intake manifold-
to-cylinder head bolt a — — —
Main bearing cap bolt
a — — —
Oil filter adapter bolt 25 18 —
Oil bypass filter to adapter 50 37 —
Oil pump screen cover and tube-
to-oil pump bolt 10 — 89
Oil pan-to-
cylinder block bolt a — — — Klj . 4 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

a
Refer to the procedure. Oil pan-to-
engine front cover bolts a — — —
Oil pump-
to-cylinder block bolt 10 — 89
Radio ignition interference capacitor bolts 25 18 —
Oil pump screen and pickup tube-
to-main bearing cap stud spacer bolt 25 18 —
Water pump pulley bolts 25 18 —
Throttle body spacer nuts 25 18 —
Vacuum accessory bracket fasteners 10 — 89
Valve cover bolt 10 — 89
Wiring harness support bracket 25 18 —
Water pump-
to-cylinder block bolt 25 18 —
EGR valve to exhaust manifold tube nuts 40 30 —
Power steering pump to engine 25 18 —
Power steering hose bracket nut 25 18 —
Power steering reservoir bracket fasteners 10 — 89
Supercharger degas bottle bolts 10 — 89
Camshaft cap cluster to cylinder head 10 — 89
Timing chain tensioner bolts—
primary 25 18 —
Timing chain tensioner bolts—
secondary 10 — 89
Ignition coil cover bolts 10 — 89
Generator mounting bracket retainers 10 — 89
Oil level indicator tube retainer 10 — 89
Primary timing chain guide-
to-engine bolts 10 — 89
Oil pump screen and pickup tube spacer to main bearing stud 25 18 —
Belt idler pulley bolt 25 18 —
Subframe brace nuts 41 30 — Klj . 5 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Klj . 6 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

DESCRIPTION AND OPERATION
Engine
WARNING: Do not operate the engine with the hood open until the fan blade has been first
examined for possible cracks and separation.
The 4.6L (4V) (281 CID) Cobra engine is a V- 8 with the following features:
z intercooled supercharger
z dual overhead camshafts
z four valves per cylinder
z sequential multiport fuel injection (SFI)
z an aluminum intake manifold
z aluminum cylinder heads
z a cast aluminum, 90-degree V- cylinder block
z individually chain- driven camshafts with a hydraulic timing chain tensioner on each timing chain
z the electronic ignition system with eight ignition coils
Identification
Always refer to these labels when replacement parts are necessary or when checking engine
calibrations. The engine parts often differ within a CID family. Verification of the identification codes will
ensure that the correct parts are obtained. These codes contain all the pertinent information relating to
the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete
listing of the codes and their application.
Code Information
The engine code information label, located on the side of the valve cover and the front side of the
valve cover, contains the following:
zengine build date
z engine plant code
z engine code
Exhaust Emission Control System
Operation and necessary maintenance of the exhaust emission control devices used on this engine is
covered in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The sequential multiport fuel injection (SFI) provides the fuel/air mixture needed for combustion in the
cylinders. The eight solenoid- operated fuel injectors:
z are mounted in the lower intake manifold.
z meter fuel into the air intake stream in accordance with engine demand.
SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
162003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

z
are positioned so that their tips direct fuel just ahead of the engine intake valves.
z are connected in series with the fuel pressure sensor.
z supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.
A constant fuel pressure drop is maintained across the fuel injectors by the fuel pressure sensor. The
fuel pressure sensor:
zis positioned upstream from the fuel injectors on the fuel injection supply manifold.
Valve Train
The valve train operates as follows:
zball- tip hydraulic lash adjusters provide automatic lash adjustment.
z roller followers ride on the camshaft lobes, transferring the up-and- down motion of the
camshafts to the valves in the cylinder heads.
Positive Crankcase Ventilation System
All engines are equipped with a closed- type positive crankcase ventilation system recycling the
crankcase vapors to the upper intake manifold.
Lubrication System
The engine lubrication system operates as follows:
zoil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil
pan.
z oil is pumped through the oil bypass filter on the left front side of the cylinder block.
z oil enters the main oil gallery where it is distributed to the crankshaft main journals and to both
cylinder heads.
z From the main journals, the oil is routed through cross- drilled passages in the crankshaft to
lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings
and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as
well as the entire connecting rod, piston and piston rings assembly.
z The left cylinder head is fed from a drilling into the supply passage feeding the main gallery at
the front of the cylinder block. The right cylinder head is fed from a drilling into the rear of the
main gallery. Main gallery pressure is reduced as it enters the cylinder head galleries through
fixed serviceable orifices located at the upper part of the feed passages. It is this reduced
pressure in the cylinder head galleries which feeds the camshaft journals, the hydraulic lash
adjusters and the primary and secondary timing chain tensioners.
z The camshaft lobe and roller followers are lubricated by splash created through valve train
operation.
Oil Pump
The lubrication system of the 4.6L (4V) engine is designed to provide optimum oil flow to critical
components of the engine through its entire operating range. The heart of the system is a positive
displacement internal gear oil pump using top seal rotors. Generically this design is known as a gerotor
pump, which operates as follows.
zThe oil pump is mounted on the front face of the cylinder block. Klj . 2 ba
162003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

z
The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
z System pressure is limited by an integral, internally- vented relief valve which directs the
bypassed oil back to the inlet side of the oil pump.
z Oil pump displacement has been selected to provide adequate volume to ensure correct oil
pressure both at hot idle and maximum speed.
z The relief valve calibration protects the system from excessive pressure during high viscosity
conditions.
z The relief valve is designed to provide adequate connecting rod bearing lubrication under high-
temperature and high- speed conditions.
Cooling System
The engine cooling system includes the following:
zradiator
z water pump
z the electric cooling fan motor and fan blade, activated by the variable control module
z the degas bottle, which aids in maintaining the correct volume of engine coolant
z water thermostat
z upper radiator hose
z lower radiator hose
z heater water hoses
Drive Belt System
The 4.6L (4V) DOHC engine is equipped with a serpentine drive belt. To ensure maximum life, a
replacement drive belt should be of the same type as originally installed.
zThe accessories mounted on the front of the engine are belt- driven by the crankshaft.
z The serpentine drive belt is routed over each accessory pulley, driven by the crankshaft pulley
bolted to the crankshaft.
For service procedures, including tensioning, refer to Section 303 - 05 . Klj . 3 ba
162003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Item Part Number Description
1 6F066 Supercharger assembly
2 N806154 Screws (2 req'd)
3 9F715 Idle air control valve
4 — Idle air control valve gasket
5 9P697 Spacer assembly
6 9E936 Throttle body gasket
7 9E926 Throttle body
8 — Bolts (4 req'd)
9 — Bolts (2 req'd)
10 9E926 Throttle position sensor
11 N804178 Nuts (4 req'd)
12 — Studs (4 req'd)
13 — Spacer assembly gasket
14 9D475 Exhaust gas recirculation valve
15 — Stud
16 9D477 Exhaust gas recirculation tube
17 — Manifold absolute pressure sensor
18 9J460 Differential pressure feedback EGR system
19 9J459 Exhaust gas recirculation vacuum regulator
20 9J472 Vacuum accessory bracket Klj . 4 ba
162003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Item Part Number Description
1 12B637 Wiring harness
2 9C986 Fuel pulse damper
3 9F792 Fuel injection supply manifold
4 9F593 Fuel injector
5 — Stud
6 9D475 Exhaust gas recirculation valve
7 W701232 Bolt
8 N806979 Stud Klj . 5 ba
162003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

9 — EGR vacuum hoses
10 6F089 Vacuum actuator valve
11 N605892 Bolts (2 req'd)
12 — Bolts (10 req'd)
13 9J447 Lower intake manifold
14 9L438 Coolant intake manifold gasket
15 — Coolant tubes
16 9N491 Coolant intake manifold
17 W701592 Bolt
18 NL443 Inter cooler hose
19 NL443 Inter cooler hose
20 W506404 Bolts (10 req'd)
21 6K755 Charge air cooler
22 6F066 Supercharger assembly
23 N605892 Bolt
24 9726 Accelerator cable bracket Klj . 6 ba
162003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...