FORD MUSTANG 2003 Workshop Manual

Assembly
NOTE:
Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint
and foreign material. Also, make sure the coolant and oil passages are clear.
1. Record the main bearing code found on the front of the engine block. Installer, Crankshaft Rear Oil
Seal
303-
516 (T95P-6701- BH) Compressor, Piston Ring
303-
D032 (D81L-6002- C) or
equivalent Holding Tool, Crankshaft
303-
448 (T93P-6303- A)
Material Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 SAE 5W-
20 Premium Synthetic
Blend Engine Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Motorcraft Premium Engine
Coolant
VC
-4-A (in Canada CXC- 10; in
Oregon VC- 5) or equivalent ESE-
M97B44-
A Motorcraft Premium Gold
Engine Coolant
VC
-7-A (in Canada VC-7- B) or
equivalent WSS-
M97B51-
A1 Klj . 2 ba
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2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings determine
the required bearing grade for each main bearing.
zRead the first letter of the engine block main bearing code and the first letter of the
crankshaft main bearing code.
z Read down the column below the engine block main bearing code letter, and across the
row next to the crankshaft main bearing code letter, until the two intersect. This is the
required bearing grade for the number one crankshaft main bearing.
z As an example, if the engine block code letter is "F" and the crankshaft code letter is "D",
the correct bearing grade for this main bearing is a "2".
z Repeat this process for the remaining four main bearings. Klj . 3 ba
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4. If oversize bearings are being used, use the procedure in the previous step and the Bearing
Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main
bearing.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. Install the crankshaft onto the upper main bearings. Klj . 4 ba
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7.
NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the
crankshaft thrust surface).
Install the thrust washer to the rear of the No. 5 upper main bearing.
8. NOTE: Rotate the jack screws into the bearing caps enough to provide clearance to the cylinder
block, prior to installing the bearing caps
NOTE: Install the thrust bearing to the rear main bearing cap and lubricate it with clean engine
oil.
NOTE: Install the crankshaft lower main bearings into the main bearing caps and lubricate them
with clean engine oil.
Apply forward force to the crankshaft, so that the crankshaft thrust face is against the No. 5
bulkhead. With the crankshaft in this position, locate the No. 5 main bearing cap on the cylinder
block and tap into place using a plastic or dead blow hammer.
zInstall the four remaining main bearing caps. Klj . 5 ba
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9. Install the vertical main bearing cap fasteners and tighten in the sequence shown, in two stages.
zStage 1: Tighten to 40 Nm (30 lb- ft).
z Stage 2: Tighten an additional 90 degrees.
10. Tighten the jack screws against the cylinder block in the sequence shown, in two stages. zStage 1: Tighten to 5 Nm (44 lb- in).
z Stage 2: Tighten to 10 Nm (89 lb- in). Klj . 6 ba
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11. Install the side bolts and tighten them in the sequence shown.
12. Check the crankshaft end play. For additional information, refer to Section 303
- 00 .
13. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the
connecting rod. NOTE: Make sure that the piston arrow is facing forward. Klj . 7 ba
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NOTE:
Lubricate the piston rings, cylinder walls and connecting rod bearings with clean engine
oil.
Using the special tool push the pistons through the top of the cylinder block.
14. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the
connecting rod.
NOTE: Make sure the crankshaft is at top dead center (TDC).
Using the special tool, install the connecting rod assemblies.
15. NOTE: The rod bearing cap 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 25 Nm (18 lb- ft).
z Stage 2: Tighten to 45 Nm (33 lb- ft).
z Stage 3: Tighten an additional 90 degrees. Klj . 8 ba
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16. Check the connecting rod bearing clearance. For additional information, refer to
Section 303 -
00 .
17. Install the windage tray.
18. Install and tighten the oil pump screen spacer.
19. Position the oil pump; tighten the bolts in the sequence shown.
20. NOTE: Install a new O- ring if necessary.
Install the oil pump screen cover and tube. Klj . 9 ba
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21. Install the cylinder head gaskets.
22.
NOTE: Install new cylinder head bolts.
NOTE: LH is shown, RH is similar.
NOTE: Lubricate the bolt heads and threads. Use clean engine oil.
Install the LH and RH cylinder heads and 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.
23. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. Klj . 10 ba
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Compress the tensioner plunger, using a vise.
24. Install a retaining clip on the tensioner to hold the plunger in during installation.
25. Remove the tensioner from the vise.
26. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
27. Install the timing chain guides. Klj . 11 ba
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