oil FORD MUSTANG 2003 Workshop Manual

4. Inspect the components. For additional information, refer to
Section 303 - 00 .
5. CAUTION: Lubricate the parts with clean engine oil before installing.
To assemble, reverse the disassembly procedure. Klj . 2 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Piston
Disassembly
1. Using the special tool, press the piston pin out from the connecting rod and piston assembly.
2. Remove the connecting rod from the piston.
3. Clean and inspect the connecting rod and piston. For additional information, refer to Section 303 - 00 .
Assembly SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Piston Pin Tool or equivalent
303-
D034 (D81L- 6135-A)
Material Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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1. Lubricate the piston pin and piston pin bore with clean engine oil.
2.
NOTE: The connecting rod can be installed in either direction.
Position the piston pin in the bore aligned with the connecting rod bore.
3. Using the special tool, press the piston pin into the piston and rod assembly. Klj . 2 ba
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CAUTION: The moving components must be lubricated with clean engine oil before
assembly.
CAUTION: The components with oil holes must be correctly aligned with the oil feed
holes.
1. If necessary, install the following: 1. the cylinder block dowels.
2. the oil gallery plugs.
3. the water jacket plugs.
2. If equipped, install the engine coolant heater. For additional information refer to Section 303 -
03A .
3. Using the camshaft bearing service set, install the engine dynamic balance shaft bearings. Adapter, Crankshaft Rear Seal
(Use only the adapter and the
center jack screw)
303-
S560 (T96T-6701- A) Spreader Bar
303-
D089 (D93P-6001- A3)
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 Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Pipe Sealant with Teflon®
XW7Z-19554-
AA WSK-
M2G350-
A2 Klj . 2 ba
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11.
CAUTION: The crankshaft journals must be protected from damage when installing
the crankshaft.
Position the crankshaft.
CAUTION: The main bearings are precision selective fit. Inspect the bearing clearance.
For additional information, refer to Section 303 - 00 .
12. NOTE: If the rear main bearing cap is not secured within four minutes, the sealant must be
removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no
sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause
future oil leakage.
Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket
and sealant to the rear main bearing cap- to-cylinder block parting line. Klj . 5 ba
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19. Install the oil pan bridge and baffle assembly.
20. Using a new gasket, install the oil pump screen cover and tube.
21. Install the timing chain tensioner.
1. Position the timing chain tensioner.
2. Install the bolts.
22. Retract the tensioner pad retracting mechanism. 1. Compress the tensioner pad retracting mechanism.
2. Insert a retaining pin. Klj . 8 ba
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28. Remove the retaining pin.
CAUTION: The components removed should be marked for location. Make sure the used
parts are installed in the correct location.
29. NOTE: Install the new cylinder head gaskets with the small hole to the front of the engine.
Using new gaskets, install the RH and the LH cylinder heads.
30. CAUTION: Always use new bolts.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
Position the new bolts. 1. Position the new long bolts.
2. Position the new short bolts. Klj . 10 ba
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31. Tighten the bolts in three stages in the sequence shown:
zStage 1: Tighten to 20 Nm (15 lb- ft).
z Stage 2: Tighten to 40 Nm (30 lb- ft).
z Stage 3: Tighten to 50 Nm (37 lb- ft).
32. CAUTION: Do not loosen all of the bolts at one time. Each bolt must be loosened
and tightened prior to working on the next bolt in the sequence.
Tighten the bolts in four stages in the sequence shown: short bolts numbered 2, 4, 6 and 8:
zStage 1: Tighten to 25 Nm (18 lb- ft).
z Stage 2: Tighten an additional 180 degrees.
Long bolts numbered 1, 3, 5 and 7:
z Stage 3: Tighten to 45 Nm (33 lb- ft).
z Stage 4: Tighten an additional 180 degrees.
33. NOTE: Lubricate the valve tappets with clean engine oil prior to installing.
Install the valve tappets. Klj . 11 ba
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z
Install the valve tappets.
z Install the tappet guide plates and retainers.
z Install the bolts.
34. NOTE: Lubricate the push rods with clean engine oil prior to installation.
Install the 12 push rods.
35. Install the 12 rocker arms. For additional information, refer to Rocker Arm in this section.
36. NOTE: Use pipe sealant with Teflon® on studs No. 4 and 6, and bolt No. 12.
Using a new gasket, install the engine front cover. Tighten the nuts and the bolts in the
sequence shown. zInstall a 135.5 mm (5.42 in) stud at location No. 5 and tighten to 7 Nm (62 lb- in).
z Install a 137 mm (5.48 in) stud at locations No. 4, 6, 7 and 10, and tighten to 7 Nm (62 lb-
in).
z Using a new gasket, install the water pump.
z Tighten bolt No. 12 to 10 Nm (89 lb- in). All other nuts and bolts are to be tightened to 28 Klj . 12 ba
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Nm (21 lb-
ft).
37. NOTE: Lubricate the parts with clean engine oil before assembly.
Using the special tool, install the front crankshaft seal.
38. Install the crankshaft position sensor.
39. Apply a bead of silicone gasket and sealant to the keyway in the crankshaft damper. Using the special tool, position and install the crankshaft damper. Klj . 13 ba
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