FORD MUSTANG 2003 Workshop Manual

ASSEMBLY
Engine
SECTION 303-
01D: Engine — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Special Tool(s)
Guides, Connecting Rod
303-
442 (T93P-6136- A) Installer, Crankshaft Vibration
Damper
303-
102 (T74P-6316- B) Installer, Front Cover Oil Seal
303-
335 (T88T-6701- A) Installer, Crankshaft Rear Oil
Seal
303-
518 (T95P-6701- DH) Installer, Crankshaft Rear Oil
Slinger
303-
517 (T95P-6701- CH) Compressor, Valve Spring
(Intake)
303-
452 (T93P-6565- AR) Compressor, Valve Spring
(Exhaust)
303-
567 (T97P-6565- AH) Installer, Crankshaft Rear Oil
Seal Klj . 1 ba
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Assembly
All vehicles
1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft. 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 Super Premium SAE 5W-20
Engine Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Motorcraft Premium Gold
Engine Coolant VC-7-
A (in
Oregon VC-7- B) (yellow color) WSS-
M97B51-
A1 Klj . 2 ba
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3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart
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 "2."
z Repeat this process for the remaining four main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearing Chart to determine the required grade for each main bearing. Klj . 3 ba
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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.
5. Install the upper main bearings into the cylinder block and the lower main bearing into the crankshaft main bearing caps. Lubricate the main bearings with clean engine oil.
6. Install the crankshaft into the cylinder block.
7. CAUTION: Make sure the coated side of the thrust washer with the 5- mm wide oil
grooves faces the crankshaft thrust surface.
Push the crankshaft rearward and install the crankshaft thrust washer at the back of the No. 5
main boss. Klj . 4 ba
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8. Loosely install the main bearing caps and the bolts.
9. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the
forward position.
10. Tighten bolts 1- 20 in sequence shown in four stages.
z Stage 1: tighten to 10 Nm (89 lb- in).
z Stage 2: tighten to 25 Nm (18 lb- ft).
z Stage 3: tighten to 40 Nm (30 lb- ft). Klj . 5 ba
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z
Stage 4: tighten an additional 90 degrees.
11. Install and tighten the cross- mounted bolts in two stages.
z Stage 1: tighten to 40 Nm (30 lb- ft).
z Stage 2: tighten an additional 90 degrees.
12. Check the crankshaft end play. For additional information, refer to Section 303 - 00 . Klj . 6 ba
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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.
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 T.D.C.
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 . 7 ba
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16. Check the connecting rod bearing clearance. For additional information, refer to
Section 303 -
00 .
17. Install the LH engine mount.
18. Install the RH engine mount.
19. Install the nuts and the windage tray.
20. Install and tighten the oil pump screen spacer. Klj . 8 ba
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21. Position the oil pump and tighten the bolts in the sequence shown.
22.
NOTE: Install a new O- ring if necessary.
Install the oil pump screen cover and tube.
23. Install the cylinder head gaskets.
24. CAUTION: The camshafts must be positioned so the camshaft keyway is 90 degrees
from the valve cover gasket surface to avoid damage to valves and pistons during timing Klj . 9 ba
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procedures.
Make sure the camshaft timing sprockets are positioned correctly.
25. NOTE: The LH is shown; the 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.
26. CAUTION: Timing chain procedures must be followed exactly or damage to valves
and pistons will result.
Compress the tensioner plunger, using a vise. Klj . 10 ba
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