lock FORD MUSTANG 2003 Workshop Manual

65. Clean and inspect pistons. For additional information, refer to
Section 303 - 00 .
66. Remove the crankshaft bearing cap fasteners. 1. Remove and discard the cross- mounted main cap bolts.
2. Loosen the jackscrews.
3. Remove and discard the main cap bolts.
67. Remove the main bearing cap and the crankshaft main bearings from the cylinder block.
68. Remove the crankshaft, crankshaft main bearings and the thrust washer. Klj . 23 ba
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Assembly
NOTE:
During engine assembly, it may by necessary to check bearing clearances and end play. For
additional information, refer to Section 303 - 00 .
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.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart Crankshaft Seal Installer
303-
635
Material Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Super Premium SAE 5W-20
Motor Oil
XO- 5W20- QSP or equivalent WSS-
M2C153- H Klj . 3 ba
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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 . 4 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 crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. NOTE: Do not install the upper thrust washer until the crankshaft is installed. Refer to Step 3.
NOTE: Do not install the upper thrust washer until the crankshaft (6303) is installed. Refer to
Step 3.
Install the crankshaft onto the upper main bearings. Klj . 5 ba
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7.
NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the
crankshaft surface).
Push the crankshaft rearward and install the crankshaft upper thrust washer at the rear of the
No. 5 main boss.
8. NOTE: Rotate the jackscrews into the bearing caps enough to provide clearance to the cylinder
block prior to installing the bearing caps.
Install the lower main bearings into the main bearing caps and lubricate them with clean engine
oil.
9. Install the rear main bearing cap.
10. Install the remaining main bearing caps on the cylinder block and tap into place using a plastic or dead- blow hammer. Klj . 6 ba
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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
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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
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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
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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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