engine FORD MUSTANG 2003 Workshop Manual

7. Install the camshaft thrust plate.
1. Position the camshaft thrust plate.
2. Install the bolts.
8. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic balance shaft assembly into the cylinder block. Turn the engine balance shaft driven gear so
that the timing mark aligns up with the timing mark on the engine balance shaft drive gear.
9. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and
the camshaft keyway will be at 6 o'clock on the camshaft.
Install the bolts.
10. CAUTION: Make sure the components are installed in the correct location.
NOTE: Lubricate the crankshaft main bearings prior to installation.
Install the crankshaft upper main bearings and the crankshaft upper thrust main bearing. Klj . 4 ba
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CAUTION: Do not damage the cylinder wall with the sharp edges of the connecting
rod.
Install the piston with the arrow on the piston face pointing toward the front of the engine.
16. CAUTION: Inspect the connecting rod bearing clearance. For additional information,
refer to Section 303 - 00 .
CAUTION: The connecting rod cap will fit only one way.
Position the connecting lower rod bearing and the connecting rod cap on the connecting rod
and the crankshaft journal.
17. Install the rod caps. Tighten the bolts 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 105 degrees. 18. Install the remaining pistons and the connecting rods. Klj . 7 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
282003 Mustang Workshop Manual
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59. Install the stud bolt.
60. Position the engine wire harness.
61. Connect the crankshaft position sensor electrical connector.
62. Install the pin-
type retainer. Klj . 20 ba
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63. Connect the engine oil pressure sender electrical connector.
64. Connect the camshaft position (CMP) sensor electrical connector.
65. Connect the cylinder head temperature (CHT) sensor.
66. Install the fuel injectors and the fuel injection supply manifold as an assembly. For additional
information, refer to Section 303 - 04A .
67. Install a new upper intake manifold gasket. Klj . 21 ba
282003 Mustang Workshop Manual
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82. Install the special tool.
83. Install the special tool.
84. Install the RH engine support insulator.
85. Install the LH engine support insulator.
86. Remove the engine from the stand. Klj . 26 ba
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87.
NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.
Assemble the special tools and the crankshaft rear seal.
88. Install the special tools on the rear of the crankshaft.
89. Install the crankshaft rear seal. Tighten the center jack screw (303- S560) until the spacer (303-
561) contacts the engine block. Klj . 27 ba
282003 Mustang Workshop Manual
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