engine FORD MUSTANG 2003 Workshop Manual

N806155 Bolt (2 req'd)
92 6C315 Crankshaft position sensor
93 N806300 Stud bolt (5 req'd)
94 6C086 Engine front cover
95 N806155 Bolt
96 6B288 Camshaft position sensor
97 N606543 Bolt (4 req'd)
98 6L266 Timing chain tensioner
99 6268 Timing chain belt
100 6K297 Timing chain cover
101 6M269 Timing chain tensioner
102 6L253 Timing chain tensioner arm
103 N806184 Bolt (3 req'd)
104 19D629 A/C compressor
105 8501 Water pump
106 N806177 Bolt (4 req'd)
107 N806183 Bolt (4 req'd)
108 6621 Oil pump
109 N806201 Woodruff key
110 6333 Crankshaft main bearing (5 req'd)
111 6A341 Crankshaft thrust washer (3 req'd)
112 6C357 Crankshaft main bearing side bolt (10 req'd)
113 6010 Cylinder block
114 9439 Intake manifold gasket (2 req'd)
115 6083 Head gasket
116 6505 Exhaust valve (8 req'd)
117 6507 Intake valve (8 req'd)
118 87838 Pipe plug (8 req'd)
119 12405 Spark plug (8 req'd)
120 6F087 Dowel
121 9431 Exhaust manifold
122 6C501 Valve tappet (16 req'd)
123 6529 Rocker arm (16 req'd)
124 6049 Cylinder head, RH
125 W701681 Stud (8 req'd)
126 9Y431 Exhaust manifold gasket
127 9F485 EGR valve tube to manifold connector
128 W701706 Nut (8 req'd)
129 181198A Engine lifting eye
130 6A517 Valve stem seal (16 req'd)
131 6513 Valve spring (16 req'd)
132 Klj . 6 ba
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A modular engine is built around four modules:
zthe intake module
z the cylinder head module (RH)
z the cylinder head module (LH)
z the lower engine module
While not all repairs can take advantage of the modular concept, most out-of- vehicle repairs benefit
due to the reduction of necessary time and labor.
The basic engine components consist of the following:
zsingle overhead camshafts
z two valves per cylinder
z sequential multiport fuel injection (SFI)
z aluminum cylinder heads (6049)
z cast iron, 90- degree V-shaped cylinder block
z individual ignition coils for each spark plug
z composite-material intake manifold
z large- bore throttle body N605919 Bolt
174 18663 Heater water tube
175 N806007 Dowel (2 req'd)
176 N807198 Dowel (2 req'd)
177 N806168 Bolt (6 req'd)
178 6375 Flywheel (automatic transmission)
179 6310 Crankshaft oil slinger
180 6701 Crankshaft rear oil seal
181 N806155 Bolt (6 req'd)
182 6K318 Crankshaft rear oil seal and retainer
183 7120 Transmission input shaft pilot bearing
184 N806435 Pipe plug
185 N87836 Dowel (2 req'd) Klj . 8 ba
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DIAGNOSIS AND TESTING
Engine
For basic mechanical concerns, refer to
Section 303 - 00 . Refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual. SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Klj . 1 ba
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IN-
VEHICLE REPAIR
Intake Manifold
Removal 1. Drain the engine cooling system. For additional information, refer to Section 303 - 03A or
Section 303 - 03B .
2. Remove the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
3. Disconnect the fuel line. For additional information, refer to Section 310 - 00 .
4. Disconnect the upper radiator hose from the water outlet connector.
5. Disconnect and remove the upper radiator hose.
6. Disconnect the accelerator cable, speed control actuator cable and return spring.
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Klj . 1 ba
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36. Separate the engine harness and position it out of the way.
37. Disconnect the water temperature indicator sender.
38. Remove the water outlet connector.
39. Remove the water thermostat and the O-
ring.
z Inspect the O- ring and discard if necessary. Klj . 9 ba
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3. Install the water outlet adapter.
4. Connect the water temperature indicator sender.
5. Position the engine harness and attach to the intake manifold in two locations.
6. Connect the heater hose. Klj . 11 ba
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40. Refill the engine cooling system. For additional information, refer to
Section 303 - 03A or
Section 303 - 03B . Klj . 20 ba
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IN-
VEHICLE REPAIR
Valve Cover RH
Removal and Installation 1. Remove the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
2. Disconnect the fuel line. For additional information, refer to Section 310 - 00 .
3. Separate the engine wiring harness from the valve cover studs.
4. Separate the engine wiring harness from the valve cover studs.
5. Remove the positive crankcase ventilation (PCV) hose from the valve cover and position aside.
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Material
Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323- A4 Klj . 1 ba
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6. Raise and support the vehicle. For additional information, refer to
Section 100 - 02 .
7. Remove the bolt and position the transmission filler tube aside.
8. Remove the bolts, studs and the valve cover in the sequence shown. zClean and inspect the sealing surfaces.
9. NOTE: Apply an eight millimeter bead of silicone gasket and sealant at the intersection of the
engine front cover and the cylinder head.
To install, reverse the removal procedure. Klj . 2 ba
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IN-
VEHICLE REPAIR
Valve Cover LH
Removal and Installation 1. Position the oil level tube (6754) out of the way.
2. Disconnect the breather tube.
3. Separate the engine wiring harness in the locations shown.
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Material
Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323- A4 Klj . 1 ba
32003 Mustang Workshop Manual
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