lock FORD MUSTANG 2003 Workshop Manual

36. Index-
mark the driveshaft flange and the rear axle pinion flange.
37. Remove the four bolts
38. Index- mark the driveshaft at the six o'clock position.
39. CAUTION: the driveshaft flange fits tightly on the rear axle pinion flange pilot. Never
hammer on the driveshaft or any of its components to disconnect the driveshaft flange
from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange. Klj . 9 ba
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NOTE:
Do not rotate the driveshaft.
Using a suitable tool, disconnect the driveshaft flange from the rear axle flange and remove the
driveshaft.
40. Index- mark the transmission output shaft at the six o'clock position.
41. Remove the starter motor terminal cover.
42. Disconnect the starter wiring. 1. Remove the nut and disconnect the battery positive cable.
2. Remove the nut and disconnect the starter solenoid wire. Klj . 10 ba
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33. Remove the bolts and the coolant pump pulley.
34. Remove the coolant pump from the cylinder block.
zRemove the bolts.
z Inspect and clean the sealing surfaces.
35. Remove the bolt. Klj . 10 ba
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63.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the
connecting rod.
NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the
ridge or carbon deposits from each cylinder using a cylinder ridge reamer following
manufacturer's instructions.
Using the special tool, push pistons number 1 and 6 through the top of the cylinder block.
64. To remove pistons 3 and 5, 4 and 7, 2 and 8, turn crankshaft 90 degrees and repeat the previous two steps.
65. Remove the side main bearing cap bolts. Klj . 19 ba
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66. Remove and discard the main bearing cap bolts.
67. Remove the main bearing caps and the crankshaft lower main bearings from the cylinder block.
68. Remove the crankshaft, the crankshaft thrust washer, and the crankshaft upper main bearings
from the cylinder block. Klj . 20 ba
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Install the special tool.
2. Remove the exhaust camshaft sprocket and the intake camshaft bolt, washer and spacer.
3. Compress the tensioner and install a lock pin.
4. Remove the special tool.
5. Remove the timing chain and the camshaft sprocket. Klj . 2 ba
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Install the tensioner.
11. CAUTION: Timing marks must be at 12 o'clock and indexed at 6 o'clock.
Install the camshaft sprockets and the chain as an assembly.
12. Install the special tool.
13. Install the camshaft spacer, washer and bolt, and hand- tighten the bolt. Klj . 9 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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