engine FORD MUSTANG 2003 Workshop Manual

53. Install a new engine front cover gasket on the engine front cover.
54. Install the engine front cover.
Item Part
Number Description
1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
6 W706508 Stud, Hex Shldr Pilot, M8 x 1.25 x 50 —
M6 x 1 x
10 7 N808586 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 60
—
M6 x 1 x 26 Klj . 21 ba
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55. Tighten the four oil pan bolts in the sequence shown in three stages.
zStage 1: Tighten to 2 Nm (18 lb- in).
z Stage 2: Tighten to 20 Nm (15 lb- ft).
z Stage 3: Tighten an additional 60 degrees.
56. Install the belt idler pulleys. 57. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil. 8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
11 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 12 W706560 Stud and Washer, Hex-
Head Pilot, M8 x 1.25 x 65
— M8 x 1.25 x 16 13 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 14 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 15 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 Klj . 22 ba
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62.
NOTE: Use special tool 303- 009 or a suitable strap wrench to hold the crankshaft pulley.
Install the washer and the bolt. Tighten the bolt in four stages. zStage 1: Tighten to 90 Nm (66 lb- ft).
z Stage 2: Loosen one full turn.
z Stage 3: Tighten to 50 Nm (37 lb- ft).
z Stage 4: Tighten an additional 90 degrees.
63. Install the LH engine mount.
64. Install the RH engine mount. Klj . 24 ba
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Apply an eight millimeter bead of silicone gasket and sealant at the intersection of the engine
front cover and the cylinder head.
71. NOTE: RH valve cover shown, LH similar.
Install the valve covers.
72. NOTE: Lubricate the O- ring seal with clean engine oil.
Install a new O- ring.
73. Install the tube. Klj . 27 ba
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94. Install the breather tube.
95. Install the engine control sensor wiring.
Item Part Number Description
1 — To crankshaft position sensor
2 — To A/C compressor
3 — To radio ignition interference capacitor (2)
4 — To fuel injectors (8) Klj . 33 ba
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96. Install the RH and LH special tools.
97. Using the special tool, remove the engine from the stand.
98. Using the special tool, install the crankshaft rear main seal.
zLubricate the oil seal using clean engine oil. 5 — To ignition coils (8)
6 — To engine coolant temperature sensor
7 — To throttle position sensor
8 — To idle air control valve
9 — To EGR vacuum regulator
10 — To differential pressure feedback EGR
11 — To fuel pressure regulator
12 — Fuel injection ground
13 — To generator
14 — To camshaft position sensor
15 — To body
16 — To heated oxygen sensor (2)
17 — Engine bulkhead connector
18 — To low coolant sensor
19 — To body
20 — To power distribution box
21 — To body Klj . 34 ba
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INSTALLATION
Cylinder Heads
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Special Tool(s)
Installer, Crankshaft Vibration
Damper
303-
102 (T74P-6316- B) Installer, Front Cover Oil Seal
303-
335 (T88T-6701- A) Holding Tool, Crankshaft
303-
448 (T93P-6303- A) Spreader Bar
303-
D089 (D93P-6001- A3) Lifting Bracket Set, Engine
303-
D074 (D91P-6001- A) Strap Wrench
303-
D055 (D85L-6000- A) or
equivalent Compressor, Valve Spring
303-
567 (T97P-6565- AH) Compressor Spacer, Valve
Spring Klj . 1 ba
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Both cylinder heads
1. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block
must be clean. For additional information, refer to Cylinder Heads in the Removal portion
of this section.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not
permitted. The gasket must be installed dry.
CAUTION: The new gasket has a film coating which is crucial to the gasket's ability
to seal correctly. Do not scratch the gasket.
NOTE: RH head gasket shown; LH head gasket similar.
Install the head gasket over the dowel pins. 303-
382 (T91P-6565- AH) Remover/Installer, Cylinder
Head
303-
572 (T97T-6000- A)
Material Item Specification
Motorcraft Silicone Gasket
Remover
ZC-
30 —
Motorcraft Metal Surface Prep
ZC-
31 —
Hydraulic Chain Tensioner
Retaining Clip
1L3Z-6P250-
AA —
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 Klj . 2 ba
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4. Remove the special tools from both ends of the cylinder head.
NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.
5. Install the hydraulic lash adjusters in their original locations.
6. CAUTION: Timing chain procedures must be followed exactly or damage to the
valves and pistons will result.
NOTE: LH shown, RH similar. Klj . 4 ba
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11. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock
position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12
o'clock position.
12. CAUTION: When instructed to do so, rotate the crankshaft counterclockwise only.
Do not rotate past the position shown or severe piston and valve damage can occur.
NOTE: The number one cylinder is at top dead center (TDC) when the stud on the engine block
fits into the slot in the handle of the special tool.
Using the special tool, position the crankshaft so the number one cylinder is at TDC. Klj . 6 ba
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