engine FORD MUSTANG 2003 Workshop Manual

5.
NOTE: This step will allow the installation of the exhaust manifold through the bottom and
access for the removal of the engine lift brackets.
Using a suitable floor crane raise the engine.
6. Remove the RH and LH special tool.
7. Install new gaskets and the exhaust manifolds, tighten the nuts in the sequence shown.
8. Lower the engine, remove the special tool. Klj . 3 ba
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36. Install the safety clip to the manifold suction line.
37. Connect the electrical connector.
38. Connect the harness in three locations.
39. Connect the engine bulkhead connector. Klj . 10 ba
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44. Connect the upper radiator hose from the water outlet adapter.
45. Connect the fuel lines. For additional information, refer to Section 310
- 00 .
46. Install the battery. For additional information, refer to Section 414 - 01 .
47. Install the air cleaner and outlet tube. For additional information, refer to Section 303 - 12 .
48. Install the degas bottle. For additional information, refer to Section 303 - 03A or
Section 303 -
03B .
49. Fill the fluids to the correct levels.
50. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
51. Recharge the A/C system. For additional information, refer to Section 412 - 00 .
52. Install the hood. Klj . 12 ba
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SPECIFICATIONS
SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Motorcraft Premium Engine Coolant VC-4-
A
(In Oregon VC- 5, In Canada CXC- 10) ESE-
M97B44- A Motorcraft Premium Gold Engine Coolant VC-7-
A
(In Oregon VC-7- B) WSS-
M97B51- A1 SAE 5W-
20 Engine Premium Synthetic Blend Engine Oil
XO- 5W20- QSP WSS-
M2C153- H Metal Surface Cleaner
F4AZ-
19A536- RA WSE-
M5B392- A Silicone Gasket and Sealant F7AZ-19554-
EA WSE-
M4G323- A4 Pipe Sealant with Teflon® D8AZ-19554-
A WSK-
M2G350- A2 Threadlock 262 E2FZ-19554-
B WSK-
M2G351- A6 Engine
Displacement 4.6L (4V) (281 CID)
Number of cylinders 8
Bore 90.2 mm (3.55 in)
Stroke 90.0 mm (3.54 in)
Firing order 1-3-7-2-6-5-4-
8 Oil pressure 138-310 kPa
Oil capacity
6 ±
0.25 a Compression ratio 8.5:1
Cylinder Head and Valve Train
Cylinder head gasket surface flatness 0.10 mm (0.004 inch) max. overall
Combustion chamber volume 52.6 ±
0.5 cm Valve arrangement (front to rear)
b
Intake (left hand): S-P-S-P-S-P-S-P
Valve arrangement (front to rear)
Exhaust (left hand): E-E-E-E-E-E-E-E
Valve arrangement (front to rear)
Intake (right hand): P-S-P-S-P-S-P-S
Valve arrangement (front to rear)
Exhaust (right hand): E-E-E-E-E-E-E-E
Valve guide bore diameter 7.015-
7.044 mm (0.2762- 0.2773 in) Valve stem diameter—
intake 6.975-
6.995 mm (0.2754- 0.2746 inch) Valve stem diameter—
exhaust 6.949-
6.970 mm (0.2744- 0.2736 inch) Valve stem-
to-guide clearance— intake 0.020-
0.069 mm (0.00078- 0.00272 inch) Valve stem-
to-guide clearance— exhaust 0.046-
0.094 mm (0.0018- 0.0037 in) Valve head diameter—
intake 37 mm (1.46 inch) Klj . 1 ba
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b
P=Primary, S=Secondary, E=Exhaust
c Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in
tappet.
Torque Specifications Description Nm lb-
ft lb-
in A/C compressor bolts 25 18 —
A/C peanut fittings 8 — 71
A/C muffler nut 25 18 —
Accelerator bracket bolts 10 — 89
Battery tray bolts 11 8 —
Belt idler support bracket assembly fasteners 25 18 —
Camshaft sprocket bolt 115 85 —
Coolant bypass tube studs 25 18 —
Coolant bypass tube bolts 25 18 —
Coolant hose and tube assembly bolt 25 18 —
Cooling fan motor and shroud bolts 10 — 89
Connecting rod bolt
a — — —
Engine front cover bolt a a a
Drive belt tensioner bolts 25 18 —
Cylinder head bolt
a — — —
Idler pulley bracket 25 18 —
Power steering pump bolts 25 18 —
Power steering hose fitting 65 48 —
Power steering hose bracket bolt 10 — 89
Pulley to crankshaft bolt
a — — —
EGR valve to intake manifold
a — — —
Engine coolant degas bottle bolts 10 — 89
Exhaust manifold studs 25 18 —
Generator bolts 25 18 —
Generator support bracket bolts 25 18 —
Hood prop bolt 10 — 89
Hood mounting nuts 12 9 —
Heater water inlet tube 10 — 89
Heater water outlet tube 24 18 —
Lower intake manifold-
to-cylinder head bolt a — — —
Main bearing cap bolt
a — — —
Oil filter adapter bolt 25 18 —
Oil bypass filter to adapter 50 37 —
Oil pump screen cover and tube-
to-oil pump bolt 10 — 89
Oil pan-to-
cylinder block bolt a — — — Klj . 4 ba
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a
Refer to the procedure. Oil pan-to-
engine front cover bolts a — — —
Oil pump-
to-cylinder block bolt 10 — 89
Radio ignition interference capacitor bolts 25 18 —
Oil pump screen and pickup tube-
to-main bearing cap stud spacer bolt 25 18 —
Water pump pulley bolts 25 18 —
Throttle body spacer nuts 25 18 —
Vacuum accessory bracket fasteners 10 — 89
Valve cover bolt 10 — 89
Wiring harness support bracket 25 18 —
Water pump-
to-cylinder block bolt 25 18 —
EGR valve to exhaust manifold tube nuts 40 30 —
Power steering pump to engine 25 18 —
Power steering hose bracket nut 25 18 —
Power steering reservoir bracket fasteners 10 — 89
Supercharger degas bottle bolts 10 — 89
Camshaft cap cluster to cylinder head 10 — 89
Timing chain tensioner bolts—
primary 25 18 —
Timing chain tensioner bolts—
secondary 10 — 89
Ignition coil cover bolts 10 — 89
Generator mounting bracket retainers 10 — 89
Oil level indicator tube retainer 10 — 89
Primary timing chain guide-
to-engine bolts 10 — 89
Oil pump screen and pickup tube spacer to main bearing stud 25 18 —
Belt idler pulley bolt 25 18 —
Subframe brace nuts 41 30 — Klj . 5 ba
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DESCRIPTION AND OPERATION
Engine
WARNING: Do not operate the engine with the hood open until the fan blade has been first
examined for possible cracks and separation.
The 4.6L (4V) (281 CID) Cobra engine is a V- 8 with the following features:
z intercooled supercharger
z dual overhead camshafts
z four valves per cylinder
z sequential multiport fuel injection (SFI)
z an aluminum intake manifold
z aluminum cylinder heads
z a cast aluminum, 90-degree V- cylinder block
z individually chain- driven camshafts with a hydraulic timing chain tensioner on each timing chain
z the electronic ignition system with eight ignition coils
Identification
Always refer to these labels when replacement parts are necessary or when checking engine
calibrations. The engine parts often differ within a CID family. Verification of the identification codes will
ensure that the correct parts are obtained. These codes contain all the pertinent information relating to
the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete
listing of the codes and their application.
Code Information
The engine code information label, located on the side of the valve cover and the front side of the
valve cover, contains the following:
zengine build date
z engine plant code
z engine code
Exhaust Emission Control System
Operation and necessary maintenance of the exhaust emission control devices used on this engine is
covered in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The sequential multiport fuel injection (SFI) provides the fuel/air mixture needed for combustion in the
cylinders. The eight solenoid- operated fuel injectors:
z are mounted in the lower intake manifold.
z meter fuel into the air intake stream in accordance with engine demand.
SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
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z
are positioned so that their tips direct fuel just ahead of the engine intake valves.
z are connected in series with the fuel pressure sensor.
z supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.
A constant fuel pressure drop is maintained across the fuel injectors by the fuel pressure sensor. The
fuel pressure sensor:
zis positioned upstream from the fuel injectors on the fuel injection supply manifold.
Valve Train
The valve train operates as follows:
zball- tip hydraulic lash adjusters provide automatic lash adjustment.
z roller followers ride on the camshaft lobes, transferring the up-and- down motion of the
camshafts to the valves in the cylinder heads.
Positive Crankcase Ventilation System
All engines are equipped with a closed- type positive crankcase ventilation system recycling the
crankcase vapors to the upper intake manifold.
Lubrication System
The engine lubrication system operates as follows:
zoil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil
pan.
z oil is pumped through the oil bypass filter on the left front side of the cylinder block.
z oil enters the main oil gallery where it is distributed to the crankshaft main journals and to both
cylinder heads.
z From the main journals, the oil is routed through cross- drilled passages in the crankshaft to
lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings
and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as
well as the entire connecting rod, piston and piston rings assembly.
z The left cylinder head is fed from a drilling into the supply passage feeding the main gallery at
the front of the cylinder block. The right cylinder head is fed from a drilling into the rear of the
main gallery. Main gallery pressure is reduced as it enters the cylinder head galleries through
fixed serviceable orifices located at the upper part of the feed passages. It is this reduced
pressure in the cylinder head galleries which feeds the camshaft journals, the hydraulic lash
adjusters and the primary and secondary timing chain tensioners.
z The camshaft lobe and roller followers are lubricated by splash created through valve train
operation.
Oil Pump
The lubrication system of the 4.6L (4V) engine is designed to provide optimum oil flow to critical
components of the engine through its entire operating range. The heart of the system is a positive
displacement internal gear oil pump using top seal rotors. Generically this design is known as a gerotor
pump, which operates as follows.
zThe oil pump is mounted on the front face of the cylinder block. Klj . 2 ba
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z
The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
z System pressure is limited by an integral, internally- vented relief valve which directs the
bypassed oil back to the inlet side of the oil pump.
z Oil pump displacement has been selected to provide adequate volume to ensure correct oil
pressure both at hot idle and maximum speed.
z The relief valve calibration protects the system from excessive pressure during high viscosity
conditions.
z The relief valve is designed to provide adequate connecting rod bearing lubrication under high-
temperature and high- speed conditions.
Cooling System
The engine cooling system includes the following:
zradiator
z water pump
z the electric cooling fan motor and fan blade, activated by the variable control module
z the degas bottle, which aids in maintaining the correct volume of engine coolant
z water thermostat
z upper radiator hose
z lower radiator hose
z heater water hoses
Drive Belt System
The 4.6L (4V) DOHC engine is equipped with a serpentine drive belt. To ensure maximum life, a
replacement drive belt should be of the same type as originally installed.
zThe accessories mounted on the front of the engine are belt- driven by the crankshaft.
z The serpentine drive belt is routed over each accessory pulley, driven by the crankshaft pulley
bolted to the crankshaft.
For service procedures, including tensioning, refer to Section 303 - 05 . Klj . 3 ba
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9 6268 Timing chain (2 req'd)
10 6M256 Timing chain guide
11 6L266 Timing chain tensioner
12 6L253 Timing chain tensioner arm
13 6268 Timing chain (2 req'd)
14 N804958 Bolt (2 req'd)
15 6B274 Timing chain guide
16 N606527 Bolt
17 19D269 A/C compressor
18 N806184 Bolts (3 req'd)
19 6306 Crankshaft sprocket
20 6L253 Timing chain tensioner arm
21 12A227 Ignition pulse ring
22 6C086 Engine front cover
23 N806177 Bolts (8 req'd)
24 N806300 Studs (5 req'd)
25 6700 Crankshaft front seal
26 6316 Crankshaft pulley
27 N806165 Washer
28 W701512 Stud
29 8A528 Water pump pulley
30 N806282 Bolts (4 req'd)
31 N806177 Bolts (4 req'd)
32 8501 Water pump
33 N808102 Bolt
34 19A216 Belt idler pulley
35 N804178 Nut
36 N806300 Harness support bracket
37 N806300 Stud
38 N806155 Bolt
39 6C315 Crankshaft position sensor
40 N806155 Bolt
41 6B288 Camshaft position sensor
42 N808920 Bolts (3 req'd)
43 6C254 Crankshaft extension support pulley
44 10153 Lower support bracket
45 N605909 Bolts (2 req'd)
46 8620 Accessory drive belt
47 N811268 Bolt
48 8B603 Belt idler bracket support
49 N808198 Stud
50 Klj . 8 ba
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