engine FORD MUSTANG 2003 Workshop Manual

NOTE:
Lubricate the piston rings, cylinder walls and connecting rod bearings with clean engine
oil.
Using the special tool push the pistons through the top of the cylinder block.
14. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the
connecting rod.
NOTE: Make sure the crankshaft is at top dead center (TDC).
Using the special tool, install the connecting rod assemblies.
15. NOTE: The rod bearing cap bolts are torque- to-yield. Install new bolts, each time they are
serviced.
Install the connecting rod bearing caps and bolts. and tighten 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 90 degrees. Klj . 8 ba
352003 Mustang Workshop Manual
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21. Install the cylinder head gaskets.
22.
NOTE: Install new cylinder head bolts.
NOTE: LH is shown, RH is similar.
NOTE: Lubricate the bolt heads and threads. Use clean engine oil.
Install the LH and RH cylinder heads and tighten the bolts in six stages, in the sequence shown. zStage 1: Tighten to 40 Nm (30 lb- ft).
z Stage 2: Tighten an additional 90 degrees.
z Stage 3: Loosen the bolts a minimum of one full turn.
z Stage 4: Tighten to 40 Nm (30 lb- ft).
z Stage 5: Tighten an additional 90 degrees.
z Stage 6: Tighten an additional 90 degrees.
23. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. Klj . 10 ba
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44. Install the oil pan and gasket, and loosely install the bolts.
45. Tighten the bolts in the sequence shown, in two stages.
zStage 1: Tighten to 20 Nm (15 lb- ft).
z Stage 2: Rotate an additional 60 degrees.
46. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed
and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of
wetness, or four minutes, whichever is longer. Failure to follow this procedure can result in
future oil leakage.
Apply silicone gasket and sealant in the locations shown. Klj . 17 ba
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47. Install the engine front cover, the bolts and the studs, and tighten the fasteners in the sequence
shown to 25 Nm (18 lb- ft). 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 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 1.25 x 91.1
7 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 1.25 x 91.1
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 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
12 W706560 Stud, Hex Head Pilot, M8 x 1.25 x 65 —
M8 x
1.25 x 16 Klj . 18 ba
352003 Mustang Workshop Manual
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58. Lubricate the front oil seal and the engine front cover with clean engine oil.
59. Using the special tools, install the front oil seal.
60.
NOTE: If the crankshaft pulley is not installed within four minutes, the sealant must be removed
and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of
wetness, or four minutes, whichever is longer. Failure to follow this procedure can result in
future oil leakage.
Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.
61. Using the special tool, install the crankshaft pulley. Klj . 22 ba
352003 Mustang Workshop Manual
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62. Install the crankshaft pulley and tighten the bolt in four stages.
zStage 1: Tighten to 90 Nm (66 lb- ft).
z Stage 2: Loosen the bolt one full turn.
z Stage 3: Tighten to 50 Nm (37 lb- ft).
z Stage 4: Tighten an additional 90 degrees.
63. NOTE: Lubricate the O- ring seal with clean engine coolant.
Install the water pump.
64. Install the water pump pulley and the bolts. Klj . 23 ba
352003 Mustang Workshop Manual
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65. Install the supercharger belt idler support bracket assembly.
66.
NOTE: Lubricate the O- rings with clean engine coolant.
NOTE: LH is shown, RH is similar.
Install the coolant bypass tube and mounting bolts.
67. NOTE: LH is shown, RH is similar.
Install the coolant bypass tube studs. Klj . 24 ba
352003 Mustang Workshop Manual
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68.
NOTE: Lubricate the O- ring with clean engine coolant.
Install the heater water inlet tube.
69. NOTE: Lubricate the O- rings with clean engine coolant.
Install the heater water outlet tube and the mounting bolts.
70. NOTE: Inspect the intake manifold gaskets and install new gaskets, if necessary.
Install the intake manifold, supercharger and fuel supply manifold as an assembly, and tighten
the bolts to 10 Nm (89 lb- in) in the sequence shown. Klj . 25 ba
352003 Mustang Workshop Manual
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71. Position the wiring harness onto the engine and attach it to the four fuel supply manifold studs.
72. Connect the eight fuel injector electrical connectors.
73.
NOTE: RH is shown, LH is similar.
Install the RH and LH ignition coils and connect the electrical connectors.
74. Install the harness support bracket. Klj . 26 ba
352003 Mustang Workshop Manual
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79.
NOTE: LH is shown, RH is similar.
Install the RH and LH radio ignition interference capacitors.
80. NOTE: LH is shown, RH is similar.
Connect the two radio ignition interference capacitor electrical connectors.
81. Connect the engine coolant temperature (ECT) sensor electrical connector, and attach the harness to the stud. Klj . 28 ba
352003 Mustang Workshop Manual
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