service FORD MUSTANG 2003 Manual PDF

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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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
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Valve Head Diameter
·
Intake 37 mm (1.46 inch)
·
Exhaust 30 mm (1.18 inch)
·
Gauge Diameters 35.0 and 28.0 mm (1.378-
1.102 inch) Valve Face Runout Limit 0.05 mm (0.002 inch)
Valve Face Angle 45.5 degrees
Valve Stem Diameter (Std)
·
Intake 6.975-
6.995 mm (0.2754- 0.2746 inch) ·
Exhaust 6.949-
6.970 mm (0.2744- 0.2736 inch) Valve Springs
·
Compression Pressure (N (Lb) @ Spec
Length) ·
Intake 711.47 N @ 26.19 mm (159.9 Lb-
Ft @ 1.031
inch) ·
Exhaust 711.47 N @ 26.19 mm (159.9 Lb-
Ft @ 1.031
inch) ·
Free Length (Approximate) ·
Intake 42.16 mm (1.6598 inch)
·
Exhaust 42.16 mm (1.6598 inch)
·
Installed Pressure (N (Lb- Ft) @ Spec. Length) ·
Intake 289.1 N @ 36.14 mm (64.99 Lb-
Ft @ 1.4228
inch) ·
Exhaust 289.1 N @ 36.14 mm (64.99 Lb-
Ft @ 1.4228
inch) ·
Service Limit 10% Pressure Loss @ 28.02 mm (1.103 inch)
Roller Follower
·
Ratio 1.8:1
Hydraulic Lash Adjuster
·
Diameter (Std) 16.000-
15.988 mm (0.6299- 0.6294 inch) ·
Clearance to Bore 0.018-
0.069 mm (0.000709- 0.002717 inch) ·
Service Limit 0.016 mm (1.0006299 inch)
·
Hydraulic Leakdown Rate d 5-
25 seconds ·
Collapsed Lash Adjuster Gap— Desired 0.80-
1.20 mm (0.0315- 0.0472 inch) CAMSHAFT
Theoretical Valve Lift @ Zero Lash
·
Intake (Primary) 10.0 mm (0.3937 inch)
·
Intake (Secondary) 10.0 mm (0.3937 inch)
·
Exhaust 10.0 mm (0.3937 inch)
End Play 0.025-
0.165 mm (0.00098- 0.00649 inch) ·
Service Limit 0.190 mm (0.007480 inch)
Journal to Bearing Clearance 0.025-
0.076 mm (0.00098- 0.002992 inch) ·
Service Limit 0.100 mm (0.003937 inch) MAX
Journal Diameter (All) 26.962-
26.936 mm (1.0615- 1.0605 inch) Klj . 2 ba
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Bearing Inside Diameter (All) 27.012-
26.987 mm (1.0635- 1.0625 inch) Front Bearing Location e
CYLINDER BLOCK
·
Head Gasket Face Flatness 0.15 mm (0.006 in) MAX overall
·
Head Gasket Surface Finish b Main Bearing Bore Diameter 72.400-
72.424 mm (2.8504- 2.8513 inch) CRANKSHAFT
Main Bearing Journal Diameter 67.481-
67.505 mm (2.6567269- 2.6576718 inch) Connecting Rod Journal
·
Diameter 52.983-
53.003 mm (2.085941- 2.086728 inch) Crankshaft Free End Play 0.130-
0.301 mm (0.005118- 0.011850 inch) Crankshaft Runout to Rear Face of Block 0.050 mm (0.01969 inch) MAX
Connecting Rod Bearings
Clearance to Crankshaft
·
Desired 0.027-
0.069 mm (0.0010629- 0.0027165 inch) ·
Allowable 0.027-
0.069 mm (0.0010629- 0.0027165 inch) Bearing Wall Thickness (Std)
f 1.920-
1.928 mm (0.075591- 0.075905 inch) Main Bearings
Clearance to Crankshaft
·
Desired 0.025-
0.045 mm (0.00098- 0.00177 inch) ·
Allowable 0.025-
0.050 mm (0.00098- 0.00197 inch) Bearing Wall Thickness (Std)
f 2.451 mm (0.0965 inch)
Connecting Rod
·
Pin Bore Diameter 22.012-
22.024 mm (0.86661- 0.86708 inch) ·
Crankshaft Bearing Bore Diameter 56.866-
56.886 mm (2.23881- 2.23960 inch) ·
Length (Center- to-Center) 150.7 mm (5.933 inch)
Alignment (Bore-To-
Bore Max. Diff.) g ·
Twist 0.050 per 25 mm (0.00197 per 0.9843 inch)
·
Bend 0.038 per 25 mm (0.00150 per 0.9843 inch)
Side Clearance (Assembled to Crank)
·
Standard 0.15-
0.45 mm (0.00591- 0.01772 inch) ·
Service Limit 0.50 mm (0.01969 inch) MAX
CYLINDER BORE AND PISTON
Cylinder Bore
Diameter
h ·
Surface Finish (RMS) 0.2-
0.6 Microns ·
Out- of-Round Limit 0.015 mm
·
Out- of-Round Service Limit 0.020 mm
·
Taper Service Limit 0.006 mm
Piston
·
Diameter i .028 mm (.0010 inch) Klj . 3 ba
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a
Newly Installed— Refers to the condition of the "NEW" drive belt before the engine has made no more
than one rotation and before the belt has had a chance to stretch or seat into the pulley grooves.
c P=Primary, S=Secondary, E=Exhaust
d Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in
tappet.
e Distance front edge of bearing is installed below front face of cylinder block.
f 0.050 Undersize— add 0.025 to standard thickness.
g Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total
difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline.
h Cylinder Bore Diameter
Red— 90.200-90.213
Blue— 90.213-90.226
Yellow— 90.226-90.239 ·
Coded Red 1 90.167-
90.188 mm (3.299- 3.5505 inch) ·
Coded Blue 2 90.180-
90.195 mm (3.5504- 3.5510 inch) ·
Coded Yellow 3 90.198-
90.208 mm Coated Piston-
to-Bore Clearance -
0.010/+0.026 mm (- 0.0003937/+0.0010236 inch) Pin Bore Diameter 21.9985-
22.0025 mm (0.866081- 0.866238 inch) Ring Groove Width
·
Compression (Top) 1.230-
1.250 mm (0.484- 0.0492 inch) ·
Compression (Bottom) 1.520-
1.540 mm (0.05984- 0.06062 inch) ·
Oil Ring 3.030-
3.055mm Piston Pin
·
Length 61.601-
62.030 mm (2.42523- 2.44212 inch) ·
Diameter 22.0005-
22.0030 mm (0.8661596- 0.8662581
inch) Pin to Piston Fit
j -
0.0045/+0.002 mm (- 0.000177/+0.0000787 inch) Pin to Rod Clearance
·
Standard 0.004-
0.0175 mm (0.000157- 0.00689 inch) ·
Service Limit 0.035 mm (0.001378 inch)
Oil Ring 1.15 mm (0.04528 inch) MAX
·
Side Clearance .075
-.1000 mm (.0030 -.0040 inch) ·
Compression (Top) 0.0090-
0.0235 mm (0.000354- 0.000925 inch) ·
Compression (Bottom) 0.030-
0.080 mm (0.00118- 0.00315 inch) ·
Oil Ring Snug Fit
Ring Gap
k ·
Compression (Top) .150
-.300 mm (.006- 0.0018 inch) ·
Compression (Bottom) 0.300-
0.550 mm (0.0018- 0.0022 inch) ·
Oil Ring (Steel Rail) 0.15-
0.66 mm (0.00591- 0.02598 inch) Piston Rings
·
Ring Gap ·
Compression (Top) 1.00 mm (0.03937 inch) MAX
·
Compression (Bottom) 1.00 mm (0.03937 inch) MAX
·
Service Limit 1.15 mm (0.04528 inch) MAX
LUBRICATION SYSTEM
Oil Capacity (Quarts U.S.)
6 ±
0.25 l Klj . 4 ba
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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.
z The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft. Klj . 2 ba
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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 coolant 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 thermostat
z upper radiator hose
z lower radiator hose
z heater coolant 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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IN-
VEHICLE REPAIR
Valve — Springs, Retainer and Valve Stem Seal
Removal 1. Remove the roller followers. For additional information, refer to Roller Followers in this section.
2. Remove the spark plugs. For additional information, refer to Section 303 - 07C .
3. Position the piston of the cylinder being serviced at the bottom of the stroke.
4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder any
loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be
removed support the valve prior to removal. Use compressed air in the cylinder to hold both valves in position. SECTION 303-
01D: Engine — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Special Tool(s)
Compressor, Valve Spring
303-
452 (T93P-6565- AR) Installer, Valve Stem Oil Seal
303-
383 (T91P-6571- A) Compressor, Valve Spring
303-
567 (T97P-6565- AH) Spacer, Valve Spring
Compressor
303-
382 (T91P-6565- AH) Klj . 1 ba
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13.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the
connecting rod.
NOTE: Make sure that the piston arrow is facing forward.
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 T.D.C.
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 . 7 ba
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DESCRIPTION AND OPERATION
Engine Cooling
CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant VC -7-A (in Oregon VC -7-B) or equivalent meeting Ford specification WSS- M97B51-A1
(yellow color). Always fill the cooling system with the same coolant that is present in the
system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
The 4.6L cooling system components include the:
zblock heater
z engine coolant temperature (ECT) sensor
z fan blade, fan motor and fan shroud assembly
z radiator
z pressure relief cap
z radiator draincock
z coolant pump
z coolant thermostat
z oil filter adapter
z radiator overflow hose
z upper radiator hose
z lower radiator hose
The radiator overflow hose circulates the coolant.
The coolant thermostat:
zcontrols the engine coolant temperature.
z allows for quicker engine warm- up.
The degas bottle/coolant expansion tank:
zprovides a location for service fill.
z contains coolant expansion and system pressurization.
z provides air separation during operation.
z replenishes the engine coolant to the system.
The engine coolant flows:
zfrom the lower radiator hose to the coolant pump.
z from the coolant pump to the engine block and the cylinder heads.
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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