torque FORD MUSTANG 2003 Owners Manual

A/C compressor bracket-
to-cylinder head stud bolt 25 18 —
Oil level indicator tube-
to-cylinder head bolt 10 — 89
Coolant recovery reservoir bracket-to-
GOP bolts 9 — 80
Motor mount-
to-subframe nuts 115 85 —
Oil pan drain plug 26 19 —
Wire harness bracket to motor mount nut 27 20 —
Steering column pinch bolt 47 35 —
Front subframe-
to-body bolts 90 66 —
Front subframe-
to-shock tower bolts 115 85 —
Oil pan-to-
cylinder block bolts a — — —
Oil pan-to-
transmission bell housing 45 33 —
Main bearing bridge nuts 32 24
Oil pump cover-
to-engine front cover bolts 25 18 —
Oil pump cover-
to-engine front cover bolt 10 89 —
Oil pickup tube-
to-cylinder block bolts 25 18 —
Oil pickup tube-
to-oil pan baffle nut 48 35 —
Flywheel-
to-crankshaft bolts 80 59 —
Wire harness bracket-
to-motor mount stud- nut 27 20 —
Engine ground strap-
to-motor mount nut 27 20 —
Motor mount-
to-motor mount bracket bolts 70 52 —
RH motor mount-
to-motor mount bracket nut 70 52 —
Hood ground strap-
to-hood hinge bolt 12 9 —
Hood hinge nuts 12 9 —
Generator mounting bracket 25 18 —
Power steering pump bracket nuts 8 — 71
Power steering pump bolts 25 18 —
Valve tappet guide plate bolts 12 9 —
Generator positive cable nut 10 — 89
Power steering pressure tube to pump nut 40 30 —
Accelerator cable bracket-
to-intake manifold bolts 10 — 89
42-
pin connector bolt 10 — 89
Transmission oil cooler tube bracket-
to-motor mount bracket nut 27 20
Torque converter-
to-flywheel nuts 36 27 —
Engine-
to-transmission bolts 40 30 —
Engine mount bracket-
to-engine bolts 70 52 —
Engine mount bracket-
to-engine nuts 70 52 —
Water pump pulley bolts 25 18 —
Oil filter
b — — —
Upper intake manifold-
to-lower intake manifold bolts a — — —
Lower intake manifold-
to-cylinder head bolts a — — —
Rocker arm pivot-
to-cylinder head bolts a — — — Klj . 5 ba
62003 Mustang Workshop Manual
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Vehicle equipped with automatic transmission
33. Remove the access cover.
34. NOTE: Discard the torque converter nuts.
Disconnect the torque converter (7902). zRemove the four nuts.
35. Remove the oil pan- to-transmission bolts. Klj . 8 ba
112003 Mustang Workshop Manual
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Vehicles equipped with automatic transmission
9. Install the five bellhousing upper bolts.
10. Install the bolts.
11. Install the four torque converter nuts.
All vehicles Klj . 3 ba
102003 Mustang Workshop Manual
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e
Specification in 90.200 mm diameter gauge.
f If applicable, measured vertically, +0.030- 0.050 mm (0.001-0.002 inch) measured horizontally (oval
pin bore).
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.
Torque Specifications Description Nm lb-
ft lb-
in Main bearing cap adjusting bolts
a — — —
EGR sensor bracket 10 — 89
Belt idler pulley 25 18 —
Oil filter 15 11 —
Oil filter adapter insert 58 43 —
Camshaft sprocket bolt
a — — —
Connecting rod bolt
a — — —
Engine mount nuts 150 111 —
Engine mount-
to-cylinder block bolts 70 52 —
Exhaust manifolds
a — — —
Engine front cover bolts
a — — —
Drive belt tensioner bolts 25 18 —
A/C muffler 20 15 —
Battery cable support brackets 20 15 —
Cylinder head bolt
a — — —
Pulley-
to-crankshaft bolt a — — —
EGR valve to intake manifold 25 18 —
EGR valve tube to exhaust manifold fittings 40 30 —
Intake manifold-
to-cylinder head bolt 25 18 —
Main bearing cap bolt
a — — —
Oil filter adapter bolts 25 18 —
Oil level indicator tube bolt 10 — 89
Oil pump screen cover and tube-
to-oil pump bolt 10 — 89
Oil pan-to-
cylinder block bolt a — — —
Flywheel 80 59
Oil pan-to-
engine front cover bolts a — — —
Oil pump-
to-cylinder block bolt 10 — 89
Oil pump screen cover and tube-
to-main bearing cap stud spacer bolt 25 18 —
Water pump pulley bolts 25 18 —
Cam cover bolt
a — — —
Water pump-
to-cylinder block bolt 25 18 —
Water bypass tube 25 18 —
EGR tube nuts (2 req'd) 40 30 —
Power steering pump to engine 25 18 — Klj . 4 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

a
Refer to the procedure in this section. Power steering reservoir bolts 10 — 89
Water outlet connector bolts 25 18 —
Camshaft cap cluster to cylinder head bolts 10 — 89
Torque converter nuts 25 18 —
Timing chain tensioner bolts 25 18 —
Transmission filler tube bolt 47 35 —
A/C compressor bolts 25 18 —
Ignition coil bolts 6 — 53
Generator brace bolts 10 — 89
Primary timing chain guide-
to-engine bolts 10 — 89
Accelerator cable bracket bolts 10 — 89
Rear seal retainer bolts 10 — 89
Pressure plate bolts 2 — 47
Spark plugs 18 13 —
Crankshaft timing bolt sensor assembly 10 — 89
Camshaft timing bolt sensor assembly 10 — 89
Fuel rail studs 10 — 89
Engine coolant sensor 15 11 —
Exhaust manifold—
stud to cylinder head 10-
13 7-10 —
Throttle body adaptor bolts
a — — —
Throttle body bolts 10 — 89
Idle air control valve 10 — 89
RFI capacitor nut 10 — 89
Generator bolts 25 18 —
Oil pan drain plug 14 10 —
Water bypass tube bracket bolt 25 18 —
Subframe bolts 115 85 —
Battery lead to generator 10 — 89
EGR vacuum regulator solenoid bracket 10 — 89
Pipe plug—
water drain 20 15 —
Screen and cover assembly to main bearing cap stud spacer 25 18 —
Wiring harness retainer nut 10 — 89
Oil pressure switch
a — — —
A/C muffler stud to cylinder head 10 — 89
EGR tube to exhaust manifold connector 50 37 — Klj . 5 ba
62003 Mustang Workshop Manual
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NOTE:
Only one connecting rod assembly shown, others similar.
Using the special tool install the piston and connecting rod assembly by pushing the pistons
through the top of the cylinder block.
21. NOTE: These 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 25Nm (18 lb- ft).
z Stage 2: Tighten to 40Nm (30 lb- ft).
z Stage 3: Tighten an additional 90 degrees.
22. Rotate the crankshaft and install the remaining piston and connecting rod assemblies.
23. Check the connecting rod bearing clearance. For additional information, refer to Section 303 -
00 .
24. Install the oil pump and tighten the bolts. 25. NOTE: Install a new O - ring if necessary. Klj . 11 ba
362003 Mustang Workshop Manual
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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
62003 Mustang Workshop Manual
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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
352003 Mustang Workshop Manual
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i
Measured at 42 mm from piston dome, at 90 degrees to the piston pin.
j Piston pin outer diameter is larger than piston pin bore, providing a possible interference fit.
k Specification in 90.200 mm diameter gauge.
l With installation of a new filter.
a "Fixed" refers to systems with manually- adjusted centers which are bolted in place and considered
fixed. Drive Belt Tension Belt Type Belt Tension
6 Rib (Fixed)
a 110-
120 Lbs
Torque Specifications Description Nm lb-
ft lb-
in Camshaft sprocket bolt 115 85 —
Connecting rod bolt a a a
Engine front cover bolt a a a
Drive belt tensioner bolts 25 18 —
Cylinder head bolt a a a
Pulley to crankshaft bolt a a a
EGR valve to intake manifold a a a
Exhaust manifold studs 25 18 —
Lower intake manifold-
to-cylinder head bolt a a a
Main bearing cap bolt a a 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 a a
Oil pan-to-
engine front cover bolts a a a
Oil pump-
to-cylinder block bolt 10 — 89
Oil pump screen and pickup tube-
to-main bearing cap stud spacer bolt 25 18 —
Coolant pump pulley bolts 25 18 —
Valve cover bolt 10 — 89
Coolant pump-
to-cylinder block bolt 25 18 —
EGR valve to exhaust manifold tube nuts 40 30 —
Power steering pump to engine 25 18 —
Outlet heater hose stud bolts 25 18 —
Camshaft cap cluster to cylinder head 10 — 89
Timing chain tensioner bolts—
primary 25 18 —
Timing chain tensioner bolts—
secondary 10 — 89
A/C compressor bolts 25 18 —
Ignition coil cover bolts 10 — 89
Generator mounting bracket retainers 10 — 89 Klj . 5 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

a
Refer to the procedure. Flexplate bolts 80 59 —
Flywheel bolts 85 63 —
Torque converter nuts 36 27 —
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 —
Accelerator cable bracket 10 — 89
Belt idler pulley bolt 25 18 —
Sub-
frame brace nuts 41 30 —
Air intake scoop bolts 25 18 —
Air intake scoop bracket bolt 25 18 —
Air intake scoop bracket nuts 25 18 —
Air intake scoop bracket throttle body nut 9 — 80
Exhaust gas recirculation (EGR) vacuum regulator solenoid bolts 10 — 89 Klj . 6 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...