FORD MUSTANG 2003 Workshop Manual

Klj . 3 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

ASSEMBLY
Engine
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Slide Hammer
307-
005 (T59L- 100-B) Remover Adapter, Vibration
Damper
303-
176 (T82L-6316- B) Installer, Crankshaft Front Seal
303-
474 (T94P-6701- AH) Replacer, Steering Pump
Pulley
211-
009 (T65P-3A733- C) Engine Lift Bracket Set
303-
D095 (D94L-6001- A) Replacer, Rear Crankshaft
Seal
303-
516 (T95P-6701- BH) Spacer, Rear Crank Seal
Replacer
303-
561 (T96T-6701- B) Adapter, Crankshaft Rear Seal
(Use only the adapter retaining
bolts)
303-
518 (T95P-6701- DH) Klj . 1 ba
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CAUTION: The moving components must be lubricated with clean engine oil before
assembly.
CAUTION: The components with oil holes must be correctly aligned with the oil feed
holes.
1. If necessary, install the following: 1. the cylinder block dowels.
2. the oil gallery plugs.
3. the water jacket plugs.
2. If equipped, install the engine coolant heater. For additional information refer to Section 303 -
03A .
3. Using the camshaft bearing service set, install the engine dynamic balance shaft bearings. Adapter, Crankshaft Rear Seal
(Use only the adapter and the
center jack screw)
303-
S560 (T96T-6701- A) Spreader Bar
303-
D089 (D93P-6001- A3)
Material Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Pipe Sealant with Teflon®
XW7Z-19554-
AA WSK-
M2G350-
A2 Klj . 2 ba
282003 Mustang Workshop Manual
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4. Using the camshaft bearing service set, install the camshaft bearings.
5. Install the following:
1. the engine dynamic balance shaft bearing cover.
2. the camshaft bearing cover.
6. CAUTION: Do not damage the camshaft lobes when installing the camshaft.
Install the camshaft and the camshaft spacer. Klj . 3 ba
282003 Mustang Workshop Manual
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7. Install the camshaft thrust plate.
1. Position the camshaft thrust plate.
2. Install the bolts.
8. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic balance shaft assembly into the cylinder block. Turn the engine balance shaft driven gear so
that the timing mark aligns up with the timing mark on the engine balance shaft drive gear.
9. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and
the camshaft keyway will be at 6 o'clock on the camshaft.
Install the bolts.
10. CAUTION: Make sure the components are installed in the correct location.
NOTE: Lubricate the crankshaft main bearings prior to installation.
Install the crankshaft upper main bearings and the crankshaft upper thrust main bearing. Klj . 4 ba
282003 Mustang Workshop Manual
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11.
CAUTION: The crankshaft journals must be protected from damage when installing
the crankshaft.
Position the crankshaft.
CAUTION: The main bearings are precision selective fit. Inspect the bearing clearance.
For additional information, refer to Section 303 - 00 .
12. NOTE: If the rear main bearing cap 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 cause
future oil leakage.
Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket
and sealant to the rear main bearing cap- to-cylinder block parting line. Klj . 5 ba
282003 Mustang Workshop Manual
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13. Install the main bearing caps. Tighten the bolts in two stages:
zStage 1: Tighten to 50 Nm (37 lb- ft).
z Stage 2: Rotate an additional 120 degrees.
14. Compress the piston rings.
15. CAUTION: Inspect the piston clearance. For additional information, refer to Section 303 - 00 . Klj . 6 ba
282003 Mustang Workshop Manual
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CAUTION: Do not damage the cylinder wall with the sharp edges of the connecting
rod.
Install the piston with the arrow on the piston face pointing toward the front of the engine.
16. CAUTION: Inspect the connecting rod bearing clearance. For additional information,
refer to Section 303 - 00 .
CAUTION: The connecting rod cap will fit only one way.
Position the connecting lower rod bearing and the connecting rod cap on the connecting rod
and the crankshaft journal.
17. Install the rod caps. Tighten the bolts 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 105 degrees. 18. Install the remaining pistons and the connecting rods. Klj . 7 ba
282003 Mustang Workshop Manual
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19. Install the oil pan bridge and baffle assembly.
20. Using a new gasket, install the oil pump screen cover and tube.
21. Install the timing chain tensioner.
1. Position the timing chain tensioner.
2. Install the bolts.
22. Retract the tensioner pad retracting mechanism. 1. Compress the tensioner pad retracting mechanism.
2. Insert a retaining pin. Klj . 8 ba
282003 Mustang Workshop Manual
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23. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at
the 12 o'clock position.
24. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.
25. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
26. Make sure the timing marks and the keyways are aligned.
27. Install the camshaft position sensor drive gear and retaining bolt. Klj . 9 ba
282003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...