FORD MUSTANG 2003 Workshop Manual

Klj . 4 ba
42003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Piston
Disassembly
1. Press the piston pin out of the connecting rod and piston assembly.
2. Remove the connecting rod from the piston.
3. Clean and inspect the piston and connecting rod. For additional information, refer to Section 303 - 00 .
Assembly 1. NOTE: Connecting rod must be installed into piston with identification markings toward front.
Position the connecting rod in the piston.
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Material
Item Specification
Super Premium SAE 5W-20
Motor Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
32003 Mustang Workshop Manual
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2. Press the piston into the piston and connecting rod assembly.
3. Install the piston rings.
1. Using a suitable ring expander tool install the upper compression ring with the top side identification mark towards the dome.
2. Using a suitable ring expander tool install the lower compression ring with the top side
identification mark towards the dome.
3. NOTE: Assemble with end gaps up.
Using a suitable tool install the piston oil control segment ring spacer.
4. NOTE: Install one segment ring above and one segment ring below the spacer.
Using a suitable tool install the piston oil control segment rings.
5. Orient the upper compression ring gap to the center line at the rear of the piston, parallel to the wrist pin bore.
6. Orient the oil control ring gaps as shown.
7. Orient the expander ring gap and lower compression ring gap as shown. Klj . 2 ba
32003 Mustang Workshop Manual
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Klj . 3 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

ASSEMBLY
Engine
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Special Tool(s)
Guides, Connecting Rod
303-
442 (T93P-6136- A) Installer, Crankshaft Rear Oil
Seal
303-
518 (T95P-6701- DH) Installer, Crankshaft Rear Oil
Seal
303-
516 (T95P-6701- BH) Installer, Crankshaft Rear Oil
Slinger
303-
517 (T95P-6701- CH) Impact Slide Hammer
100-
001 (T50T-100- A) Spreader Bar
303-
D089 (D93P-6001- A3) Lifting Bracket, Engine
303-
D087 (D93P-6001- A1) Lifting Bracket, Engine
303-
D088 (D93P-6001- A2) Klj . 1 ba
362003 Mustang Workshop Manual
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Lifting Bracket Set, Engine
303-
D074 (D91P-6001- A) Installer, Crankshaft Vibration
Damper
303-
102 (T74P-6316- B) Installer, Front Cover Oil Seal
303-
335 (T88T-6701- A) Compressor, Piston Ring
303-
D032 (D81L-6002- C) or
equivalent Holding Tool, Crankshaft
303-
448 (T93P-6303- A) Remover/Installer, Cylinder
Head
303-
572 (T97T-6000- A) Compressor, Valve Spring
303-
576 (T97P-6565- AH) Strap Wrench
303-
D055 (D85L-6000- A) or
equialent Klj . 2 ba
362003 Mustang Workshop Manual
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Assembly
NOTE:
During engine assembly, it may by necessary to check bearing clearances and end play. For
additional information, refer to Section 303 - 00 .
1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart Crankshaft Seal Installer
303-
635
Material Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Super Premium SAE 5W-20
Motor Oil
XO- 5W20- QSP or equivalent WSS-
M2C153- H Klj . 3 ba
362003 Mustang Workshop Manual
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determine the required bearing grade for each main bearing.
zRead the first letter of the engine block main bearing code and the first letter of the
crankshaft main bearing code.
z Read down the column below the engine block main bearing code letter, and across the
row next to the crankshaft main bearing code letter, until the two intersect. This is the
required bearing grade for the number one crankshaft main bearing.
z As an example, if the engine block code letter is "F" and the crankshaft code letter is "D,"
the correct bearing grade for this main bearing is "2."
z Repeat this process for the remaining four main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearing Chart to determine the required grade for each main bearing. Klj . 4 ba
362003 Mustang Workshop Manual
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NOTE:
Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint
and foreign material. Also, make sure the coolant and oil passages are clear.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. NOTE: Do not install the upper thrust washer until the crankshaft is installed. Refer to Step 3.
NOTE: Do not install the upper thrust washer until the crankshaft (6303) is installed. Refer to
Step 3.
Install the crankshaft onto the upper main bearings. Klj . 5 ba
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7.
NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the
crankshaft surface).
Push the crankshaft rearward and install the crankshaft upper thrust washer at the rear of the
No. 5 main boss.
8. NOTE: Rotate the jackscrews into the bearing caps enough to provide clearance to the cylinder
block prior to installing the bearing caps.
Install the lower main bearings into the main bearing caps and lubricate them with clean engine
oil.
9. Install the rear main bearing cap.
10. Install the remaining main bearing caps on the cylinder block and tap into place using a plastic or dead- blow hammer. Klj . 6 ba
362003 Mustang Workshop Manual
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