FORD MUSTANG 2003 Workshop Manual

Item Part Number Description
1 N806177 Bolt (4 req'd)
2 N806459 Dowel (4 req'd)
3 6A341 Thrust washer
4 6303 Crankshaft
5 6A339 Thrust bearing
6 6325 Main bearing cap (5 req'd)
7 6345 Bolt (10 req'd)
8 6K258 Stud (4 req'd) Klj . 14 ba
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9 6687 Oil pan baffle
10 N806180 Spacer
11 N605904 Bolt
12 6710 Oil pan gasket
13 6675 Oil pan
14 W701240 Bolt (16 req'd)
15 6622 Oil pump screen pickup and tube
16 N806155 Bolt (2 req'd)
17 N806180 Nut (2 req'd)
18 6345 Bolt (6 req'd)
19 6C360 Main bearing cap adjusting screw (10 req'd)
20 6A338 Crankshaft main bearing (4 req'd)
21 N806201 Woodruff key
22 6621 Oil pump
23 N806183 Bolt (4 req'd)
24 6333 Crankshaft main bearing
25 8501 Coolant pump Klj . 15 ba
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DIAGNOSIS AND TESTING
Engine
Refer to
Section 303 - 00 for basic mechanical concerns or refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for driveability concerns. SECTION 303-
01D: Engine — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
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IN-
VEHICLE REPAIR
Intake Manifold — Upper
Removal 1. Remove the air intake scoop bracket. For additonal information, refer to Section 303 - 12 .
2. Remove the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
3. Disconnect the accelerator cable, the speed control actuator cable and the return spring.
4. Remove the bolts, disconnect the clip and position the cables out of the way.
5. Disconnect the throttle position (TP) sensor. 6. Disconnect the evaporative emissions (EVAP) return hose. SECTION 303-
01D: Engine — Mach I 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
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7. Disconnect the idle air control valve and the differential pressure feedback EGR.
8. Disconnect the main chassis vacuum supply line and the EGR valve vacuum line.
9. Disconnect the differential pressure feedback EGR hoses.
10. Disconnect the EGR valve to exhaust manifold tube from the EGR valve. Klj . 2 ba
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11. Disconnect the electrical connector and the vacuum lines from the EGR vacuum regulator
solenoid.
12. Remove the PCV valve- to-intake manifold tube.
13. Remove the upper intake manifold bolts in the sequence shown and remove the intake manifold assembly.
14. Inspect and clean the sealing surfaces. Klj . 3 ba
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Installation
1. Install the upper intake manifold gasket.
2. Install the intake manifold and bolts in the sequence shown.
3. Install the PCV valve- to-intake manifold tube.
4. Connect the vacuum hoses and the electrical connector to the EGR vacuum regulator solenoid. Klj . 4 ba
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5. Connect the EGR tube to the EGR valve.
6. Connect the hoses to the differential pressure feedback EGR.
7. Connect the main chassis vacuum supply line and the EGR valve vacuum line.
8. Connect the IAC valve and the differential pressure feedback EGR electrical connectors. Klj . 5 ba
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9. Connect the EVAP return hose.
10. Connect the TP sensor.
11. Position the cables and bracket. zInstall the bolts, connect the clip.
12. Connect the throttle cable, the speed control actuator cable and throttle return spring. Klj . 6 ba
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13. Install the air cleaner outlet tube. For additional information, refer to
Section 303 - 12 .
14. Install the air intake scoop bracket. For additional information, refer to Section 303 - 12 . Klj . 7 ba
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