oil FORD MUSTANG 2003 Workshop Manual

40. Connect the battery negative cable. For additional information, refer to
Section 414 - 01 .
41. Fill the engine with clean engine oil.
42. Fill the engine cooling system. For additional information, refer to Section 303 - 03A .
43. Recharge the A/C refrigerant system. For additional information, refer to Section 412 - 00 .
44. Fill and bleed the power steering system. For additional information, refer to Section 211 - 00 . Klj . 10 ba
102003 Mustang Workshop Manual
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SPECIFICATIONS
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Silicone Gasket and Sealant F7AZ-19554-
EA WSE-
M4G323- A4 Premium Engine Coolant VC-
4A,
VC- 5 in Oregon, CXC- 10 in Canada ESE-
M97B44- A Super Premium 5W-
20 Motor Oil XO-5W20-QSP WSS-
M2C153- H Threadlock 262 E2FZ-19554-
B WSK-
M2G351- A6 Metal Surface Cleaner F4AZ-19A536-
RA or
equivalent WSE-
M5B392- A Engine
Displacement 4.6L (2V) (281 CID)
Number of cylinders 8
Bore 90.2 mm (3.55 in)
Stroke 90.0 mm (3.54 in)
Firing order 1-3-7-2-6-5-4-
8 Oil pressure (hot 1,500 rpm) 138-
310 kPa (20- 45 psi) Oil capacity
6.25 ±
0.25 quarts a Compression ratio 9.37:1 (+0.61/-
0.46) Cylinder Head and Valve Train
Combustion chamber volume
43.9 ±
1.5 cm 3 Valve arrangement (front to rear) —
LH b E-I-E-I-E-I-E-I
Valve arrangement (front to rear) —
RH b I-E-I-E-I-E-I-E
Valve guide bore diameter 7.015-
7.044 mm (0.2762- 0.2773 in) Valve stem diameter 6.975-
6.995 mm (0.2754- 0.2746 in) Valve stem-
to-guide clearance — intake 0.020-
0.069 mm (0.00078- 0.00272 in) Valve stem-
to-guide clearance — exhaust 0.046-
0.095 mm (0.0018- 0.0037 in) Valve head diameter —
intake 44.37-
44.63 mm (1.75- 1.76 in) Valve head diameter —
exhaust 35.88-
36.14 mm (1.41- 1.43 in) Valve face runout 0.05 mm (0.002 in)
Valve face angle 45.5 degrees
Valve seat width 1.3-
1.5 mm (0.051- 0.060 in) Valve seat runout (T.I.R.) Recommended 0.025 mm (0.001 in) max. 0.050
mm (0.002 in) Valve seat angle 45 degrees
Valve spring free length (approx.) 51.77-
54.97 mm (2.04- 2.16 in) Valve spring squareness 2 degrees
Valve spring compression pressure 720.0-
800.0 N @ 28.80 mm (161.9 lb @ 1.13 in) Klj . 1 ba
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a
With installation of a new filter.
b Distance front edge of bearing is installed below front face of cylinder block.
c Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in
tappet.
d Measured at 31.5 mm from top of block. Measured at 43 mm from top of piston, at 90 degrees to the
piston pin. Connecting rod journal maximum taper 0.004 mm (0.0002 in)
Connecting rod journal maximum out-of-
round 0.05 mm (0.002 in)
Crankshaft maximum end play 0.075-
0.377 mm (0.003- 0.015 in) Piston and Connecting Rod
Piston diameter —
code red 1 d 90.185-
90.205 mm (3.55- 3.551 in) Piston diameter —
code blue 2 d 90.195-
90.215 mm (3.55- 3.551 in) Piston diameter —
code yellow 3 d 90.205-
90.225 mm (3.551- 3.552 in) Piston-
to-cylinder bore clearance -0.005-
0.025 mm (- 0.002/+0.001 in) Piston ring end gap —
compression (top) e 0.130-
0.280 mm (0.005- 0.011 in) Piston ring end gap —
compression (bottom) e 0.300-
0.550 mm (0.0018- 0.0022 in) Piston ring end gap —
oil ring (steel rail) e 0.150-
0.650 mm (0.006- 0.0256 in) Piston ring groove width —
compression (top) 1.530-
1.550 mm (0.06- 0.061 in) Piston ring groove width —
compression
(bottom) 1.520-
1.540 mm (0.06- 0.061 in) Piston ring groove width —
oil ring 3.030-
3.050 mm (0.12- 0.12 in) Piston ring width —
compression (top) 1.480-
1.500 mm (0.058- 0.059 in) Piston ring width —
compression (bottom) 1.470-
1.490 mm (0.0587- 0.0586 in) Piston ring-
to-groove clearance — compression
(top) 0.050-
0.090 mm (0.002- 0.004 in) Piston ring-
to-groove clearance — compression
(bottom) 0.030-
0.080 mm (0.00118- 0.00315 in) Piston ring-
to-groove clearance — oil ring Snug fit
Piston pin bore diameter
f 21.008-
22.014 mm (0.866- 0.867 in) Piston pin diameter 22.0010-
22.0030 mm (0.87- 0.871 in) Piston pin length 61.601-
62.030 mm (2.42523- 2.44212 in) Piston pin-
to-piston fit -
0.005/+0.0135 mm (- 0.0002/+0.0005 in) Piston-
to-connecting rod clearance — standard 0.009-
0.0235 mm (0.0004- 0.00092 in) Piston-
to-connecting rod clearance — service
limit 0.035 mm (0.001378 in)
Connecting rod-
to-pin clearance 0.009-
0.023 mm (0.0004- 0.0009 in) Connecting rod pin bore diameter 22.012-
22.024 mm (0.86661- 0.86708 in) Connecting rod length (center-
to-center) 150.7 mm (5.933 in)
Connecting rod maximum allowed bend
g 0.038 per 25 mm (0.00150 per 0.9843 in)
Connecting rod maximum allowed twist
c 0.050 per 25 mm (0.00197 per 0.9843 in)
Connecting rod bearing bore diameter 56.866-
56.886 mm (2.23881- 2.23960 in) Connecting rod bearing-
to-crankshaft clearance 0.027-
0.069 mm (0.0010629- 0.0027165 in) Connecting rod side clearance —
standard 0.125-
0.475 mm (0.005- 0.019 in) Connecting rod side clearance —
service limit 0.50 mm (0.01969 in) max. Klj . 3 ba
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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
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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
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9 6161 Piston ring
10 6200 Connecting rod assy.
11 6100 Piston and rod assy (8 req'd)
12 N806164 Washer
13 6256 Camshaft sprocket
14 6265 Camshaft sprocket spacer
15 6766 Oil filler cap
16 6C324 Crankcase vent connector and hose
17 6582 Valve cover
18 6B280 Camshaft bearing cap
19 6250 Camshaft
20 9H308 Idle air control valve inlet tube
21 N806155 Bolt (2 req'd)
22 9F715 Idle air control valve
23 N806154 Bolt (4 req'd)
24 9F670 Idle air control gasket
25 9E926 Throttle body
26 9E936 Throttle body gasket
27 9A589 Throttle body gasket
28 N807309 Bolt (3 req'd)
29 9728 Bracket
30 N806154 Bolt (5 req'd)
31 9D476 EGR valve gasket
32 9D460 EGR valve
33 W701625 Bolt (2 req'd)
34 N811017 Stud bolt (4 req'd)
35 9F792 Fuel injection supply manifold
36 9D477 EGR valve to exhaust manifold tube
37 9E498 Main emission vacuum control connector
38 12A522 Engine control sensor extension wire
39 N806459 Dowel (4 req'd)
40 8555 Water bypass tube
41 N646419 Dowel (2 req'd)
42 W623454 Washer (2 req'd)
43 N806040 Dowel (2 req'd)
44 N806007 Dowel (2 req'd)
45 6A636 Oil filter adapter gasket
46 6881 Oil filter adapter (manual transmission)
47 N806156 Bolt (4 req'd)
48 6714 Oil bypass filter
49 N87838 Dowel
50 Klj . 4 ba
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6754 Oil level indicator tube
51 N806155 Bolt
52 N806139 Bolt
53 6750 Oil level dipstick
54 N811363 Bolt (2 req'd)
55 18198A Engine lifting eye
56 9430 Exhaust manifold
57 9448 Exhaust manifold gasket
58 6049 Cylinder head, RH
59 12405 Spark plug
60 W701681 Stud (8 req'd)
61 W701706 Nut (8 req'd)
62 6051 Head gasket
63 N807071 Bolt
64 10153 Generator mounting bracket
65 N811011 Bolt (2 req'd)
66 8549 Water outlet connector
67 10884 Water temperature indicator sender unit
68 N808130 Bolt (9 req'd)
69 N806807 O-
ring 70 N807309 Bolt (2 req'd)
71 12A366 Coil on plug (8 req'd)
72 9F593 Fuel injector
73 8575 Water thermostat
74 9424 Intake manifold
75 N806139 Bolt
76 N806164 Washer
77 6256 Camshaft sprocket
78 6265 Camshaft sprocket spacer
79 N807352 Bolt (4 req'd)
80 6A505 Valve cover
81 6758 Crankcase ventilation tube
82 N806070 Bolt (24 req'd)
83 6B280 Camshaft bearing cap
84 N806282 Bolt (4 req'd)
85 N807173 Bolt (2 req'd)
86 N808102 Bolt
87 19A216 Belt idler pulley
88 10300 Generator
89 N804178 Nut (2 req'd)
90 19A439 Bracket
91 Klj . 5 ba
92003 Mustang Workshop Manual
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N806155 Bolt (2 req'd)
92 6C315 Crankshaft position sensor
93 N806300 Stud bolt (5 req'd)
94 6C086 Engine front cover
95 N806155 Bolt
96 6B288 Camshaft position sensor
97 N606543 Bolt (4 req'd)
98 6L266 Timing chain tensioner
99 6268 Timing chain belt
100 6K297 Timing chain cover
101 6M269 Timing chain tensioner
102 6L253 Timing chain tensioner arm
103 N806184 Bolt (3 req'd)
104 19D629 A/C compressor
105 8501 Water pump
106 N806177 Bolt (4 req'd)
107 N806183 Bolt (4 req'd)
108 6621 Oil pump
109 N806201 Woodruff key
110 6333 Crankshaft main bearing (5 req'd)
111 6A341 Crankshaft thrust washer (3 req'd)
112 6C357 Crankshaft main bearing side bolt (10 req'd)
113 6010 Cylinder block
114 9439 Intake manifold gasket (2 req'd)
115 6083 Head gasket
116 6505 Exhaust valve (8 req'd)
117 6507 Intake valve (8 req'd)
118 87838 Pipe plug (8 req'd)
119 12405 Spark plug (8 req'd)
120 6F087 Dowel
121 9431 Exhaust manifold
122 6C501 Valve tappet (16 req'd)
123 6529 Rocker arm (16 req'd)
124 6049 Cylinder head, RH
125 W701681 Stud (8 req'd)
126 9Y431 Exhaust manifold gasket
127 9F485 EGR valve tube to manifold connector
128 W701706 Nut (8 req'd)
129 181198A Engine lifting eye
130 6A517 Valve stem seal (16 req'd)
131 6513 Valve spring (16 req'd)
132 Klj . 6 ba
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6514 Valve spring retainer (16 req'd)
133 6518 Valve spring retainer key (32 req'd)
134 6065 Cylinder head bolt (20 req'd)
135 6C255 Camshaft
136 9J434 EGR transducer
137 N807309 Bolt (2 req'd)
138 N806139 Bolt
139 8620 Drive belt
140 N806165 Washer
141 6316 Crankshaft pulley
142 8A528 Water pump pulley
143 6700 Crankshaft front seal
144 N808793 Stud bolt (2 req'd)
145 N806177 Bolt (6 req'd)
146 N806176 Bolt (3 req'd)
147 3A674 Power steering pump
148 12A227 Ignition pulse ring
149 6306 Crankshaft sprocket (2 req'd)
150 6268 Timing chain/belt
151 6K297 Timing chain guide
152 N804958 Bolt (4 req'd)
153 6A338 Crankshaft main bearing (4 req'd)
154 6A346 Crankshaft main bearing cap dowel pin (10 req'd)
155 6345 Crankshaft main bearing cap bolt (9 req'd)
156 N806155 Bolt (2 req'd)
157 W701240 Bolt (16 req'd)
158 6675 Oil pan
159 6710 Oil pan gasket
160 N605904 Bolt
161 6622 Oil pump screen cover and tube
162 N806180 Spacer
163 6K258 Crankshaft main bearing cap stud
164 6325 Main bearing cap (5 req'd)
165 6A339 Crankshaft thrust main bearing
166 N602549 Bolt
167 6303 Crankshaft
168 7563 Clutch pressure plate
169 7550 Clutch disc
170 N808139 Bolt (6 req'd)
171 6375 Flywheel (manual transmission)
172 N811363 Bolt (2 req'd)
173 Klj . 7 ba
92003 Mustang Workshop Manual
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A modular engine is built around four modules:
zthe intake module
z the cylinder head module (RH)
z the cylinder head module (LH)
z the lower engine module
While not all repairs can take advantage of the modular concept, most out-of- vehicle repairs benefit
due to the reduction of necessary time and labor.
The basic engine components consist of the following:
zsingle overhead camshafts
z two valves per cylinder
z sequential multiport fuel injection (SFI)
z aluminum cylinder heads (6049)
z cast iron, 90- degree V-shaped cylinder block
z individual ignition coils for each spark plug
z composite-material intake manifold
z large- bore throttle body N605919 Bolt
174 18663 Heater water tube
175 N806007 Dowel (2 req'd)
176 N807198 Dowel (2 req'd)
177 N806168 Bolt (6 req'd)
178 6375 Flywheel (automatic transmission)
179 6310 Crankshaft oil slinger
180 6701 Crankshaft rear oil seal
181 N806155 Bolt (6 req'd)
182 6K318 Crankshaft rear oil seal and retainer
183 7120 Transmission input shaft pilot bearing
184 N806435 Pipe plug
185 N87836 Dowel (2 req'd) Klj . 8 ba
92003 Mustang Workshop Manual
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