engine coolant FORD MUSTANG 2003 User Guide

IN-
VEHICLE REPAIR
Crankshaft Pulley
Removal 1. Remove the drive belt (8620). For additional information, refer to Section 303 - 05 .
2. Remove the radiator coolant recovery reservoir (8A080).
3. Raise the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
4. Remove the crankshaft pulley bolt. SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Remover, Crankshaft Vibration
Damper
303-
009 (T58P-6316- D) Remover, Crankshaft Vibration
Damper
303-
176 (T82L-6316- B) Installer, Crankshaft
Damper/Crankshaft Front Oil
Seal
303-
175 (T82L-6316- A)
Material Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323- A4 Klj . 1 ba
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16.
CAUTION: The cap screw is hidden; make sure to remove it or the engine front
cover will be damaged.
NOTE: Record the location, type and size of the fasteners.
Remove the engine front cover. zSlide the engine front cover off the two dowels.
z Remove and discard the engine front cover gasket.
Installation 1. CAUTION: In order to prevent foreign material from contaminating the engine block
or the engine front cover it is necessary to seal the coolant and oil passages of both
components. Failure to follow these directions will result in engine damage.
CAUTION: Do not use a surface conditioning pad or any other type of fibrous
abrasive disc to clean the gasket surfaces. Failure to follow these directions will result in
engine damage.
Clean and inspect the engine block and front cover as follows:
zPack the exposed portion of the oil pan with clean shop towels.
z Plug the oil and coolant passages.
z Clean the gasket surfaces.
z Clean all surfaces requiring gasket sealant with metal surface cleaner.
z Using compressed air, remove any remaining foreign material from the engine block and
engine front cover.
z Remove the shop towels from the oil pan.
z Remove the plugs or seals from the engine block and engine front cover. Klj . 4 ba
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IN-
VEHICLE REPAIR
Oil Pan
Removal 1. Disconnect the battery ground cable.
2. Remove the air cleaner outlet pipe. For additional information, refer to Section 303 - 12 .
3. Remove the radiator sight shield.
4. Remove the coolant recovery reservoir. 1. Disconnect the hose.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
3 Bar Engine Support Kit
303-
F072 Lifting Bracket Set, Engine
303-
D095 (D94L-6001- A) or
equivalent
Material Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Klj . 1 ba
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17. Install the LH engine mount nut.
18. Lower the vehicle.
19. Remove the special tools.
20. Install the coolant recovery reservoir.
21. Install the radiator sight shield. Klj . 11 ba
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22. Install the air cleaner outlet pipe. For additional information, refer to
Section 303 - 12 .
23. Connect the battery ground cable. For additional information, refer to Section 414 - 01 .
24. Fill the engine with clean engine oil.
25. CAUTION: Correct coolant bleeding is critical for correct engine cooling.
Fill and bleed the engine cooling system. For additional information, refer to Section 303 - 03A . Klj . 12 ba
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IN-
VEHICLE REPAIR
Engine Support Insulators
Removal 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414 -
01 .
2. Remove the air cleaner outlet tube (9B659). For additional information, refer to Section 303 - 12 .
3. Remove the radiator sight shield (8C291).
4. Remove the coolant recovery reservoir (8A080). 1. Disconnect the hose.
2. Remove the bolts. 3. Remove the coolant recovery reservoir. SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
3 Bar Engine Support Kit
303-
F072 Engine Lift Bracket Set
303-
D095 (D94L-6001- A) or
equivalent 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
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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
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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IN-
VEHICLE REPAIR
Oil Filter Adapter
Removal and Installation 1. Drain the cooling system. For additional information, refer to Section 303 - 03A or
Section 303 -
03B .
2. Disconnect the lower radiator hose.
3. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
4. Drain the engine oil.
5. Disconnect the oil pressure sensor electrical connector.
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 Premium Engine Coolant
VC-
4A (In Canada CXC- 10; In
Oregon VC- 5) or equivalent ESE-
M97B44-
A Klj . 1 ba
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