engine oil FORD MUSTANG 2003 Workshop Manual

21. Install the cylinder head gaskets.
22.
NOTE: Install new cylinder head bolts.
NOTE: LH is shown, RH is similar.
NOTE: Lubricate the bolt heads and threads. Use clean engine oil.
Install the LH and RH cylinder heads and tighten the bolts in six stages, in the sequence shown. zStage 1: Tighten to 40 Nm (30 lb- ft).
z Stage 2: Tighten an additional 90 degrees.
z Stage 3: Loosen the bolts a minimum of one full turn.
z Stage 4: Tighten to 40 Nm (30 lb- ft).
z Stage 5: Tighten an additional 90 degrees.
z Stage 6: Tighten an additional 90 degrees.
23. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. Klj . 10 ba
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44. Install the oil pan and gasket, and loosely install the bolts.
45. Tighten the bolts in the sequence shown, in two stages.
zStage 1: Tighten to 20 Nm (15 lb- ft).
z Stage 2: Rotate an additional 60 degrees.
46. NOTE: If the engine front cover 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 result in
future oil leakage.
Apply silicone gasket and sealant in the locations shown. Klj . 17 ba
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58. Lubricate the front oil seal and the engine front cover with clean engine oil.
59. Using the special tools, install the front oil seal.
60.
NOTE: If the crankshaft pulley is not installed 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 result in
future oil leakage.
Apply silicone gasket and sealant to the Woodruff key on the crankshaft pulley.
61. Using the special tool, install the crankshaft pulley. Klj . 22 ba
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71. Position the wiring harness onto the engine and attach it to the four fuel supply manifold studs.
72. Connect the eight fuel injector electrical connectors.
73.
NOTE: RH is shown, LH is similar.
Install the RH and LH ignition coils and connect the electrical connectors.
74. Install the harness support bracket. Klj . 26 ba
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99. Install the special tools.
100. Attach the special tool to a floor crane and the engine, and remove the engine from the stand.
101. NOTE: If not secured within four minutes, the sealant must be removed and the sealing surface
must be cleaned with metal surface cleaner. Allow the surface to dry until there is no sign of
wetness or four minutes, whichever is longer. Failure to follow this procedure can result in future
oil leakage.
Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer
plate sealing surface. Also apply a bead of silicone gasket and sealant at the junction where the
cylinder block, oil pan and rear oil seal retainer plate meet. Klj . 33 ba
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INSTALLATION
Engine
Installation
1. Install the engine in the vehicle and remove the floor crane and the special tool.
SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Special Tool(s)
Lifting Bracket, Engine
303-
D087 (D93P-6001- A1) Lifting Bracket, Engine
303-
D088 (D93P-6001- A2) Spreader Bar
303-
D089 (D93P-6001- A3) or
equivalent
Material Item Specification
SAE 5W-
20 Premium Synthetic
Blend Engine Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Motorcraft Premium Engine
Coolant
VC
-4-A (in Canada CXC- 10; in
Oregon VC- 5) or equivalent ESE-
M97B44-
A Motorcraft Premium Gold
Engine Coolant
VC
-7-A (in Oregon VC-7- B) or
equivalent WSS-
M97B51-
A1 Threadlock and Sealer
E0AZ-
19554- AA WSK-
M2G351-
A5 PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (MC YN-12- C) WSH-
M1C231-
B Klj . 1 ba
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60.
NOTE: Use reference marks made during removal to aid in the installation.
Install the hood and the four nuts.
61. Install the hood- to-body ground strap.
62. Connect the battery ground cable. For additional information, refer to Section 414 - 01 .
63. Fill the crankcase with clean engine oil and check that all other fluids are at the correct levels.
64. Fill and bleed the engine cooling system. For additional information, refer to Section 303 - 03A .
65. Fill and purge the power steering system. For additional information, refer to Section 211 - 00 .
66. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
67. Charge the A/C system. For additional information, refer to Section 412 - 00 . Klj . 16 ba
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SPECIFICATIONS
SECTION 303-
01D: Engine — Mach I 4.6L (4V) 2003 Mustang Workshop Manual General Specifications
Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA WSE-
M5B392- A Silicone Gasket and Sealant F7AZ-19554-
EA WSE-
M4G323-
A4 Motorcraft Premium Gold Engine Coolant VC-7-
A (in Oregon VC-7-B) (Yellow
Color) WSS-
M97B51- A1 Pipe Sealant with Teflon® D8AZ-19554-
A WSK-
M2G350-
A2 Motorcraft MERCON® Super Premium 5W-
20 Motor Oil XO-5W20-QSP WSS-
M2C153- H Threadlock 262 E2FZ-19554-
B WSK-
M2G351-
A6
Engine Specifications Description Specification
GENERAL SPECIFICATIONS
Displacement 4.6L (4V) (281 CID)
Number of Cylinders 8
Bore and Stroke 90.2 x 90.0 mm (3.55 x 3.54 inch)
Firing Order 1-3-7-2-6-5-4-
8 Oil Pressure (HOT 1500 RPM) 138-
310 kPa Drive Belt Tension a
Combustion Chamber Volume (cc)
52.6±
0.5 cm c Valve Seats
·
Width— Intake 1.8-
2.2 mm (0.071- 0.086 inch) ·
Width— Exhaust 1.8-
2.2 mm (0.071- 0.086 inch) ·
Angle 45 degrees
·
Runout (T.I.R.) Max 0.05 mm (0.002 inch)
Valve Arrangement (Front-
to-Rear) c ·
(Left Hand) Intake: S-P-S-P-S-P-S-P
·
Exhaust: E-E-E-E-E-E-E-E
·
(Right Hand) Intake: P-S-P-S-P-S-P-S
·
Exhaust: (C) E-E-E-E-E-E-E-E
Valve Stem to Guide Clearance
·
Intake 0.020-
0.069 mm (0.00078- 0.00272 inch) ·
Exhaust 0.046-
0.095 mm (0.0018- 0.0037 inch) Klj . 1 ba
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a
Newly Installed— Refers to the condition of the "NEW" drive belt before the engine has made no more
than one rotation and before the belt has had a chance to stretch or seat into the pulley grooves.
c P=Primary, S=Secondary, E=Exhaust
d Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in
tappet.
e Distance front edge of bearing is installed below front face of cylinder block.
f 0.050 Undersize— add 0.025 to standard thickness.
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.
h Cylinder Bore Diameter
Red— 90.200-90.213
Blue— 90.213-90.226
Yellow— 90.226-90.239 ·
Coded Red 1 90.167-
90.188 mm (3.299- 3.5505 inch) ·
Coded Blue 2 90.180-
90.195 mm (3.5504- 3.5510 inch) ·
Coded Yellow 3 90.198-
90.208 mm Coated Piston-
to-Bore Clearance -
0.010/+0.026 mm (- 0.0003937/+0.0010236 inch) Pin Bore Diameter 21.9985-
22.0025 mm (0.866081- 0.866238 inch) Ring Groove Width
·
Compression (Top) 1.230-
1.250 mm (0.484- 0.0492 inch) ·
Compression (Bottom) 1.520-
1.540 mm (0.05984- 0.06062 inch) ·
Oil Ring 3.030-
3.055mm Piston Pin
·
Length 61.601-
62.030 mm (2.42523- 2.44212 inch) ·
Diameter 22.0005-
22.0030 mm (0.8661596- 0.8662581
inch) Pin to Piston Fit
j -
0.0045/+0.002 mm (- 0.000177/+0.0000787 inch) Pin to Rod Clearance
·
Standard 0.004-
0.0175 mm (0.000157- 0.00689 inch) ·
Service Limit 0.035 mm (0.001378 inch)
Oil Ring 1.15 mm (0.04528 inch) MAX
·
Side Clearance .075
-.1000 mm (.0030 -.0040 inch) ·
Compression (Top) 0.0090-
0.0235 mm (0.000354- 0.000925 inch) ·
Compression (Bottom) 0.030-
0.080 mm (0.00118- 0.00315 inch) ·
Oil Ring Snug Fit
Ring Gap
k ·
Compression (Top) .150
-.300 mm (.006- 0.0018 inch) ·
Compression (Bottom) 0.300-
0.550 mm (0.0018- 0.0022 inch) ·
Oil Ring (Steel Rail) 0.15-
0.66 mm (0.00591- 0.02598 inch) Piston Rings
·
Ring Gap ·
Compression (Top) 1.00 mm (0.03937 inch) MAX
·
Compression (Bottom) 1.00 mm (0.03937 inch) MAX
·
Service Limit 1.15 mm (0.04528 inch) MAX
LUBRICATION SYSTEM
Oil Capacity (Quarts U.S.)
6 ±
0.25 l Klj . 4 ba
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i
Measured at 42 mm from piston dome, at 90 degrees to the piston pin.
j Piston pin outer diameter is larger than piston pin bore, providing a possible interference fit.
k Specification in 90.200 mm diameter gauge.
l With installation of a new filter.
a "Fixed" refers to systems with manually- adjusted centers which are bolted in place and considered
fixed. Drive Belt Tension Belt Type Belt Tension
6 Rib (Fixed)
a 110-
120 Lbs
Torque Specifications Description Nm lb-
ft lb-
in Camshaft sprocket bolt 115 85 —
Connecting rod bolt a a a
Engine front cover bolt a a a
Drive belt tensioner bolts 25 18 —
Cylinder head bolt a a a
Pulley to crankshaft bolt a a a
EGR valve to intake manifold a a a
Exhaust manifold studs 25 18 —
Lower intake manifold-
to-cylinder head bolt a a a
Main bearing cap bolt a a a
Oil filter adapter bolt 25 18 —
Oil bypass filter to adapter 50 37 —
Oil pump screen cover and tube-
to-oil pump bolt 10 — 89
Oil pan-to-
cylinder block bolt a a a
Oil pan-to-
engine front cover bolts a a a
Oil pump-
to-cylinder block bolt 10 — 89
Oil pump screen and pickup tube-
to-main bearing cap stud spacer bolt 25 18 —
Coolant pump pulley bolts 25 18 —
Valve cover bolt 10 — 89
Coolant pump-
to-cylinder block bolt 25 18 —
EGR valve to exhaust manifold tube nuts 40 30 —
Power steering pump to engine 25 18 —
Outlet heater hose stud bolts 25 18 —
Camshaft cap cluster to cylinder head 10 — 89
Timing chain tensioner bolts—
primary 25 18 —
Timing chain tensioner bolts—
secondary 10 — 89
A/C compressor bolts 25 18 —
Ignition coil cover bolts 10 — 89
Generator mounting bracket retainers 10 — 89 Klj . 5 ba
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