lock FORD MUSTANG 2003 Workshop Manual

70. Using the camshaft bearing service set, remove the engine dynamic balance shaft bearings.
71. If equipped, remove the engine block heater. For additional information, refer to
Section 303 -
03A .
72. NOTE: For cleaning purposes, the plugs should be removed.
If necessary, remove the following: 1. the cylinder block dowels.
2. the oil gallery plugs.
3. the water jacket plugs. Klj . 20 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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7. Install the camshaft thrust plate.
1. Position the camshaft thrust plate.
2. Install the bolts.
8. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic balance shaft assembly into the cylinder block. Turn the engine balance shaft driven gear so
that the timing mark aligns up with the timing mark on the engine balance shaft drive gear.
9. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and
the camshaft keyway will be at 6 o'clock on the camshaft.
Install the bolts.
10. CAUTION: Make sure the components are installed in the correct location.
NOTE: Lubricate the crankshaft main bearings prior to installation.
Install the crankshaft upper main bearings and the crankshaft upper thrust main bearing. Klj . 4 ba
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11.
CAUTION: The crankshaft journals must be protected from damage when installing
the crankshaft.
Position the crankshaft.
CAUTION: The main bearings are precision selective fit. Inspect the bearing clearance.
For additional information, refer to Section 303 - 00 .
12. NOTE: If the rear main bearing cap 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 cause
future oil leakage.
Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket
and sealant to the rear main bearing cap- to-cylinder block parting line. Klj . 5 ba
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23. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at
the 12 o'clock position.
24. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.
25. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
26. Make sure the timing marks and the keyways are aligned.
27. Install the camshaft position sensor drive gear and retaining bolt. Klj . 9 ba
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87.
NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.
Assemble the special tools and the crankshaft rear seal.
88. Install the special tools on the rear of the crankshaft.
89. Install the crankshaft rear seal. Tighten the center jack screw (303- S560) until the spacer (303-
561) contacts the engine block. Klj . 27 ba
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26. Connect the fuel supply tube spring lock coupling. For additional information, refer to
Section 310 - 00 .
27. Connect the A/C compressor electrical connector.
28. Connect the A/C manifold and tube. For additional information, refer to Section 412 - 03 .
29. Install the air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
30. Install the accelerator cable bracket.
31. Connect the accelerator cable. Klj . 7 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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Valve spring installed height 42.3-
42.9 mm (1.67- 1.69 in) Valve spring installed pressure 283.0-
321.0 N @ 42.56 mm (63.61 lb @ 1.68 in) Roller follower ratio —
intake 2.02:1
Roller follower ratio —
exhaust 2.03:1
Hydraulic Lash Adjuster
Diameter 16.000-
15.988 mm (0.6299- 0.6294 in) Clearance-
to-bore 0.018-
0.069 mm (0.0007- 0.0027 in) Service limit 15.988 mm
Hydraulic leakdown rate
c 5-
25 seconds Collapsed lash adjuster gap —
desired 0.45-
0.85 mm (0.02- 0.03 in) Camshaft
Theoretical valve lift @ 0 lash —
intake 13.00 mm (0.51 in)
Theoretical valve lift @ 0 lash —
exhaust 13.75 mm (0.54 in)
Lobe lift —
intake 7.11038 mm (0.28 in)
Lobe lift —
exhaust 7.4794 mm (0.30 in)
Allowable lobe lift loss 0 mm (0.0 in)
Journal diameter 26.962-
26.936 mm (1.0615- 1.0605 in) Camshaft journal bore inside diameter 27.012-
26.987 mm (1.0635- 1.0625 in) Camshaft journal-
to-bearing clearance 0.025-
0.076 mm (0.00098- 0.002992 in) Camshaft journal-
to-bearing clearance —
service limit 0.100 mm (0.003937 in) max.
Runout —
Front and rear journals 0.03 mm (0.001 in)
Runout —
four inner journals 0.09 mm (0.003 in)
End play 0.027-
0.190 mm (0.001- 0.007 in) End play —
service limit 0.190 mm (0.007480 in)
Cylinder Block
Cylinder bore diameter 31 mm (1.24 in) from top of block
red — 90.200-90.210
blue — 90.210-90.220
yellow — 90.220-90.230 Cylinder bore maximum taper 0.70 mm (0.027559 in)
Cylinder bore maximum out-of-
round —limit 0.20 mm (0.007874 in)
Cylinder bore maximum out-of-
round —service
limit 0.70 mm (0.027559 in)
Main bearing bore inside diameter 72.400-
72.424 mm (2.8504- 2.8513 in) Crankshaft
Main bearing journal diameter 67.482-
67.504 mm (2.66- 21.661 in) Main bearing journal maximum taper 0.004 mm (0.0002 in)
Main bearing journal maximum out-of-
round 0.05 mm (0.002 in)
Main bearing journal-
to-cylinder block clearance
— desired 0.025-
0.044 mm (0.001- 0.002 in) Main bearing journal-
to-cylinder block clearance
— allowable 0.025-
0.050 mm (0.00098- 0.00197 in) Connecting rod journal diameter 52.983-
53.003 mm (2.085941- 2.086728 in) Klj . 2 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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