lock FORD MUSTANG 2003 Workshop Manual

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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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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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
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Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean and inspect the mating surfaces.
2. NOTE: If the oil pan 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 the silicone gasket and sealant at the rear oil seal retainer- to-cylinder block sealing
surface.
3. NOTE: If the oil pan 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 the silicone gasket and sealant at the engine front cover- to-cylinder block mating surface. 4. Install the oil pan and gasket and loosely install the bolts. Klj . 5 ba
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30.
NOTE: LH shown; RH similar.
Using a suitable container, drain coolant from the engine block. zInstall the drain plugs when finished.
31. Remove the four bolts and the power steering pump.
RH cylinder head 32. Remove the RH exhaust manifold. 1. Remove the RH exhaust manifold nuts.
2. Remove the RH exhaust manifold.
3. Remove the RH exhaust manifold gasket and discard. Klj . 10 ba
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50. Position the crankshaft with the keyway at the 12 o'clock position.
51. Remove the RH and LH timing chain tensioning system from both timing chains.
1. Remove the bolts.
2. Remove the timing chain tensioners.
3. Remove the timing chain tensioner arms.
52. Remove the LH and RH timing chains and the crankshaft sprocket. zRemove the RH timing chain from camshaft sprocket.
z Remove the RH timing chain from the crankshaft sprocket.
z Remove the LH timing chain from the camshaft sprocket.
z Remove the LH timing chain and crankshaft sprocket. Klj . 16 ba
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Both cylinder heads
58. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all application directions
contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean
and prepare the surfaces.
Clean the cylinder head- to-cylinder block mating surfaces of both the cylinder head and the
cylinder block. 1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material
remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt
to make the metal shiny. Some staining of the metal surfaces is normal.
59. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the
deck face with a straightedge, paying particular attention to the oil pressure feed area. The
cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm
(1.5 in) square area, or scratches more than 0.0254 mm (0.001 in) . Klj . 20 ba
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50.
NOTE: This step will allow removal of the exhaust manifold through the bottom and access for
the installation of the engine lift brackets.
Using a suitable floor crane, raise the engine to remove the exhaust manifold.
51. Install the RH and LH special tool.
52. NOTE: Before carrying out this step it will be necessary to support the transmission with a floor
jack and a block of wood.
Install the special tool. Klj . 11 ba
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31.
NOTE: One side shown, other side similar.
Using a suitable container, drain coolant from the engine block. zInstall the drain plugs when finished.
32. Remove the four bolts and the power steering pump.
33. Remove the compressor. 1. Remove the bolts.
2. Remove the compressor. Klj . 11 ba
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62.
CAUTION: Do not scratch cylinder walls or crankshaft journals with the connecting
rod.
NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the
ridge or carbon deposits from each cylinder using a cylinder ridge reamer following the
manufacturer's instructions.
Remove the piston removing pistons number 1 and 6 through the top of the cylinder block.
63. Repeat the previous two steps to remove the remaining pistons, rotating the crankshaft 90 degrees between piston pairs 3 and 5, 4 and 7, 2 and 8.
64. Remove the piston rings. Klj . 22 ba
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