oil FORD MUSTANG 2003 Workshop Manual

ASSEMBLY
Engine
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Special Tool(s)
Guides, Connecting Rod
303-
442 (T93P-6136- A) Installer, Crankshaft Rear Oil
Seal
303-
518 (T95P-6701- DH) Installer, Crankshaft Rear Oil
Seal
303-
516 (T95P-6701- BH) Installer, Crankshaft Rear Oil
Slinger
303-
517 (T95P-6701- CH) Impact Slide Hammer
100-
001 (T50T-100- A) Spreader Bar
303-
D089 (D93P-6001- A3) Lifting Bracket, Engine
303-
D087 (D93P-6001- A1) Lifting Bracket, Engine
303-
D088 (D93P-6001- A2) Klj . 1 ba
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Lifting Bracket Set, Engine
303-
D074 (D91P-6001- A) Installer, Crankshaft Vibration
Damper
303-
102 (T74P-6316- B) Installer, Front Cover Oil Seal
303-
335 (T88T-6701- A) Compressor, Piston Ring
303-
D032 (D81L-6002- C) or
equivalent Holding Tool, Crankshaft
303-
448 (T93P-6303- A) Remover/Installer, Cylinder
Head
303-
572 (T97T-6000- A) Compressor, Valve Spring
303-
576 (T97P-6565- AH) Strap Wrench
303-
D055 (D85L-6000- A) or
equialent Klj . 2 ba
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Assembly
NOTE:
During engine assembly, it may by necessary to check bearing clearances and end play. For
additional information, refer to Section 303 - 00 .
1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart Crankshaft Seal Installer
303-
635
Material Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Super Premium SAE 5W-20
Motor Oil
XO- 5W20- QSP or equivalent WSS-
M2C153- H Klj . 3 ba
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NOTE:
Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint
and foreign material. Also, make sure the coolant and oil passages are clear.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. NOTE: Do not install the upper thrust washer until the crankshaft is installed. Refer to Step 3.
NOTE: Do not install the upper thrust washer until the crankshaft (6303) is installed. Refer to
Step 3.
Install the crankshaft onto the upper main bearings. Klj . 5 ba
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7.
NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the
crankshaft surface).
Push the crankshaft rearward and install the crankshaft upper thrust washer at the rear of the
No. 5 main boss.
8. NOTE: Rotate the jackscrews into the bearing caps enough to provide clearance to the cylinder
block prior to installing the bearing caps.
Install the lower main bearings into the main bearing caps and lubricate them with clean engine
oil.
9. Install the rear main bearing cap.
10. Install the remaining main bearing caps on the cylinder block and tap into place using a plastic or dead- blow hammer. Klj . 6 ba
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17. Make sure the ring gaps (oil spacer [A], oil ring [B], and compression ring [C]) are properly
spaced around the circumference of the piston.
18. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the
connecting rod.
NOTE: Only one piston and connecting rod shown, others similar.
NOTE: Make sure the crankshaft is facing forward.
NOTE: Lubricate the piston rings, cylinder walls and connecting rod bearings with clean engine
oil.
Install the upper bearings in the connecting rod as shown. Klj . 9 ba
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NOTE:
Only one connecting rod assembly shown, others similar.
Using the special tool install the piston and connecting rod assembly by pushing the pistons
through the top of the cylinder block.
21. NOTE: These bolts are torque- to-yield. Install new bolts each time they are serviced.
Install the connecting rod bearing caps and bolts and tighten in three stages. zStage 1: Tighten to 25Nm (18 lb- ft).
z Stage 2: Tighten to 40Nm (30 lb- ft).
z Stage 3: Tighten an additional 90 degrees.
22. Rotate the crankshaft and install the remaining piston and connecting rod assemblies.
23. Check the connecting rod bearing clearance. For additional information, refer to Section 303 -
00 .
24. Install the oil pump and tighten the bolts. 25. NOTE: Install a new O - ring if necessary. Klj . 11 ba
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Install the oil pump screen cover and tube.
26. NOTE: If not secured within four minutes, sealant must be removed and sealing area cleaned
with metal surface cleaner. Allow to dry until there are no signs of wetness, or four minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.
If the retainer plate was removed, apply a 4 mm (0.16 in) bead of silicone gasket and sealant
around the rear oil seal retainer sealing surface.
27. Install the rear main seal retainer plate. Tighten the bolts in the sequence shown. zTighten bolts 1- 6 to 10 Nm (89 lb- in).
z Hand- tighten bolts 7 and 8.
z Tighten bolts 7 and 8 to 20 Nm (15 lb- ft).
z Tighten bolts 7 and 8 an additional 60 degrees.
28. Install the oil pan and gasket and loosely install the bolts. Klj . 12 ba
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55. Tighten the four oil pan bolts in the sequence shown in three stages.
zStage 1: Tighten to 2 Nm (18 lb- in).
z Stage 2: Tighten to 20 Nm (15 lb- ft).
z Stage 3: Tighten an additional 60 degrees.
56. Install the belt idler pulleys. 57. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil. 8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
11 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 12 W706560 Stud and Washer, Hex-
Head Pilot, M8 x 1.25 x 65
— M8 x 1.25 x 16 13 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 14 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 15 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 Klj . 22 ba
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58. Using the special tool, install the front oil seal.
59. Install the water pump pulley and bolts.
60.
NOTE: The crankshaft pulley must be installed within four minutes of applying sealant.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
61. Using the special tool, install the crankshaft pulley. Klj . 23 ba
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