engine FORD MUSTANG 2003 Workshop Manual

DIAGNOSIS AND TESTING
Engine
Refer to
Section 303 - 00 for basic mechanical concerns or refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for driveability concerns. SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
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IN-
VEHICLE REPAIR
Lower Intake Manifold
Removal and Installation 1. Drain the engine coolant. For additional information, refer to Section 303 - 03A in this section.
2. Drain the supercharger coolant. For additional information, refer to Section 303 - 03B .
3. Release the fuel system pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the radiator upper hose, radiator lower hose and the supercharger degas hose.
5. Remove the supercharger belt. For additional information, refer to Section 303 - 05 .
6. Disconnect the coolant hose.
SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Material
Item Specification
Motorcraft Premium Engine
Coolant
VC
-4-A (in Oregon VC- 5, in
Canada CXC- 10) (green color) ESE-
M97B44-
A Motorcraft Premium Gold
Engine Coolant
VC
-7-A (in Oregon VC-7- B)
(yellow color) WSS-
M97B51-
A1 Klj . 1 ba
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25. Separate the fuel charging wiring harness from the fuel injection supply manifold in four places
and position the harness aside.
26. Remove the ten bolts and the intake manifold, and the supercharger and fuel supply manifold as an assembly.
27. NOTE: Inspect the intake manifold gaskets and install new gaskets, if necessary.
NOTE: Install new bypass tube O- rings and lubricate them, using premium engine coolant.
To install, reverse the removal procedure. zTighten the intake manifold bolts in the sequence shown. Klj . 6 ba
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28. Fill and bleed the engine cooling system. For additional information, refer to
Section 303 - 03A in
this section.
29. Fill and bleed the supercharger cooling system. For additional information, refer to Section 303 -
03B . Klj . 7 ba
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IN-
VEHICLE REPAIR
Valve Cover RH
Removal and Installation 1. Remove the RH ignition coils. For additional information, refer to Section 303 - 07C .
2. Remove the A/C condenser to evaporator tube. For additional information, refer to Section 412 -
03 .
3. Remove the A/C manifold and tube assembly. For additional information, refer to Section 412 -
03 .
4. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve electrical connectors.
5. Disconnect the vacuum hose.
6. Disconnect the fuel hose spring lock coupling. For additional information, refer to Section 310 -
00 .
SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Material
Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA WSE-
M4G323- A4 Metal Surface Cleaner
F4AZ-
19A536- RA WSE-
M5B392- A Klj . 1 ba
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IN-
VEHICLE REPAIR
Valve Cover LH
Removal and Installation 1. Remove the Hydro Boost brake booster. For additional information, refer to Section 206 - 07 .
2. Remove the LH ignition coils. For additional information, refer to Section 303 - 07C .
3. Disconnect the engine coolant temperature (ECT) sensor and unclip the wiring harness from the stud.
4. Unclip the wiring harness from the power steering bracket.
5. Disconnect the electrical connectors from the fuel pulse damper, EGR vacuum regulator solenoid, supercharger bypass vacuum solenoid, and the differential pressure feedback EGR
system.
SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Material
Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA WSE-
M4G323- A4 Metal Surface Cleaner
F4AZ-
19A536- RA WSE-
M5B392- A Klj . 1 ba
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IN-
VEHICLE REPAIR
Crankshaft Pulley
Removal 1. Remove the auxiliary crankshaft pulley. For additional information, refer to Crankshaft Pulley —
Auxiliary in this section.
2. Remove the accessory drive belt. For additional information, refer to Section 303 - 05 .
3. Remove the bolt. 4. Using the special tool, remove the crankshaft pulley. SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Special Tool(s)
Remover, Crankshaft Vibration
Damper
303-
009 (T58P-6316- D) Installer, Crankshaft Vibration
Damper
303-
102 (T74P-6316- B)
Material Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA WSE-
M4G323- A4 Klj . 1 ba
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IN-
VEHICLE REPAIR
Crankshaft Pulley — Auxiliary
Removal and Installation 1. Remove the cooling fan. For additional information, refer to Section 303 - 03A .
2. Remove the supercharger drive belt cover.
3. Rotate the supercharger belt tensioner clockwise and remove the supercharger belt. 4. Remove the coolant hose assembly bolt. SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Special Tool(s)
Locking Tool, Flywheel
303-
673 Klj . 1 ba
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IN-
VEHICLE REPAIR
Crankshaft Front Seal
Removal 1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this
section. 2. Using the special tool, remove the crankshaft front seal. SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Special Tool(s)
Installer, Front Cover Oil Seal
303-
335 (T88T-6701- A) Remover, Crankshaft Front Oil
Seal
303-
107 (T74P-6700- A) Installer, Crankshaft Front Oil
Seal
303-
635 Installer, Crankshaft Vibration
Damper
303-
102 (T74P-6316- B)
Material Item Specification
SAE 5W-
20 Premium Synthetic
Blend Engine Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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Installation
1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
2. Using the special tool, install the crankshaft front seal.
3. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
4. Install the auxiliary crankshaft pulley. For additional information, refer to Crankshaft Pulley —
Auxiliary in this section. Klj . 2 ba
32003 Mustang Workshop Manual
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