engine FORD MUSTANG 2003 Workshop Manual

13. Remove the valve stem seals.
14.
CAUTION: The outer bolts on the outer cam bearing cap (exhaust) are longer and
must be returned to the same location or engine damage may occur.
NOTE: Identify the camshaft- to-cylinder head location. Caps are not interchangeable.
Remove the bolts and the camshaft bearing cap assemblies. Klj . 5 ba
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4. Compress the valve spring compressor and install the key on the valves.
5.
NOTE: LH is shown, RH is similar.
Install the camshafts. zLubricate the camshafts with clean engine oil.
6. Install the camshaft bearing cap assemblies. Klj . 7 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Piston
Disassembly
1. Remove the clips.
2. Remove the piston pin (6135) from the piston (6108) and connecting rod assembly.
3. Remove the connecting rod (6200) from the piston.
SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Material
Item Specification
Super Premium SAE 5W-20
Motor Oil
XO- 5W20- QSP WSS-
M2C153-
H Klj . 1 ba
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4. Clean and inspect the piston and connecting rod. For additional information, refer to
Section 303 - 00 .
Assembly 1. NOTE: Connecting rod must be installed into piston with identification markings toward front.
Position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly. Klj . 2 ba
32003 Mustang Workshop Manual
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Intake Manifold Assembly
Disassembly and Assembly
1. Disconnect and remove the PCV hoses.
2. Remove the coolant supply and return manifold.
3. Remove the coolant supply and return tubes and seals. 4. Remove the bolts, the supercharger and the charge air cooler (CAC) assembly. SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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ASSEMBLY
Engine
SECTION 303-
01C: Engine — Cobra 4.6L (4V) 2003 Mustang Workshop Manual Special Tool(s)
Installer, Connecting Rod
303-
442 (T93P-6136- A) Installer, Crankshaft Vibration
Damper
303-
102 (T74P-6316- B) Installer, Front Cover Oil Seal
303-
335 (T88T-6701- A) Installer, Crankshaft Front Oil
Seal
303-
635 Installer, Crankshaft Rear Oil
Seal
303-
518 (T95P-6701- DH) Installer, Crankshaft Rear Oil
Slinger
303-
517 (T95P-6701- CH) Compressor, Valve Spring
(Intake)
303-
452 (T93P-6565- AR) Compressor, Valve Spring
(Exhaust)
303-
567 (T97P-6565- AH) Klj . 1 ba
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Assembly
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.
1. Record the main bearing code found on the front of the engine block. Installer, Crankshaft Rear Oil
Seal
303-
516 (T95P-6701- BH) Compressor, Piston Ring
303-
D032 (D81L-6002- C) or
equivalent Holding Tool, Crankshaft
303-
448 (T93P-6303- A)
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 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 Canada VC-7- B) or
equivalent WSS-
M97B51-
A1 Klj . 2 ba
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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 determine
the required bearing grade for each main bearing.
zRead the first letter of the engine block main bearing code and the first letter of the
crankshaft main bearing code.
z Read down the column below the engine block main bearing code letter, and across the
row next to the crankshaft main bearing code letter, until the two intersect. This is the
required bearing grade for the number one crankshaft main bearing.
z As an example, if the engine block code letter is "F" and the crankshaft code letter is "D",
the correct bearing grade for this main bearing is a "2".
z Repeat this process for the remaining four main bearings. Klj . 3 ba
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4. If oversize bearings are being used, use the procedure in the previous step and the Bearing
Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main
bearing.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. Install the crankshaft onto the upper main bearings. Klj . 4 ba
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7.
NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the
crankshaft thrust surface).
Install the thrust washer to the rear of the No. 5 upper main bearing.
8. NOTE: Rotate the jack screws into the bearing caps enough to provide clearance to the cylinder
block, prior to installing the bearing caps
NOTE: Install the thrust bearing to the rear main bearing cap and lubricate it with clean engine
oil.
NOTE: Install the crankshaft lower main bearings into the main bearing caps and lubricate them
with clean engine oil.
Apply forward force to the crankshaft, so that the crankshaft thrust face is against the No. 5
bulkhead. With the crankshaft in this position, locate the No. 5 main bearing cap on the cylinder
block and tap into place using a plastic or dead blow hammer.
zInstall the four remaining main bearing caps. Klj . 5 ba
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