clock FORD MUSTANG 2003 Service Manual

27. Install a retaining clip on the tensioner to hold the plunger in during installation.
28. Remove the tensioner from the vise.
29. If the copper links are not visible, mark two links on one end and one link on the other end, and
use as timing marks.
30. Install the timing chain guides.
31. Rotate the LH camshaft timing sprocket until the timing mark is approximately at the 12 o'clock Klj . 11 ba
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position. Rotate the RH camshaft timing sprocket until the timing mark is at approximately 11
o'clock position.
32. CAUTION: Unless otherwise instructed, at no time when the timing chains are
removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated.
Severe piston and valve damage will occur.
CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position
shown or severe piston and/or valve damage will occur.
Using the special tool, position the crankshaft.
zRemove the special tool.
33. Install the crankshaft sprocket with the flange facing forward.
34. Install the LH and RH timing chain onto the crankshaft sprocket, aligning the one copper (or marked) link on the timing chain with the slot on the crankshaft sprocket. Klj . 12 ba
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32. Install the torque converter nuts.
33. Install the flywheel inspection cover.
34. Install the driveshaft onto the transmission output shaft, aligning the index-
mark in the six
o'clock position.
35. CAUTION: Use new bolts to install the driveshaft. If new bolts are not available,
apply threadlock to the threads of the original bolts.
CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion
flange pilot. To make sure the yoke seats squarely on the flange, tighten the bolts evenly
in the sequence shown.
NOTE: Align the marks made on the flange and driveshaft during removal.
Position the driveshaft and install the driveshaft- to-pinion flange bolts in the sequence shown. Klj . 10 ba
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GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding
Draining
WARNING: Never remove the pressure relief cap while the engine is operating or when the
cooling system is hot. Failure to follow these instructions can result in damage to the cooling
system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of
the degas bottle when removing the pressure relief cap, wait until the engine is cooled, then
wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the
pressure is released from the cooling system. When you are sure all the pressure has been
released, turn and remove the pressure relief cap (still with a cloth).
CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the
coolant is contaminated, it must be recycled or disposed of correctly.
NOTE: Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty
or contaminated coolant should be drained and filled with new coolant.
1. Release the pressure in the cooling system by slowly turning the pressure relief cap one half turn counterclockwise or the radiator cap counterclockwise to the first stop. When the pressure
is released, remove the pressure relief cap/radiator cap.
2. Place a suitable container below the radiator draincock. If equipped, disconnect the coolant return hose at the fluid cooler. Open the draincock and drain the engine coolant.
zClose the radiator draincock.
Filling — 3.8L
CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant VC -7-A (in Oregon VC -7-B) or equivalent meeting Ford specification WSS- M97B51-A1
(yellow color). Always fill the cooling system with the same coolant that is present in the
system. Do not mix coolant types.
CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency,
and corrosion protection to the engine and cooling components. In order to obtain these
protections, the engine coolant must be maintained at the correct concentration and fluid level
in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water. SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Material
Item Specification
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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REMOVAL AND INSTALLATION
Water Pump —
4.6L(2V) and 4.6L(4V)
Removal and Installation
Mach I 1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
Cobra
2. Remove the supercharger drive belt cover.
3. Rotate the supercharger belt tensioner clockwise and remove the supercharger drive belt.
4. Remove the coolant hose mounting bolt.
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Material
Item Specification
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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Component Tests Test Step Result / Action to
Take A1 CHECK THE INTERCOOLER COOLANT LEVEL
WARNING: Never remove the pressure relief cap under
any conditions while the engine is operating. Failure to follow
these instructions could result in damage to the cooling system
or engine and/or personal injury. To avoid having scalding hot
coolant or steam blow out of the cooling system, use extreme
care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is released
from the cooling system. When certain all the pressure has
been released, remove the pressure relief cap (still with a
cloth). NOTE: Allow the engine to cool before checking the engine
coolant level. The engine must be off to check the coolant.
z Key in OFF position.
z Visually check the intercooler coolant level at the degas bottle.
z Is the coolant level within specification? Yes
GO to
A2 .
No
REFILL the coolant
as necessary. GO
to A2 .
A2 CHECK THE DEGAS BOTTLE PRESSURE RELIEF CAP
z
WARNING: Never remove the pressure relief cap under
any conditions while the engine is operating. Failure to follow
these instructions could result in damage to the cooling system
or engine and/or personal injury. To avoid having scalding hot
coolant or steam blow out of the cooling system, use extreme
care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is released
from the cooling system. When certain all the pressure has
been released, remove the pressure relief cap (still with a
cloth).
z Remove the pressure relief cap.
z Inspect the pressure relief cap for foreign material between the
sealing gasket and the diaphragm.
z Is the pressure relief cap OK? Yes
GO to
A3 .
No
CLEAN or INSTALL
a new pressure
relief cap. TEST the
system for normal
operation. A3 CHECK THE DEGAS BOTTLE
z
WARNING: Never remove the pressure relief cap under
any conditions while the engine is operating. Failure to follow
these instructions could result in damage to the cooling system
or engine and/or personal injury. To avoid having scalding hot
coolant or steam blow out of the cooling system, use extreme
care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly one turn
(counterclockwise). Step back while the pressure is released
from the cooling system. When certain all the pressure has
been released, remove the pressure relief cap (still with a
cloth).
z NOTE: The engine must be cool when coolant is added to the degas
bottle.
z Add coolant to the degas bottle until fluid is between the coolant fill
level marks.
z Does the degas bottle leak? Yes
INSTALL a new
degas bottle. TEST
the system for
normal operation.
No
CARRY OUT the
cooling system
pressure test.
REFER to the
Component Tests
in this section.
REPAIR as
necessary. TEST
the system for
normal operation. Klj . 4 ba
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Pressure Test
1. Turn the engine OFF.
2. WARNING: Never remove the pressure relief cap under any conditions while the
engine is operating. Failure to follow these instructions could result in damage to the
cooling system or engine and/or personal injury. To avoid having scalding hot coolant or
steam blow out of the cooling system, never remove the pressure relief cap from a hot
degas bottle. Wait until the engine has cooled, then wrap a thick cloth around the
pressure relief cap and turn it slowly one turn (counterclockwise). Step back while the
pressure is released from the cooling system. When certain all the pressure has been
released, remove the pressure relief cap (still with a cloth).
Check the intercooler coolant level. For additional information, refer to Supercharger Cooling System Draining, Filling and Bleeding in this section.
3. Connect the Radiator/Heater Core Pressure Tester to the degas bottle nipple. Install a pressure test pump to the quick- connect fitting of the test adapter.
4. NOTE: If the plunger of the pump is depressed too fast, an erroneous pressure reading will
result.
Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops
increasing and note the highest pressure reading obtained.
5. If the pressure relief cap does not hold pressure, remove and wash the pressure relief cap in clean water to dislodge all foreign particles from the gaskets. Check the sealing surface in the
filler neck.
6. If 69 kPa (10 psi) cannot be reached, install a new pressure relief cap. If more than 12 kPa (18 psi) shows on the gauge, install a new pressure relief cap.
7. CAUTION: If the pressure drops, check for leaks at the intercooler hoses or other
system components and connections. Any leaks which are found must be corrected and
the system rechecked.
NOTE: Intercooler system is not connected to the main engine cooling system.
Pressurize the intercooler cooling system as described in Step 4 (using a pressure relief cap
that operates within the specified upper and lower pressure limits). Observe the gauge reading
for approximately two minutes; refer to General Specifications. Pressure should not drop during
this time. zIf the pressure drops and no external leak is found, the intercooler may be the cause.
Remove and inspect the intercooler. Install a new intercooler if necessary.
8. Release the system pressure by loosening the pressure relief cap. Check the coolant level and replenish, if necessary, with the correct coolant mixture. For additional information, refer to
Supercharger Cooling System Draining, Filling and Bleeding in this section.
Cap WARNING: Never remove the pressure relief cap under any conditions while the engine is Klj . 5 ba
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operating. Failure to follow these instructions could result in damage to the cooling system or
engine and/or personal injury. To avoid having scalding hot coolant or steam blow out of the
cooling system, use extreme care when removing the pressure relief cap from a hot degas
bottle. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap
and turn it slowly one turn (counterclockwise). Step back while the pressure is released from
the cooling system. When certain all the pressure has been released, remove pressure relief
cap (still with a cloth).
1. Immerse the pressure relief cap in water and install it on the shallow filler neck of Radiator/Heater Core Pressure Tester and Radiator Cap Adapter, part of Radiator/Heater Core
Pressure Tester.
2. Immerse the filler neck seal in water and install it in the filler neck adapter.
3. Install the filler neck adapter with the filler neck seal to the Radiator Cap Adapter.
4. Connect the female quick- connect fitting of the pressure test pump to the male quick- connect
fitting of the filler neck adapter.
5. NOTE: If the plunger of the pump is depressed too fast, an erroneous pressure reading will
result.
Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops
increasing and note the highest pressure reading obtained.
6. Release the pressure by turning the relief screw counterclockwise. Then tighten the pressure relief screw and repeat Step 6 (at least twice) to make sure the reading is repeatable within the
specifications of the pressure relief cap.
7. If the pressure test gauge readings are not within specifications, install a new pressure relief cap. If the pressure test gauge readings are within specifications, carry out the cooling system
pressure test.
Radiator Leak Test, Removed From the Vehicle CAUTION: Never leak test an aluminum radiator or intercooler in the same water that
copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning
tank and they will damage aluminum radiators and intercoolers.
NOTE: Clean the radiator or intercooler before leak testing to avoid contamination of tank.
1. Leak test the radiator or intercooler in clean water with 138 kPa (20 psi) air pressure. Klj . 6 ba
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REMOVAL AND INSTALLATION
Accessory Drive Belt —
3.8L
Removal and Installation 1. Rotate the drive belt tensioner counterclockwise and remove the drive belt.
2. NOTE: Make sure the drive belt is correctly installed on each pulley.
To install, reverse the removal procedure. zRefer to Accessory Drive for drive belt routing.
SECTION 303-
05: Accessory Drive 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Accessory Drive Belt —
4.6L (2V) and (4V)
Removal and Installation
Mach I 1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
Cobra 2. Remove the supercharger drive belt cover.
3. Rotate the supercharger belt tensioner clockwise and remove the supercharger belt.
4. Remove the coolant hose mounting bolt.
5. Remove the belt idler support bracket assembly.
SECTION 303-
05: Accessory Drive 2003 Mustang Workshop Manual Klj . 1 ba
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