service FORD MUSTANG 2003 Repair Manual

70. Using the camshaft bearing service set, remove the engine dynamic balance shaft bearings.
71. If equipped, remove the engine block heater. For additional information, refer to
Section 303 -
03A .
72. NOTE: For cleaning purposes, the plugs should be removed.
If necessary, remove the following: 1. the cylinder block dowels.
2. the oil gallery plugs.
3. the water jacket plugs. Klj . 20 ba
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CAUTION: The moving components must be lubricated with clean engine oil before
assembly.
CAUTION: The components with oil holes must be correctly aligned with the oil feed
holes.
1. If necessary, install the following: 1. the cylinder block dowels.
2. the oil gallery plugs.
3. the water jacket plugs.
2. If equipped, install the engine coolant heater. For additional information refer to Section 303 -
03A .
3. Using the camshaft bearing service set, install the engine dynamic balance shaft bearings. Adapter, Crankshaft Rear Seal
(Use only the adapter and the
center jack screw)
303-
S560 (T96T-6701- A) Spreader Bar
303-
D089 (D93P-6001- A3)
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 Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Pipe Sealant with Teflon®
XW7Z-19554-
AA WSK-
M2G350-
A2 Klj . 2 ba
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4. Using the camshaft bearing service set, install the camshaft bearings.
5. Install the following:
1. the engine dynamic balance shaft bearing cover.
2. the camshaft bearing cover.
6. CAUTION: Do not damage the camshaft lobes when installing the camshaft.
Install the camshaft and the camshaft spacer. Klj . 3 ba
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Valve spring installed height 42.3-
42.9 mm (1.67- 1.69 in) Valve spring installed pressure 283.0-
321.0 N @ 42.56 mm (63.61 lb @ 1.68 in) Roller follower ratio —
intake 2.02:1
Roller follower ratio —
exhaust 2.03:1
Hydraulic Lash Adjuster
Diameter 16.000-
15.988 mm (0.6299- 0.6294 in) Clearance-
to-bore 0.018-
0.069 mm (0.0007- 0.0027 in) Service limit 15.988 mm
Hydraulic leakdown rate
c 5-
25 seconds Collapsed lash adjuster gap —
desired 0.45-
0.85 mm (0.02- 0.03 in) Camshaft
Theoretical valve lift @ 0 lash —
intake 13.00 mm (0.51 in)
Theoretical valve lift @ 0 lash —
exhaust 13.75 mm (0.54 in)
Lobe lift —
intake 7.11038 mm (0.28 in)
Lobe lift —
exhaust 7.4794 mm (0.30 in)
Allowable lobe lift loss 0 mm (0.0 in)
Journal diameter 26.962-
26.936 mm (1.0615- 1.0605 in) Camshaft journal bore inside diameter 27.012-
26.987 mm (1.0635- 1.0625 in) Camshaft journal-
to-bearing clearance 0.025-
0.076 mm (0.00098- 0.002992 in) Camshaft journal-
to-bearing clearance —
service limit 0.100 mm (0.003937 in) max.
Runout —
Front and rear journals 0.03 mm (0.001 in)
Runout —
four inner journals 0.09 mm (0.003 in)
End play 0.027-
0.190 mm (0.001- 0.007 in) End play —
service limit 0.190 mm (0.007480 in)
Cylinder Block
Cylinder bore diameter 31 mm (1.24 in) from top of block
red — 90.200-90.210
blue — 90.210-90.220
yellow — 90.220-90.230 Cylinder bore maximum taper 0.70 mm (0.027559 in)
Cylinder bore maximum out-of-
round —limit 0.20 mm (0.007874 in)
Cylinder bore maximum out-of-
round —service
limit 0.70 mm (0.027559 in)
Main bearing bore inside diameter 72.400-
72.424 mm (2.8504- 2.8513 in) Crankshaft
Main bearing journal diameter 67.482-
67.504 mm (2.66- 21.661 in) Main bearing journal maximum taper 0.004 mm (0.0002 in)
Main bearing journal maximum out-of-
round 0.05 mm (0.002 in)
Main bearing journal-
to-cylinder block clearance
— desired 0.025-
0.044 mm (0.001- 0.002 in) Main bearing journal-
to-cylinder block clearance
— allowable 0.025-
0.050 mm (0.00098- 0.00197 in) Connecting rod journal diameter 52.983-
53.003 mm (2.085941- 2.086728 in) Klj . 2 ba
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a
With installation of a new filter.
b Distance front edge of bearing is installed below front face of cylinder block.
c Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in
tappet.
d Measured at 31.5 mm from top of block. Measured at 43 mm from top of piston, at 90 degrees to the
piston pin. Connecting rod journal maximum taper 0.004 mm (0.0002 in)
Connecting rod journal maximum out-of-
round 0.05 mm (0.002 in)
Crankshaft maximum end play 0.075-
0.377 mm (0.003- 0.015 in) Piston and Connecting Rod
Piston diameter —
code red 1 d 90.185-
90.205 mm (3.55- 3.551 in) Piston diameter —
code blue 2 d 90.195-
90.215 mm (3.55- 3.551 in) Piston diameter —
code yellow 3 d 90.205-
90.225 mm (3.551- 3.552 in) Piston-
to-cylinder bore clearance -0.005-
0.025 mm (- 0.002/+0.001 in) Piston ring end gap —
compression (top) e 0.130-
0.280 mm (0.005- 0.011 in) Piston ring end gap —
compression (bottom) e 0.300-
0.550 mm (0.0018- 0.0022 in) Piston ring end gap —
oil ring (steel rail) e 0.150-
0.650 mm (0.006- 0.0256 in) Piston ring groove width —
compression (top) 1.530-
1.550 mm (0.06- 0.061 in) Piston ring groove width —
compression
(bottom) 1.520-
1.540 mm (0.06- 0.061 in) Piston ring groove width —
oil ring 3.030-
3.050 mm (0.12- 0.12 in) Piston ring width —
compression (top) 1.480-
1.500 mm (0.058- 0.059 in) Piston ring width —
compression (bottom) 1.470-
1.490 mm (0.0587- 0.0586 in) Piston ring-
to-groove clearance — compression
(top) 0.050-
0.090 mm (0.002- 0.004 in) Piston ring-
to-groove clearance — compression
(bottom) 0.030-
0.080 mm (0.00118- 0.00315 in) Piston ring-
to-groove clearance — oil ring Snug fit
Piston pin bore diameter
f 21.008-
22.014 mm (0.866- 0.867 in) Piston pin diameter 22.0010-
22.0030 mm (0.87- 0.871 in) Piston pin length 61.601-
62.030 mm (2.42523- 2.44212 in) Piston pin-
to-piston fit -
0.005/+0.0135 mm (- 0.0002/+0.0005 in) Piston-
to-connecting rod clearance — standard 0.009-
0.0235 mm (0.0004- 0.00092 in) Piston-
to-connecting rod clearance — service
limit 0.035 mm (0.001378 in)
Connecting rod-
to-pin clearance 0.009-
0.023 mm (0.0004- 0.0009 in) Connecting rod pin bore diameter 22.012-
22.024 mm (0.86661- 0.86708 in) Connecting rod length (center-
to-center) 150.7 mm (5.933 in)
Connecting rod maximum allowed bend
g 0.038 per 25 mm (0.00150 per 0.9843 in)
Connecting rod maximum allowed twist
c 0.050 per 25 mm (0.00197 per 0.9843 in)
Connecting rod bearing bore diameter 56.866-
56.886 mm (2.23881- 2.23960 in) Connecting rod bearing-
to-crankshaft clearance 0.027-
0.069 mm (0.0010629- 0.0027165 in) Connecting rod side clearance —
standard 0.125-
0.475 mm (0.005- 0.019 in) Connecting rod side clearance —
service limit 0.50 mm (0.01969 in) max. Klj . 3 ba
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IN-
VEHICLE REPAIR
Valve Seals
Removal and Installation 1. Remove the roller followers. For additional information, refer to Camshaft Roller Follower in this
section.
2. Remove the spark plug (12405) from the applicable cylinder.
3. Position the piston (6102) of the cylinder being serviced at the bottom of the stroke.
4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any
loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be
removed, support the valve prior to removal.
Use compressed air in the cylinder to hold both valves in position. 5. Using the special tool, compress the valve spring (6513). SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Special Tool(s)
Valve Spring Compressor
303-
452 (T93P-6565- AR) Valve Stem Seal Replacer
303-
383 (T91P-6571- A) Compressor, Valve Spring
(Exhaust)
303-
567 (T97P- 6565- AH)
Material Item Specification
Super Premium SAE 5W-20
Motor Oil
XO- 5W20- QSP WSS-
M2C153-
H Klj . 1 ba
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IN-
VEHICLE REPAIR
Camshaft Roller Follower
Removal 1. Remove the valve cover. For additional information, refer to Valve Cover LH or
Valve Cover RH in this section.
2. Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.
3. Using the special tool compress the intake valve spring.
4. Remove the roller follower from the intake valve.
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Special Tool(s)
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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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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Valve head diameter—
exhaust 30 mm (1.18 inch)
Valve face runout 0.05 mm (0.002 in)
Valve face angle 45.5 degrees
Valve seat width—
intake 1.8-
2.2 mm (0.071- 0.086 inch) Valve seat width—
exhaust 1.8-
2.2 mm (0.071- 0.086 inch) Valve seat runout 0.05 mm (0.002 inch)
Valve seat angle 45 degrees
Valve spring free length—
intake 42.16 mm (1.6598 inch)
Valve spring free length—
exhaust 42.16 mm (1.6598 inch)
Valve spring squareness 2 degrees
Valve spring compression pressure—
intake 711.47 N @ 26.19 mm (159.9 lb-
ft @
1.031 inch) Valve spring compression pressure—
exhaust 711.47 N @ 26.19 mm (159.9 lb-
ft @
1.031 inch) Valve spring installed height 36.14 mm (1.4228 in)
Valve spring installed pressure—
intake 289.1 N @ 36.14 mm (64.99 lb-
ft @
1.4228 inch) Valve spring installed pressure—
exhaust 289.1 N @ 36.14 mm (64.99 lb-
ft @
1.4228 inch) Roller follower ratio 1.8:1
Hydraulic Lash Adjuster
Diameter 16.000-
15.988 mm (0.6299- 0.6294 inch) Clearance-
to-bore 0.018-
0.069 mm (0.000709- 0.002717
inch) Service limit 0.016 mm (1.0006299 inch)
Hydraulic leakdown rate
c 5-
25 seconds Collapsed lash adjuster gap 0.80-
1.20 mm (0.0315- 0.0472 inch) Camshaft
Theoretical valve lift @ 0 lash—
intake (primary and
secondary) 10.0 mm (0.3937 inch)
Theoretical valve lift @ 0 lash—
exhaust 10.0 mm (0.3937 inch)
Lobe lift 5.54 mm (0.218 in)
Allowable lobe lift loss 0.130 mm (0.0051 in)
Journal diameter 26.962-
26.936 mm (1.0615- 1.0605 inch) Camshaft journal bore inside diameter 27.012-
26.987 mm (1.0635- 1.0625 in) Camshaft journal-
to bearing clearance 0.025-
0.076 mm (0.00098- 0.002992
inch) Runout 0.025 mm (0.0010 in)
End play 0.025-
0.165 mm (0.00098- 0.00649 inch) Cylinder Block
Cylinder bore diameter 90.2-
90.239 mm Cylinder bore maximum taper 0.016 mm
Cylinder bore maximum out-of-
round 0.016 mm
Main bearing bore diameter 72.402-
72.422 mm Klj . 2 ba
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z
are positioned so that their tips direct fuel just ahead of the engine intake valves.
z are connected in series with the fuel pressure sensor.
z supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.
A constant fuel pressure drop is maintained across the fuel injectors by the fuel pressure sensor. The
fuel pressure sensor:
zis positioned upstream from the fuel injectors on the fuel injection supply manifold.
Valve Train
The valve train operates as follows:
zball- tip hydraulic lash adjusters provide automatic lash adjustment.
z roller followers ride on the camshaft lobes, transferring the up-and- down motion of the
camshafts to the valves in the cylinder heads.
Positive Crankcase Ventilation System
All engines are equipped with a closed- type positive crankcase ventilation system recycling the
crankcase vapors to the upper intake manifold.
Lubrication System
The engine lubrication system operates as follows:
zoil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil
pan.
z oil is pumped through the oil bypass filter on the left front side of the cylinder block.
z oil enters the main oil gallery where it is distributed to the crankshaft main journals and to both
cylinder heads.
z From the main journals, the oil is routed through cross- drilled passages in the crankshaft to
lubricate the connecting rod bearings. Controlled leakage through the crankshaft main bearings
and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as
well as the entire connecting rod, piston and piston rings assembly.
z The left cylinder head is fed from a drilling into the supply passage feeding the main gallery at
the front of the cylinder block. The right cylinder head is fed from a drilling into the rear of the
main gallery. Main gallery pressure is reduced as it enters the cylinder head galleries through
fixed serviceable orifices located at the upper part of the feed passages. It is this reduced
pressure in the cylinder head galleries which feeds the camshaft journals, the hydraulic lash
adjusters and the primary and secondary timing chain tensioners.
z The camshaft lobe and roller followers are lubricated by splash created through valve train
operation.
Oil Pump
The lubrication system of the 4.6L (4V) engine is designed to provide optimum oil flow to critical
components of the engine through its entire operating range. The heart of the system is a positive
displacement internal gear oil pump using top seal rotors. Generically this design is known as a gerotor
pump, which operates as follows.
zThe oil pump is mounted on the front face of the cylinder block. Klj . 2 ba
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