2003 FORD MUSTANG engine

SPECIFICATIONS
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
SAE 5W-
20 Premium Synthetic Blend Motor Oil
XO- 5W20- QSP WSS-
M2C153- H Diesel engine oil Refer to owner literature
Gasoline Engine Oil Dye
164-
R3705 ESE-
M99C103-B1 Threadlock® 262
E2FZ-
19554- B WSK-
M2G351- A6 Klj . 1 ba
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DESCRIPTION AND OPERATION
Engine
NOTE:
This section contains information, steps and procedures that may not be specific to your
engine.
This section covers general procedures and diagnosis and testing of the engine system, except for
exhaust emission control devices, which are covered in the Powertrain Control/Emissions Diagnosis
Manual.
The engine incorporates the following features:
za closed positive crankcase ventilation (PCV) system. For additional information, refer to
Section 303 - 08 .
z an exhaust emission control system. For additional information, refer to Section 303 - 08 .
z an evaporative emission control system. For additional information, refer to Section 303 - 13 .
Some engines incorporate a fail- safe cooling system. Refer to the appropriate section in Group 303 for
the procedure.
The engine, fuel system, ignition system, emissions system and exhaust system all affect exhaust
emission levels and must be maintained according to the maintenance schedule. Refer to the
scheduled Maintenance Guide.
Correct engine identification is required to order parts. Refer to the appropriate section in Group 303 for the procedure.
For complete vehicle and engine identification codes, refer to
Section 100 - 01 .
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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DIAGNOSIS AND TESTING
Engine
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Commercially Available
Leakdown Tester
—
Quick Disconnect Compression
Tester
134-
R0212 or equivalent Dial Indicator Gauge Adapter
303-
007 (TOOL- 6565-AB) or
equivalent Dial Indicator Gauge with
Holding Fixture
100-
002 (TOOL- 4201-C) or
equivalent Engine Cylinder Leak
Detection/Air Pressurization Kit
014-00708 or equivalent
Oil Pressure Gauge
303-
088 (T73L-6600- A) UV Leak Detector Kit
164-
R0756 or equivalent Vacuum/Pressure Tester
164-
R0253 or equivalent Klj . 1 ba
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Inspection and Verification
1. Verify the customer concern by operating the engine to duplicate the condition.
2. Visually inspect for obvious signs of mechanical damage. Refer to the following chart.
3. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
4. If the concerns remain after the inspection, determine the symptoms. GO to Symptom Chart .
Symptom Chart Material
Item Specification
Gasoline Engine Oil
Dye
164-
R3705 or
equivalent ESE-
M99C103- B1 Engine Oil Refer to owner
literature
Visual Inspection Chart Mechanical
z
Engine coolant leaks
z Engine oil leaks
z Fuel leaks
z Damaged or severely worn parts
z Loose mounting bolts, studs and nuts
Symptom Chart Condition
Possible Sources Action
z Difficult
starting z
Damaged ignition
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Damaged starting
system. z
Refer to the appropriate section
in Group 303 for the procedure. Klj . 2 ba
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(PC/ED) manual.
z Damaged valve
tappet or lash
adjuster. z
INSTALL a new valve tappet or
lash adjuster.
z Damaged valve
tappet guide or
valve tappet. z
INSTALL a new valve tappet
guide or valve tappet.
z Burnt or sticking
valve. z
REPAIR or INSTALL a new
valve.
z Weak or broken
valve spring. z
INSTALL a new valve spring.
z Carbon
accumulation in
combustion
chamber. z
ELIMINATE carbon buildup.
z Excessive oil
consumption z
Leaking oil. zREPAIR oil leakage.
z Malfunctioning PCV
system. z
REPAIR or INSTALL new
necessary components.
z Worn valve stem
seal. z
INSTALL a new valve stem seal.
z Worn valve stem or
valve guide. z
INSTALL a new valve and valve
guide.
z Sticking piston
rings. z
REPAIR or INSTALL new piston
rings.
z Worn piston ring
groove. z
INSTALL a new piston and
piston pin.
z Worn piston or
cylinder. z
REPAIR or INSTALL a new
piston or cylinder block.
z Engine noise zLeaking exhaust
system. z
REPAIR exhaust leakage.
z Incorrect drive belt
tension. z
REFER to Section 303 - 05 .
z Malfunctioning
generator bearing. z
Refer to the appropriate section
in Group 414 for the procedure.
z Malfunctioning
water pump
bearing. z
REFER to Section 303 - 03A .
z Malfunctioning or
damaged cooling
system. z
REFER to Section 303 - 03A .
z Malfunctioning or
damaged fuel
system. z
Refer to the appropriate section
in Group 303 for the procedure.
REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Loose timing
chain/belt (6268). z
ADJUST or INSTALL a new
timing chain/belt.
z Damaged timing
chain tensioner
(6L266). z
INSTALL a new timing chain
tensioner.
z Excessive main
bearing clearance. z
ADJUST clearance or INSTALL
a new crankshaft main bearing
(6333). Klj . 4 ba
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Component Tests
Engine Oil Leaks
NOTE:
When diagnosing engine oil leaks, the source and location of the leak must be positively
identified prior to repair.
Prior to carrying out this procedure, clean all sealing surface areas with a suitable solvent to remove all
traces of oil.
Engine Oil Leaks— Fluorescent Oil Additive Method
Use the UV Leak Detector Kit to carry out the following procedure for oil leak diagnosis. 1. Add gasoline engine oil dye. Use a minimum 14.8 ml (0.5 ounce) to a maximum 29.6 ml (1 ounce) of fluorescent additive to all engines. If the oil is not premixed, fluorescent additive must
first be added to crankcase.
2. Run the engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks using the UV Leak Detector Kit. A clear bright yellow or orange area will identify the leak. For
extremely small leaks, several hours may be required for the leak to appear.
Leakage Points— Underhood
Examine the following areas for oil leakage:
zvalve cover gaskets z
Slipping
transmission. z
Refer to the appropriate section
in Group 307 for the procedure.
z Malfunctioning
valve tappet or lash
adjuster. z
INSTALL a new valve tappet or
lash adjuster.
z Damaged valve
tappet guide or
valve tappet. z
INSTALL a new valve tappet
guide or valve tappet.
z Compression
leakage at valve
seat. z
REPAIR or INSTALL a new
valve, valve seat or cylinder
head (6049).
z Seized valve stem. zINSTALL a new valve.
z Weak or broken
valve spring. z
INSTALL a new valve spring.
z Worn or damaged
camshaft. z
INSTALL a new camshaft.
z Damaged head
gasket (6051). z
INSTALL a new head gasket.
z Cracked or
distorted cylinder
head. z
INSTALL a new cylinder head.
z Damaged, worn or
sticking piston ring
(s). z
REPAIR or INSTALL a new
piston ring(s).
z Worn or damaged
piston. z
INSTALL a new piston and
piston pin. Klj . 6 ba
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z
intake manifold gaskets
z cylinder head gaskets
z oil bypass filter
z oil filter adapter
z engine front cover
z oil filter adapter and filter body
z oil level indicator tube connection
z oil pressure sensor
Leakage Points— Under Engine—With Vehicle on Hoist
z oil pan gaskets (6710)
z oil pan sealer
z oil pan rear seal (6723)
z engine front cover gasket
z crankshaft front seal (6700)
z crankshaft rear oil seal (6701)
z crankshaft main bearing cap side bolts
z oil filter adapter and filter body
z oil cooler, if equipped
Leakage Points— With Transmission and Flywheel Removed
z crankshaft rear oil seal
z rear main bearing cap parting line
z rear main bearing cap and seals
z flywheel mounting bolt holes (with flywheel [6375] installed)
z camshaft rear bearing covers (6266) or pipe plugs at the end of oil passages
Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected
when using the dye method.
Compression Test— Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the battery (10655) is correctly charged. Operate the vehicle until the engine is at normal operating
temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs
(12405).
2. Set the throttle plates in the wide- open position.
3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder.
4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression
strokes and record the highest reading. Note the approximate number of compression strokes Klj . 7 ba
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required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes.
Compression Test— Test Results
The indicated compression pressures are considered within specification if the lowest reading cylinder
is at least 75 percent of the highest reading. Refer to the Compression Pressure Limit Chart.
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the
pistons in the low- reading cylinders. Repeat the compression pressure check on these cylinders. Compression Test — Interpreting Compression Readings Compression Pressure Limit Chart
Maximum
Pressure Minimum
Pressure Maximum
Pressure Minimum
Pressure Maximum
Pressure Minimum
Pressure Maximum
Pressure Minimum
Pressure 924 kPa
(134 psi) 696 kPa
(101 psi) 1131 kPa
(164 psi) 848 kPa
(123 psi) 1338 kPa
(194 psi) 1000 kPa
(146 psi) 1544 kPa
(224 psi) 1158 kPa
(168 psi) 938 kPa
(136 psi) 703 kPa
(102 psi) 1145 kPa
(166 psi) 855 kPa
(124 psi) 1351 kPa
(196 psi) 1014 kPa
(147 psi) 1558 kPa
(226 psi) 1165 kPa
(169 psi) 952 kPa
(138 psi) 717 kPa
(104 psi) 1158 kPa
(168 psi) 869 kPa
(126 psi) 1365 kPa
(198 psi) 1020 kPa
(148 psi) 1572 kPa
(228 psi) 1179 kPa
(171 psi) 965 kPa
(140 psi) 724 kPa
(106 psi) 1172 kPa
(170 psi) 876 kPa
(127 psi) 1379 kPa
(200 psi) 1034 kPa
(150 psi) 1586 kPa
(230 psi) 1186 kPa
(172 psi) 979 kPa
(142 psi) 738 kPa
(107 psi) 1186 kPa
(172 psi) 889 kPa
(129 psi) 1303 kPa
(202 psi) 1041 kPa
(151 psi) 1600 kPa
(232 psi) 1200 kPa
(174 psi) 933 kPa
(144 psi) 745 kPa
(109 psi) 1200 kPa
(174 psi) 903 kPa
(131 psi) 1407 kPa
(204 psi) 1055 kPa
(153 psi) 1055 kPa
(153 psi) 1207 kPa
(175 psi) 1007 kPa
(146 psi) 758 kPa
(110 psi) 1214 kPa
(176 psi) 910 kPa
(132 psi) 1420 kPa
(206 psi) 1062 kPa
(154 psi) 1627 kPa
(154 psi) 1220 kPa
(177 psi) 1020 kPa
(148 psi) 765 kPa
(111 psi) 1227 kPa
(178 psi) 917 kPa
(133 psi) 1434 kPa
(208 psi) 1075 kPa
(156 psi) 1641 kPa
(238 psi) 1227 kPa
(178 psi) 1034 kPa
(150 psi) 779 kPa
(113 psi) 1241 kPa
(180 psi) 931 kPa
(135 psi) 1448 kPa
(210 psi) 1083 kPa
(157 psi) 1655 kPa
(240 psi) 1241 kPa
(180 psi) 1048 kPa
(152 psi) 786 kPa
(114 psi) 1255 kPa
(182 psi) 936 kPa
(136 psi) 1462 kPa
(212 psi) 1089 kPa
(158 psi) 1669 kPa
(242 psi) 1248 kPa
(181 psi) 1062 kPa
(154 psi) 793 kPa
(115 psi) 1269 kPa
(184 psi) 952 kPa
(138 psi) 1476 kPa
(214 psi) 1103 kPa
(160 psi) 1682 kPa
(244 psi) 1262 kPa
(183 psi) 1076 kPa
(156 psi) 807 kPa
(117 psi) 1282 kPa
(186 psi) 965 kPa
(140 psi) 1489 kPa
(216 psi) 1117 kPa
(162 psi) 1696 kPa
(246 psi) 1269 kPa
(184 psi) 1089 kPa
(158 psi) 814 kPa
(118 psi) 1296 kPa
(188 psi) 972 kPa
(141 psi) 1503 kPa
(218 psi) 1124 kPa
(163 psi) 1710 kPa
(248 psi) 1202 kPa
(186 psi) 1103 kPa
(160 psi) 827 kPa
(120 psi) 1310 kPa
(190 psi) 979 kPa
(142 psi) 1517 kPa
(220 psi) 1138 kPa
(165 psi) 1724 kPa
(250 psi) 1289 kPa
(187 psi) 1110 kPa
(161 psi) 834 kPa
(121 psi) 1324 kPa
(192 psi) 993 kPa
(144 psi) 1631 kPa
(222 psi) 1145 kPa
(166 psi) — —Klj . 8 ba
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