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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
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4. Install the piston pin retaining clips in the piston. Klj . 3 ba
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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
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5. Inspect the CAC plenum gasket and install a new gasket if necessary.
6. To assemble, reverse the disassembly procedure
7. Tighten the supercharger and CAC cooler assembly-
to-lower intake manifold bolts, in the
sequence shown, in two stages. 1. Stage 1: Tighten to 2 Nm (18 lb- in).
2. Stage 2: Tighten to 25 Nm (18 lb- ft).
8. Tighten the coolant supply and return manifold in two stages. 1. Stage 1: Tighten to 10 Nm (89 lb- ft).
2. Stage 2: Tighten an additional 90 degrees. Klj . 2 ba
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Klj . 3 ba
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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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