2003 FORD MUSTANG lock

Both cylinder heads
58. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all application directions
contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean
and prepare the surfaces.
Clean the cylinder head- to-cylinder block mating surfaces of both the cylinder head and the
cylinder block. 1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material
remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt
to make the metal shiny. Some staining of the metal surfaces is normal.
59. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the
deck face with a straightedge, paying particular attention to the oil pressure feed area. The
cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm
(1.5 in) square area, or scratches more than 0.0254 mm (0.001 in) . Klj . 20 ba
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50.
NOTE: This step will allow removal of the exhaust manifold through the bottom and access for
the installation of the engine lift brackets.
Using a suitable floor crane, raise the engine to remove the exhaust manifold.
51. Install the RH and LH special tool.
52. NOTE: Before carrying out this step it will be necessary to support the transmission with a floor
jack and a block of wood.
Install the special tool. Klj . 11 ba
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31.
NOTE: One side shown, other side similar.
Using a suitable container, drain coolant from the engine block. zInstall the drain plugs when finished.
32. Remove the four bolts and the power steering pump.
33. Remove the compressor. 1. Remove the bolts.
2. Remove the compressor. Klj . 11 ba
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62.
CAUTION: Do not scratch cylinder walls or crankshaft journals with the connecting
rod.
NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the
ridge or carbon deposits from each cylinder using a cylinder ridge reamer following the
manufacturer's instructions.
Remove the piston removing pistons number 1 and 6 through the top of the cylinder block.
63. Repeat the previous two steps to remove the remaining pistons, rotating the crankshaft 90 degrees between piston pairs 3 and 5, 4 and 7, 2 and 8.
64. Remove the piston rings. Klj . 22 ba
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65. Clean and inspect pistons. For additional information, refer to
Section 303 - 00 .
66. Remove the crankshaft bearing cap fasteners. 1. Remove and discard the cross- mounted main cap bolts.
2. Loosen the jackscrews.
3. Remove and discard the main cap bolts.
67. Remove the main bearing cap and the crankshaft main bearings from the cylinder block.
68. Remove the crankshaft, crankshaft main bearings and the thrust washer. Klj . 23 ba
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Assembly
NOTE:
During engine assembly, it may by necessary to check bearing clearances and end play. For
additional information, refer to Section 303 - 00 .
1. Record the main bearing code found on the front of the engine block.
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 Chart Crankshaft Seal Installer
303-
635
Material Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Super Premium SAE 5W-20
Motor Oil
XO- 5W20- QSP or equivalent WSS-
M2C153- H Klj . 3 ba
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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 "2."
z Repeat this process for the remaining four main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearing Chart to determine the required grade for each main bearing. Klj . 4 ba
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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.
5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
6. NOTE: Do not install the upper thrust washer until the crankshaft is installed. Refer to Step 3.
NOTE: Do not install the upper thrust washer until the crankshaft (6303) is installed. Refer to
Step 3.
Install the crankshaft onto the upper main bearings. Klj . 5 ba
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