2003 FORD MUSTANG lock

7.
NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the
crankshaft surface).
Push the crankshaft rearward and install the crankshaft upper thrust washer at the rear of the
No. 5 main boss.
8. NOTE: Rotate the jackscrews into the bearing caps enough to provide clearance to the cylinder
block prior to installing the bearing caps.
Install the lower main bearings into the main bearing caps and lubricate them with clean engine
oil.
9. Install the rear main bearing cap.
10. Install the remaining main bearing caps on the cylinder block and tap into place using a plastic or dead- blow hammer. Klj . 6 ba
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11. Install the vertical main bearing cap fasteners and tighten in the sequence shown.
zTighten to 40 Nm (30 lb- ft).
z Tighten an additional 85- 95 degrees.
12. Back out the jackscrews against the cylinder block in sequence shown. zTighten to 5 Nm (44 lb- in).
z Tighten to 10 Nm (89 lb- in). Klj . 7 ba
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13. Install the side bolts and tighten them in the sequence shown.
14. Check the crankshaft end play. For additional information, refer to Section 303
- 00 .
15. Check the piston to cylinder block and piston ring clearances. For additional information, refer to Section 303 - 00 .
16. Install the piston rings. Klj . 8 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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29. Tighten the bolts in the sequence shown.
zTighten to 20 Nm (15 lb- ft).
z Rotate an additional 60 degrees.
30. Install the cylinder head gaskets.
31. CAUTION: Cylinder head to cylinder block pre- assembly must be followed exactly
or damage to valves and pistons can result. Klj . 13 ba
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CAUTION: Camshaft keyways must maintain a 90 degree clocked position relative
to the valve cover rail.
CAUTION: To prevent piston crown and valve damage the crankshaft keyway must
be clocked at 270° (45° BTDC) before the installation of the cylinder head assembly.
NOTE: Crankshaft must be rotated clockwise only.
Align the keyways as shown.
32. NOTE: Position the RH and the LH cylinder heads over the dowels on the cylinder head
gaskets.
NOTE: The LH is shown the RH is similar.
Tighten the bolts in six stages in the sequence shown. zStage 1: Tighten to 40 Nm (30 lb- ft).
z Stage 2: Tighten an additional 90 degrees.
z Stage 3: Loosen the bolts a minimum of one full turn.
z Stage 4: Tighten to 40 Nm (30 lb- ft).
z Stage 5: Tighten an additional 90 degrees.
z Stage 6: Tighten an additional 90 degrees. Klj . 14 ba
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39. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock
position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12
o'clock position.
40. CAUTION: Unless otherwise instructed, do not rotate either the crankshaft or the
camshafts, when the timing chains are removed and the cylinder heads are installed.
Severe piston and valve damage will occur.
CAUTION: When instructed to do so, rotate the crankshaft counterclockwise only.
Do not rotate past the position shown or severe piston and valve damage can occur.
NOTE: The number one cylinder is at top dead center (TDC) when the stud on the engine block
fits into the slot in the handle of the special tool.
Using the special tool, position the crankshaft so the number one cylinder is at TDC. Klj . 17 ba
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Both cylinder heads
1. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block
must be clean. For additional information, refer to Cylinder Heads in the Removal portion
of this section.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not
permitted. The gasket must be installed dry.
CAUTION: The new gasket has a film coating which is crucial to the gasket's ability
to seal correctly. Do not scratch the gasket.
NOTE: RH head gasket shown; LH head gasket similar.
Install the head gasket over the dowel pins. 303-
382 (T91P-6565- AH) Remover/Installer, Cylinder
Head
303-
572 (T97T-6000- A)
Material Item Specification
Motorcraft Silicone Gasket
Remover
ZC-
30 —
Motorcraft Metal Surface Prep
ZC-
31 —
Hydraulic Chain Tensioner
Retaining Clip
1L3Z-6P250-
AA —
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Super Premium SAE 5W-20
Engine Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Klj . 2 ba
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