2003 FORD MUSTANG engine

Lifting Bracket Set, Engine
303-
D074 (D91P-6001- A) Installer, Crankshaft Vibration
Damper
303-
102 (T74P-6316- B) Installer, Front Cover Oil Seal
303-
335 (T88T-6701- A) Compressor, Piston Ring
303-
D032 (D81L-6002- C) or
equivalent Holding Tool, Crankshaft
303-
448 (T93P-6303- A) Remover/Installer, Cylinder
Head
303-
572 (T97T-6000- A) Compressor, Valve Spring
303-
576 (T97P-6565- AH) Strap Wrench
303-
D055 (D85L-6000- A) or
equialent Klj . 2 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
362003 Mustang Workshop Manual
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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
362003 Mustang Workshop Manual
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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
362003 Mustang Workshop Manual
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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
362003 Mustang Workshop Manual
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17. Make sure the ring gaps (oil spacer [A], oil ring [B], and compression ring [C]) are properly
spaced around the circumference of the piston.
18. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the
connecting rod.
NOTE: Only one piston and connecting rod shown, others similar.
NOTE: Make sure the crankshaft is facing forward.
NOTE: Lubricate the piston rings, cylinder walls and connecting rod bearings with clean engine
oil.
Install the upper bearings in the connecting rod as shown. Klj . 9 ba
362003 Mustang Workshop Manual
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19.
NOTE: The piston grade number will face the rear of the engine.
Check that the piston/connecting rod assembly is oriented with the identification marks facing
the front of the engine.
20. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the
connecting rod.
NOTE: Make sure the crankshaft is at TDC. Klj . 10 ba
362003 Mustang Workshop Manual
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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
362003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...