Engine System - General Information: Component Locations Ford Mustang V facelift

Special Tool(s)

SPECIAL TOOLS 12-Volt Master UV Diagnostic Inspection Kit 164-R0756 or equivalent (Leak Detector) Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent EngineEAR 107-R2103 or equivalent EngineEAR/ChassisEAR 107-R2102 or equivalent Oil Pressure Gauge 303-088 (T73L-6600-A) Vacuum/Pressure Tester 164-R0253 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Scheme 2304

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SPECIAL TOOLS Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Scheme 2310

Note. Refer to the appropriate Engine article(s) for the specification.

Scheme 2311

1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the Dial Indicator Gauge.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play. If camshaft end play exceeds specifications, install a new camshaft and recheck end play. If camshaft end play exceeds specification after camshaft installation, install a new cylinder head.

Scheme 2312

1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside the contact area.

SPECIAL TOOLS Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Scheme 2313

Note. Refer to the appropriate Engine article(s) for the specification.

Scheme 2314

1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift. Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading to figure the camshaft lobe lift.

SPECIAL TOOLS Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Scheme 2315

Note. Refer to the appropriate Engine article(s) for the specification.

Scheme 2316

1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout. Camshaft must be supported on the first and last camshaft bearing journal. Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial Indicator Gauge reading.

SPECIAL TOOLS Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Scheme 2317

Note. Refer to the appropriate Engine article(s) for the specification.

Scheme 2318

1. Install the Dial Indicator Gauge with Holding Fixture.
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the Dial Indicator Gauge.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.

SPECIAL TOOLS Scraper, Piston Ring Groove 303-D033 (D81L-6002-D) or equivalent

Scheme 2319

Note. Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can occur.

Scheme 2320

Scheme 2321

1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If wear marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Scraper to clean the piston ring grooves. Make sure the oil ring holes are clean.

SPECIAL TOOLS Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Scheme 2322

Note. Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore.

Note. Piston rings should not be transferred from one piston to another.

Note. Refer to the appropriate Engine article(s) for the specification.

Note. The cylinder bore must be within specification for taper and out-of-round.

Scheme 2323

Scheme 2324

1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
2. Use the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring end gap.

SPECIAL TOOLS Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Scheme 2325

Note. Refer to the appropriate Engine article(s) for the specification.

Scheme 2326

Scheme 2327

1. Inspect the piston for ring land damage or accelerated wear.
2. Using the Feeler Gauge Set, measure the piston ring-to-groove clearance.

SPECIAL TOOLS Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Scheme 2328

Note. Refer to the appropriate Engine article(s) for the specification.

Scheme 2329

1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the bend measurement is within specification.

SPECIAL TOOLS Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Scheme 2330

Note. Refer to the appropriate Engine article(s) for the specification.

Scheme 2331

1. Using the Feeler Gauge Set, measure the connecting rod twist on a suitable alignment fixture. Follow the instructions of the fixture manufacturer. Verify the measurement is within specification.

SPECIAL TOOLS Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Scheme 2332

Note. Refer to the appropriate Engine article(s) for the specification.

Scheme 2333

1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the crankshaft. Verify the measurement is within specification.

Scheme 2334

1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes and hydraulic lash adjuster for damage.

Scheme 2335

1. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage.

SPECIAL TOOLS Clearance Gauge, Valve Guide 303-004 (TOOL-6505-E) or equivalent Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Scheme 2336

Note. Refer to the appropriate Engine article(s) for the specification.

Note. The valve stem diameter must be within specifications before checking valve stem-to-valve guide clearance.

1. Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve guide.
2. Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture and zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial Indicator Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance.

Scheme 2337

1. Inspect the following valve areas: The end of the stem for grooves or scoring. The valve face and the edge for pits, grooves or scores. The valve head for signs of burning, erosion, warpage and cracking. The valve margin for wear.

SPECIAL TOOLS Pressure Gauge, Valve/Clutch Spring 303-006 (TOOL-6513-DD) or equivalent

Scheme 2338

Note. Refer to the appropriate Engine article(s) for the specification.

Scheme 2339

1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length.

SPECIAL TOOLS Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Scheme 2340

Note. Refer to the appropriate Engine article(s) for the specification.

1. Use a Straightedge and a Feeler Gauge Set to inspect the cylinder block for flatness.

SPECIAL TOOLS Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

Scheme 2341

Note. Refer to the appropriate Engine article(s) for the specification.

1. Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence shown in illustration.

SPECIAL TOOLS Slide Hammer 100-001 (T50T-100-A)

Scheme 2342

SPECIAL TOOLS Feeler Gauge Set 303-D027 (D81L-4201-A) or equivalent

1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket sealing surfaces.
2. Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold.

Scheme 2343

1. Inspect bearings for the following defects: Cratering - fatigue failure Spot polishing - incorrect seating Imbedded dirty engine oil Scratching - dirty engine oil Base exposed - poor lubrication Both edges worn - journal damaged One edge worn - journal tapered or bearing not seated

Scheme 2344

1. Inspect the flexplate for: any cracks. worn ring gear teeth. chipped or cracked ring gear teeth.

SPECIAL TOOLS Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Holding Tool, Flywheel 303-103 (T74P-6375-A)

Scheme 2345

Scheme 2346

Note. Do not clean the dual mass flywheel with any kind of fluid, use a dry cloth only or damage to the dual mass flywheel may occur.

Note. Do not clean the gap between the primary and secondary mass. Only clean the bolt connection surface and the clutch surface or damage to the flywheel may occur.

Note. The dual mass flywheel normally has up to a total of 14 degrees (6.5 ring gear teeth) maximum rotational freeplay between the primary (bolted to crankshaft) and the secondary mass (clutch disc face).

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Scheme 2358

1. Check the transmission fluid level and fill to the correct level as necessary.
2. With the engine operating at idle and the transmission in NEUTRAL, listen and check for unacceptable noise. Determine if any unacceptable noise is reduced when the clutch pedal is depressed.
3. If unacceptable noise is identified, remove the transmission. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION - MT82 GETRAG 6-SPEED»(ref-439775) article.
4. Inspect the clutch slave cylinder for leaks. If a leak is identified, install a new clutch slave cylinder. For additional information, refer to «CLUTCH CONTROLS»(ref-439827) article.
5. Inspect the sliding surfaces of the clutch release hub and bearing. Any scoring or burr should be removed with a fine grade of emery paper.
6. Inspect the transmission input shaft for spline wear, scoring or burrs. Any scoring or burr should be removed with a fine grade of emery paper. If spline wear is identified, install a new transmission. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION - MT82 GETRAG 6-SPEED»(ref-439775) article.
7. Remove the clutch disc and pressure plate. For additional information, refer to «CLUTCH»(ref-439828) article. Discard the clutch disc.
8. Inspect the clutch pressure plate and diaphragm spring segments and discard as necessary. Inspect the clutch pressure plate for scoring, cracks or discoloration. Any minor scoring or discoloration should be removed with a fine grade of emery cloth. Inspect the clutch diaphragm spring segments for damage, uneven height, scoring, cracks or discoloration. Any minor scoring or discoloration should be removed with a fine grade of emery cloth.
9. With the dual mass flywheel installed on the engine, inspect the dual mass flywheel surface for scoring, cracks, discoloration or damage. If any of these conditions exist, install a new flywheel.
10. Inspect the dual mass flywheel friction control plate plastic piece between the primary and secondary mass for damage or melting and install a new dual mass flywheel if necessary.
11. With the dual mass flywheel installed on the engine, inspect the dual mass flywheel rotational freeplay using the following Steps 12 through 15 .
12. Rotate the secondary mass counterclockwise and place a reference mark on the primary and secondary mass of the dual mass flywheel.
13. Using light hand pressure, rotate the secondary mass clockwise to the end of the freeplay. Place a 2nd reference mark on the primary mass of the dual mass flywheel, in line with the reference mark on the secondary mass.
14. Measure the rotational freeplay XX between the 2 reference marks on the primary mass of the dual mass flywheel. If the total rotational freeplay exceeds 14 degrees (6.5 ring gear teeth), install a new dual mass flywheel.
15. With the dual mass flywheel installed on the engine, inspect the dual mass flywheel internal spring operation using the following Steps 17 through 19 .
16. Install the Flywheel Holding Tool.
17. Using a suitable long screwdriver or bar, firmly rotate the secondary mass clockwise. The secondary mass should begin to engage the internal spring past the freeplay movement of 14 degrees (6.5 ring gear teeth) maximum. The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure. If the secondary mass does not rotate, install a new dual mass flywheel.
18. Using a suitable long screwdriver or bar, firmly rotate the secondary mass counterclockwise. The secondary mass should begin to engage the internal spring past the freeplay movement of 14 degrees (6.5 ring gear teeth) maximum. The secondary mass should continue to rotate and engage the internal spring with increasing spring pressure. If the secondary mass does not rotate, install a new dual mass flywheel.
19. Inspect the dual mass flywheel when removed from the engine and placed on a bench, using the following Steps 21 and 23 .
20. Remove the bolts and the dual mass flywheel and place it on a firm and level surface. Discard the dual mass flywheel retaining bolts and remove the Flywheel Holding Tool.
21. Using the Dial Indicator Gauge with Holding Fixture, inspect the dual mass flywheel hub bush for wear and install new as necessary. Place a dial indicator gauge at a point on the outer upper surface of the secondary mass. Using light hand pressure, press downward at the opposite point on the outer upper surface of the secondary mass and note the deflection on the dial indicator gauge. Repeat this measurement at 45 degree intervals around the dual mass flywheel and note any deflection. Some axial movement of the secondary mass flywheel is normal, if the deflection exceeds 1.1 mm (0.043 in) at any point, install a new dual mass flywheel.
22. Inspect the dual mass flywheel crankshaft mounting flange for residual thread locking compound or rust and clean as necessary.
23. Inspect the rear face of the engine block. Make sure that the 2 engine dowel pins are correctly installed and are not damaged, install new dowel pins as necessary. Inspect the engine block rear spacer plate for damage or warping and install new plate as necessary. Inspect the crankshaft flange for residual thread locking compound or rust, and clean as necessary.
24. Inspect the transmission mounting face. Make sure that the 2 dowel pin holes are not elongated or damaged.
25. Install the dual mass flywheel and 8 new bolts finger tight.
26. Install the Flywheel Holding Tool.
27. Tighten the dual mass flywheel retaining bolts in the sequence shown in illustration to 80 Nm (59 lb-ft). Remove the Flywheel Holding Tool.
28. Install the clutch disc and pressure plate. For additional information, refer to «CLUTCH»(ref-439828) article.
29. Install the transmission. For additional information, refer to «MANUAL TRANSAXLE/TRANSMISSION - MT82 GETRAG 6-SPEED»(ref-439775) article.

Scheme 2359

1. Inspect the flywheel for: any cracks. worn ring gear teeth. chipped or cracked ring gear teeth. scratches, nicks and discoloration.