FORD MUSTANG 2003 Workshop Manual

IN-
VEHICLE REPAIR
Valve Springs
Removal 1. Remove the LH and the RH valve covers. For additional information, refer to Valve Cover — LH
and
Valve Cover RH in this section.
2. Rotate the crankshaft until the piston for the valve being worked on is at the top of its stroke with both the intake valve and the exhaust valve closed.
3. Hold the valve in the cylinder head. zRemove the spark plug. For additional information, refer to Section 303 - 07A .
z Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
4. CAUTION: If the components are to be reinstalled, they must be installed in the
same position. Mark the components for location.
NOTE: If a valve drops into the cylinder, remove the cylinder head. For additional information,
refer to Cylinder Head LH or
Cylinder Head RH in this section.
Remove the rocker arms. 1. Remove the bolts.
2. Remove the rocker arms.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Compressor, Valve Spring
303-
163 (T81P-6513- A)
Material Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
32003 Mustang Workshop Manual
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5. Using the special tool, compress the valve springs.
6. Remove the valve spring assembly.
1. Remove the valve spring retainer key.
2. Remove the valve spring retainer.
3. Remove the valve spring.
4. Remove and discard the valve stem seal and spring seat assembly.
7. Inspect the components. For additional information, refer to Section 303 - 00 .
Installation Klj . 2 ba
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1.
NOTE: Lubricate the parts with clean engine oil.
To install, reverse the removal procedure. Tighten the rocker arm bolts in two stages. zStage 1: Tighten to 5 Nm (44 lb- in).
z Stage 2: Tighten to 35 Nm (26 lb- ft). Klj . 3 ba
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IN-
VEHICLE REPAIR
Valve Tappets
Removal CAUTION: If removing more than one valve tappet, mark the components removed for
correct location.
1. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in
this section.
2. Remove the push rods. For additional information, refer to Push Rod .
3. Remove the eight valve tappets. 1. Remove the bolts.
2. Remove the tappet guide plate and retainer.
3. Remove the valve tappets.
Installation 1. NOTE: Lubricate the valve tappet with clean engine oil before installing. To install, reverse the removal procedure. SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Klj . 2 ba
22003 Mustang Workshop Manual
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IN-
VEHICLE REPAIR
Camshaft
Removal 1. Remove the valve tappets. For additional information, refer to Valve Tappets in this section.
2. Remove the timing chain. For additional information, refer to Timing Chain in this section.
3. Position the wire harness aside.
4. Remove the radiator fan and shroud assembly.
5. Remove the engine balance shaft drive gear from the camshaft. 1. Remove the camshaft key.
2. Remove the engine balance shaft drive gear.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
32003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

6. Remove the camshaft.
1. Remove the bolts.
2. Remove the camshaft thrust plate.
3. Remove the spacer.
4. Remove the camshaft.
Installation 1. NOTE: Lubricate the camshaft with clean engine oil prior to installation.
To install, reverse the removal procedure. Klj . 2 ba
32003 Mustang Workshop Manual
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Klj . 3 ba
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IN-
VEHICLE REPAIR
Engine Dynamic Balance Shaft
Removal 1. Remove the timing chain (6268). For additional information, refer to Timing Chain in this
section.
2. Disconnect and position the wire harness aside.
3. Remove the radiator fan and shroud assembly (8146).
4. Remove the engine dynamic balance shaft (6A311). zRemove the bolts.
z Remove the balance shaft driver gear, thrust plate and engine dynamic balance shaft as
an assembly. Installation SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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1. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic
balance shaft assembly into the cylinder block (6010). Turn the engine balance shaft driven
gear so that the timing mark lines up with the timing mark on the engine balance shaft drive
gear (6A303).
2. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and
the camshaft keyway will be at 6 o'clock on the camshaft.
Install the bolts.
3. Install the radiator fan and shroud assembly.
4. Connect the connector and install the pin- type retainer. Klj . 2 ba
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