FORD MUSTANG 2003 Workshop Manual

59. Install the stud bolt.
60. Position the engine wire harness.
61. Connect the crankshaft position sensor electrical connector.
62. Install the pin-
type retainer. Klj . 20 ba
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63. Connect the engine oil pressure sender electrical connector.
64. Connect the camshaft position (CMP) sensor electrical connector.
65. Connect the cylinder head temperature (CHT) sensor.
66. Install the fuel injectors and the fuel injection supply manifold as an assembly. For additional
information, refer to Section 303 - 04A .
67. Install a new upper intake manifold gasket. Klj . 21 ba
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68.
NOTE: Refer to the location note made during removal and make sure the bolts are installed in
the correct location.
Install the upper intake manifold. Tighten the bolts in two stages in the sequence shown.
zStage 1: Tighten to 10 Nm (89 lb- in).
z Stage 2: Rotate an additional 90 degrees.
69. Connect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical and vacuum connections. Klj . 22 ba
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70. Connect the differential pressure feedback EGR system electrical and vacuum connections.
71. Connect the vacuum hoses.
72. Install the positive crankcase ventilation (PCV) tube.
73. Connect the ignition coil and the radio interference capacitor electrical connectors.
74. Position and connect the LH spark plug wires. Klj . 23 ba
282003 Mustang Workshop Manual
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75. Position and connect the RH spark plug wires.
76. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical
connectors.
77. Install the RH exhaust manifold. zInstall a new exhaust manifold gasket.
z Install the exhaust manifold.
z Tighten the nuts in the sequence shown. Klj . 24 ba
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78. Install the exhaust gas recirculation (EGR) tube.
79. Connect the EGR valve nut.
80. Using a new gasket, install the LH exhaust manifold. Tighten the nuts in the sequence shown.
81.
NOTE: Install a new O- ring seal.
Install the oil level indicator and tube and retaining bolt. Klj . 25 ba
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82. Install the special tool.
83. Install the special tool.
84. Install the RH engine support insulator.
85. Install the LH engine support insulator.
86. Remove the engine from the stand. Klj . 26 ba
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87.
NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.
Assemble the special tools and the crankshaft rear seal.
88. Install the special tools on the rear of the crankshaft.
89. Install the crankshaft rear seal. Tighten the center jack screw (303- S560) until the spacer (303-
561) contacts the engine block. Klj . 27 ba
282003 Mustang Workshop Manual
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Klj . 28 ba
282003 Mustang Workshop Manual
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INSTALLATION
Engine
Installation
All vehicles
1. Install the separator plate and the flywheel.
2. Using the special tools, position the engine in the vehicle.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Heavy Duty Floor Crane
014-
00071 or equivalent Spreader Bar
303-
D089 (D93P-6001- A3) or
equivalent
Material Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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