FORD MUSTANG 2003 Workshop Manual

28. Loosely install the bolts, then tighten the bolts in three stages in the sequence shown.
zStage 1: Tighten to 2 Nm (18 lb- in).
z Stage 2: Tighten to 20 Nm (15 lb- ft). Item Part
Number Description
1 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
2 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
3 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
4 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
5 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
6 W706508 Stud, hex shldr pilot, M8 x 1.25 x 50 —
m6 x 1 x
10 7 N808586 Stud and washer, hex head pilot, M8 x 1.25 x 60
—
m6 x 1 x 26 8 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
9 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
10 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
11 N806300 Stud, hex shldr pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 12 W706560 Stud and washer, hex-
head pilot, M8 x 1.25 x 65
— M8 x 1.25 x 16 13 N806300 Stud, hex shldr pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 14 N806300 Stud, hex shldr pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 15 N806300 Stud, hex shldr pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 Klj . 11 ba
252003 Mustang Workshop Manual
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z
Stage 3: Tighten an additional 60 degrees.
29. Install the belt idler pulleys.
30. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.
31. Using the special tool, install the front oil seal.
32. Install the coolant pump pulley and bolts. Klj . 12 ba
252003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

33.
NOTE: The crankshaft pulley must be installed within four minutes of applying the sealant.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
34. Using the special tool, install the crankshaft pulley.
35. NOTE: Use special tool 303- 009 or a suitable strap wrench to hold the crankshaft pulley.
Install the washer and the bolt. Tighten the bolt in four stages. zStage 1: Tighten to 90 Nm (66 lb- ft).
z Stage 2: Loosen one full turn.
z Stage 3: Tighten to 50 Nm (37 lb- ft).
z Stage 4: Tighten an additional 90 degrees. Klj . 13 ba
252003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

36. Install the RH engine mount.
37.
NOTE: Only three bolts are required for installation.
Install the power steering pump bolts. zPosition the power steering pump.
z Install the bolts.
38. Install the special tool between the valve spring coils to prevent valve stem seal damage. Klj . 14 ba
252003 Mustang Workshop Manual
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39.
NOTE: Lubricate the camshaft roller followers using clean engine oil.
NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing
each camshaft roller follower.
Install the camshaft roller followers. 1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft roller followers in their original locations.
40. Remove the special tool.
41. NOTE: One spark plug shown, others similar.
Install the spark plugs.
42. NOTE: RH side shown, LH side similar.
NOTE: If not secured within four minutes, the sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow
the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant in the locations shown. Klj . 15 ba
252003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

43.
NOTE: RH valve cover shown, LH similar.
Install the valve covers.
LH cylinder head 44. NOTE: Lubricate the O- ring seal with clean engine oil.
Install a new O- ring. Klj . 16 ba
252003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

45. Install the oil level indicator tube.
46. Install the LH exhaust manifold.
zInstall a new manifold gasket.
z Install the LH exhaust manifold.
z Tighten the nuts in the sequence shown.
47. Connect the lower end of the exhaust gas recirculation (EGR) tube to the LH exhaust manifold.
RH cylinder head 48. Install the RH exhaust manifold. zInstall a new exhaust manifold gasket.
z Install the RH exhaust manifold.
z Tighten the nuts in the sequence shown. Klj . 17 ba
252003 Mustang Workshop Manual
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Both cylinder heads
49. Inspect O- ring seals and install new O- ring seals as necessary.
50. Install the coolant bypass tube. 1. Install the bypass tube.
2. Install the nut.
51. Install the intake manifold and gaskets. Tighten the bolts in the sequence shown. Klj . 18 ba
252003 Mustang Workshop Manual
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52. Install the thermostat and O-
ring.
z Install a new O- ring as necessary.
53. Install the coolant outlet adapter.
54. Install the bolts and the generator.
55. Install the upper generator support bracket.
56. Position the power steering reservoir and bracket, then install the bolts. Klj . 19 ba
252003 Mustang Workshop Manual
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57. Install the accessory drive belt.
58. Install the radio interference capacitors.
59. Install the ignition coils and bolts.
60. Position the throttle body and install the bolts, tightening in the sequence shown. Klj . 20 ba
252003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...