steering FORD MUSTANG 2003 Workshop Manual

DISASSEMBLY
Engine
1. Remove the bolts and the LH engine support insulator.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Service Set, Camshaft
303-
017 (T65L-6250- A) Remover, Crankshaft Vibration
Damper
303-
009 (T58P-6316- D) Lifting Bracket Set, Engine
303-
D095 (D94L-6001- A) or
equivalent Remover, Power Steering
Pump Pulley
211-
016 (T69L-10300- B) Remover, Oil Seal
303-
409 (T92C-6700- CH) Remover, Crankshaft Vibration
Damper
303-
176 (T82L-6316- B) Klj . 1 ba
212003 Mustang Workshop Manual
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31. Remove the A/C compressor bracket.
32. Using the special tool, remove the power steering pump pulley.
33. Remove the power steering pump bracket.
34. Remove the bolts and the generator mounting bracket. Klj . 9 ba
212003 Mustang Workshop Manual
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ASSEMBLY
Engine
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Slide Hammer
307-
005 (T59L- 100-B) Remover Adapter, Vibration
Damper
303-
176 (T82L-6316- B) Installer, Crankshaft Front Seal
303-
474 (T94P-6701- AH) Replacer, Steering Pump
Pulley
211-
009 (T65P-3A733- C) Engine Lift Bracket Set
303-
D095 (D94L-6001- A) Replacer, Rear Crankshaft
Seal
303-
516 (T95P-6701- BH) Spacer, Rear Crank Seal
Replacer
303-
561 (T96T-6701- B) Adapter, Crankshaft Rear Seal
(Use only the adapter retaining
bolts)
303-
518 (T95P-6701- DH) Klj . 1 ba
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46. Install the LH valve cover.
47. Install the generator mounting bracket.
48. Install the power steering pump bracket.
49. Using the special tool, install the power steering pump pulley. Klj . 16 ba
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32. Install the radiator coolant recovery reservoir.
33. Connect the upper radiator hose.
34. Connect the lower radiator hose.
35. Connect the power steering pump.
zConnect the power steering return hose.
z Position the clamp. Klj . 8 ba
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z
Connect the power steering pressure tube.
36. Connect the generator electrical connections.
37. Connect the vacuum hose.
38. Install the hood.
39. Connect the hood ground strap. Klj . 9 ba
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40. Connect the battery negative cable. For additional information, refer to
Section 414 - 01 .
41. Fill the engine with clean engine oil.
42. Fill the engine cooling system. For additional information, refer to Section 303 - 03A .
43. Recharge the A/C refrigerant system. For additional information, refer to Section 412 - 00 .
44. Fill and bleed the power steering system. For additional information, refer to Section 211 - 00 . Klj . 10 ba
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e
Specification in 90.200 mm diameter gauge.
f If applicable, measured vertically, +0.030- 0.050 mm (0.001-0.002 inch) measured horizontally (oval
pin bore).
g Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total
difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline.
Torque Specifications Description Nm lb-
ft lb-
in Main bearing cap adjusting bolts
a — — —
EGR sensor bracket 10 — 89
Belt idler pulley 25 18 —
Oil filter 15 11 —
Oil filter adapter insert 58 43 —
Camshaft sprocket bolt
a — — —
Connecting rod bolt
a — — —
Engine mount nuts 150 111 —
Engine mount-
to-cylinder block bolts 70 52 —
Exhaust manifolds
a — — —
Engine front cover bolts
a — — —
Drive belt tensioner bolts 25 18 —
A/C muffler 20 15 —
Battery cable support brackets 20 15 —
Cylinder head bolt
a — — —
Pulley-
to-crankshaft bolt a — — —
EGR valve to intake manifold 25 18 —
EGR valve tube to exhaust manifold fittings 40 30 —
Intake manifold-
to-cylinder head bolt 25 18 —
Main bearing cap bolt
a — — —
Oil filter adapter bolts 25 18 —
Oil level indicator tube bolt 10 — 89
Oil pump screen cover and tube-
to-oil pump bolt 10 — 89
Oil pan-to-
cylinder block bolt a — — —
Flywheel 80 59
Oil pan-to-
engine front cover bolts a — — —
Oil pump-
to-cylinder block bolt 10 — 89
Oil pump screen cover and tube-
to-main bearing cap stud spacer bolt 25 18 —
Water pump pulley bolts 25 18 —
Cam cover bolt
a — — —
Water pump-
to-cylinder block bolt 25 18 —
Water bypass tube 25 18 —
EGR tube nuts (2 req'd) 40 30 —
Power steering pump to engine 25 18 — Klj . 4 ba
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a
Refer to the procedure in this section. Power steering reservoir bolts 10 — 89
Water outlet connector bolts 25 18 —
Camshaft cap cluster to cylinder head bolts 10 — 89
Torque converter nuts 25 18 —
Timing chain tensioner bolts 25 18 —
Transmission filler tube bolt 47 35 —
A/C compressor bolts 25 18 —
Ignition coil bolts 6 — 53
Generator brace bolts 10 — 89
Primary timing chain guide-
to-engine bolts 10 — 89
Accelerator cable bracket bolts 10 — 89
Rear seal retainer bolts 10 — 89
Pressure plate bolts 2 — 47
Spark plugs 18 13 —
Crankshaft timing bolt sensor assembly 10 — 89
Camshaft timing bolt sensor assembly 10 — 89
Fuel rail studs 10 — 89
Engine coolant sensor 15 11 —
Exhaust manifold—
stud to cylinder head 10-
13 7-10 —
Throttle body adaptor bolts
a — — —
Throttle body bolts 10 — 89
Idle air control valve 10 — 89
RFI capacitor nut 10 — 89
Generator bolts 25 18 —
Oil pan drain plug 14 10 —
Water bypass tube bracket bolt 25 18 —
Subframe bolts 115 85 —
Battery lead to generator 10 — 89
EGR vacuum regulator solenoid bracket 10 — 89
Pipe plug—
water drain 20 15 —
Screen and cover assembly to main bearing cap stud spacer 25 18 —
Wiring harness retainer nut 10 — 89
Oil pressure switch
a — — —
A/C muffler stud to cylinder head 10 — 89
EGR tube to exhaust manifold connector 50 37 — Klj . 5 ba
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6514 Valve spring retainer (16 req'd)
133 6518 Valve spring retainer key (32 req'd)
134 6065 Cylinder head bolt (20 req'd)
135 6C255 Camshaft
136 9J434 EGR transducer
137 N807309 Bolt (2 req'd)
138 N806139 Bolt
139 8620 Drive belt
140 N806165 Washer
141 6316 Crankshaft pulley
142 8A528 Water pump pulley
143 6700 Crankshaft front seal
144 N808793 Stud bolt (2 req'd)
145 N806177 Bolt (6 req'd)
146 N806176 Bolt (3 req'd)
147 3A674 Power steering pump
148 12A227 Ignition pulse ring
149 6306 Crankshaft sprocket (2 req'd)
150 6268 Timing chain/belt
151 6K297 Timing chain guide
152 N804958 Bolt (4 req'd)
153 6A338 Crankshaft main bearing (4 req'd)
154 6A346 Crankshaft main bearing cap dowel pin (10 req'd)
155 6345 Crankshaft main bearing cap bolt (9 req'd)
156 N806155 Bolt (2 req'd)
157 W701240 Bolt (16 req'd)
158 6675 Oil pan
159 6710 Oil pan gasket
160 N605904 Bolt
161 6622 Oil pump screen cover and tube
162 N806180 Spacer
163 6K258 Crankshaft main bearing cap stud
164 6325 Main bearing cap (5 req'd)
165 6A339 Crankshaft thrust main bearing
166 N602549 Bolt
167 6303 Crankshaft
168 7563 Clutch pressure plate
169 7550 Clutch disc
170 N808139 Bolt (6 req'd)
171 6375 Flywheel (manual transmission)
172 N811363 Bolt (2 req'd)
173 Klj . 7 ba
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