rocker FORD MUSTANG 2003 User Guide

A/C compressor bracket-
to-cylinder head stud bolt 25 18 —
Oil level indicator tube-
to-cylinder head bolt 10 — 89
Coolant recovery reservoir bracket-to-
GOP bolts 9 — 80
Motor mount-
to-subframe nuts 115 85 —
Oil pan drain plug 26 19 —
Wire harness bracket to motor mount nut 27 20 —
Steering column pinch bolt 47 35 —
Front subframe-
to-body bolts 90 66 —
Front subframe-
to-shock tower bolts 115 85 —
Oil pan-to-
cylinder block bolts a — — —
Oil pan-to-
transmission bell housing 45 33 —
Main bearing bridge nuts 32 24
Oil pump cover-
to-engine front cover bolts 25 18 —
Oil pump cover-
to-engine front cover bolt 10 89 —
Oil pickup tube-
to-cylinder block bolts 25 18 —
Oil pickup tube-
to-oil pan baffle nut 48 35 —
Flywheel-
to-crankshaft bolts 80 59 —
Wire harness bracket-
to-motor mount stud- nut 27 20 —
Engine ground strap-
to-motor mount nut 27 20 —
Motor mount-
to-motor mount bracket bolts 70 52 —
RH motor mount-
to-motor mount bracket nut 70 52 —
Hood ground strap-
to-hood hinge bolt 12 9 —
Hood hinge nuts 12 9 —
Generator mounting bracket 25 18 —
Power steering pump bracket nuts 8 — 71
Power steering pump bolts 25 18 —
Valve tappet guide plate bolts 12 9 —
Generator positive cable nut 10 — 89
Power steering pressure tube to pump nut 40 30 —
Accelerator cable bracket-
to-intake manifold bolts 10 — 89
42-
pin connector bolt 10 — 89
Transmission oil cooler tube bracket-
to-motor mount bracket nut 27 20
Torque converter-
to-flywheel nuts 36 27 —
Engine-
to-transmission bolts 40 30 —
Engine mount bracket-
to-engine bolts 70 52 —
Engine mount bracket-
to-engine nuts 70 52 —
Water pump pulley bolts 25 18 —
Oil filter
b — — —
Upper intake manifold-
to-lower intake manifold bolts a — — —
Lower intake manifold-
to-cylinder head bolts a — — —
Rocker arm pivot-
to-cylinder head bolts a — — — Klj . 5 ba
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Engine Front Cover Components 9 6A666 Positive crankcase ventilation valve
10 6565 Push rod
11 6564 Rocker arm
12 6A528 Rocker arm seat
13 N807699 Bolt
14 6518 Valve spring retainer key
15 6514 Valve spring retainer
16 6513 Valve spring
17 6A517 Valve stem seal
18 611497 Bolt
19 6049 Cylinder head —
LH 20 9448 Exhaust manifold gasket —
LH 21 17A084 Engine lifting eye
22 6754 Oil level indicator tube
23 9430 Exhaust manifold —
LH 24 6507 Intake valve
25 6505 Exhaust valve
26 6051 Head gasket —
LH 27 6051 Head gasket —
RH 28 9448 Exhaust manifold gasket —
RH 29 9430 Exhaust manifold —
RH 30 17A084 Engine lifting eye Klj . 2 ba
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IN-
VEHICLE REPAIR
Rocker Arm
Removal CAUTION: If removing more than one rocker arm (6564), mark the components removed
for correct location.
1. Remove the valve covers. For additional information, refer to Valve Cover — LH and
Valve Cover RH in this section.
2. Remove the rocker arm assembly. zRemove the bolt.
Installation 1. Install the rocker arms, tighten the bolts in two stages. zStage 1: tighten to 5 Nm (44- lb-in).
z Stage 2: tighten to 35 Nm (26 lb- ft).
2. Install the valve covers. For additional information, refer to Valve Cover — LH and
Valve Cover RH in this section.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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IN-
VEHICLE REPAIR
Push Rod
Removal CAUTION: Mark the components removed for correct location.
1. Remove the rocker arms (6564). For additional information, refer to Rocker Arm in this section.
2. Remove the push rods (6565).
3. Inspect the components. For additional information, refer to Section 303 - 00 .
Installation 1. To install, reverse the removal procedure.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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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
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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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39. Remove the bolts and the oil pan.
40.
CAUTION: If the components are to be reinstalled, they must be installed into the
same position. Mark the components for location.
Remove the LH rocker arms. 1. Remove the bolts.
2. Remove the rocker arms. 41. Remove the LH push rods. Klj . 11 ba
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42.
NOTE: Record the location of the long bolts and the short bolts.
Remove and discard the LH cylinder head bolts.
43. Remove the LH cylinder head and gasket. Discard the gasket.
44. Remove the RH rocker arms. 1. Remove the bolts.
2. Remove the rocker arms. Klj . 12 ba
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z
Install the valve tappets.
z Install the tappet guide plates and retainers.
z Install the bolts.
34. NOTE: Lubricate the push rods with clean engine oil prior to installation.
Install the 12 push rods.
35. Install the 12 rocker arms. For additional information, refer to Rocker Arm in this section.
36. NOTE: Use pipe sealant with Teflon® on studs No. 4 and 6, and bolt No. 12.
Using a new gasket, install the engine front cover. Tighten the nuts and the bolts in the
sequence shown. zInstall a 135.5 mm (5.42 in) stud at location No. 5 and tighten to 7 Nm (62 lb- in).
z Install a 137 mm (5.48 in) stud at locations No. 4, 6, 7 and 10, and tighten to 7 Nm (62 lb-
in).
z Using a new gasket, install the water pump.
z Tighten bolt No. 12 to 10 Nm (89 lb- in). All other nuts and bolts are to be tightened to 28 Klj . 12 ba
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N806155 Bolt (2 req'd)
92 6C315 Crankshaft position sensor
93 N806300 Stud bolt (5 req'd)
94 6C086 Engine front cover
95 N806155 Bolt
96 6B288 Camshaft position sensor
97 N606543 Bolt (4 req'd)
98 6L266 Timing chain tensioner
99 6268 Timing chain belt
100 6K297 Timing chain cover
101 6M269 Timing chain tensioner
102 6L253 Timing chain tensioner arm
103 N806184 Bolt (3 req'd)
104 19D629 A/C compressor
105 8501 Water pump
106 N806177 Bolt (4 req'd)
107 N806183 Bolt (4 req'd)
108 6621 Oil pump
109 N806201 Woodruff key
110 6333 Crankshaft main bearing (5 req'd)
111 6A341 Crankshaft thrust washer (3 req'd)
112 6C357 Crankshaft main bearing side bolt (10 req'd)
113 6010 Cylinder block
114 9439 Intake manifold gasket (2 req'd)
115 6083 Head gasket
116 6505 Exhaust valve (8 req'd)
117 6507 Intake valve (8 req'd)
118 87838 Pipe plug (8 req'd)
119 12405 Spark plug (8 req'd)
120 6F087 Dowel
121 9431 Exhaust manifold
122 6C501 Valve tappet (16 req'd)
123 6529 Rocker arm (16 req'd)
124 6049 Cylinder head, RH
125 W701681 Stud (8 req'd)
126 9Y431 Exhaust manifold gasket
127 9F485 EGR valve tube to manifold connector
128 W701706 Nut (8 req'd)
129 181198A Engine lifting eye
130 6A517 Valve stem seal (16 req'd)
131 6513 Valve spring (16 req'd)
132 Klj . 6 ba
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