spark plugs FORD MUSTANG 2003 User Guide

9. Install the valve covers.
Valve Train Analysis— Engine Running, Camshaft Lobe Lift— Push Rod Engine
Check the lift of each lobe in consecutive order and make a note of the readings. 1. Remove the valve covers.
2. Remove the rocker arm seat bolts, rocker arm seat (6A528) and rocker arms.
Typical Engine With Push Rods
3. Make sure the valve tappet is seated against camshaft (6250). Install (1) Dial Indicator Gauge with Holding Fixture so the ball socket adapter of the indicator is on top of the valve tappet or (2)
Dial Indicator Gauge Adapter is on top of push rod and in same plane as valve tappet push rod
movement.
4. Remove the spark plugs.
5. Connect an auxiliary starter switch in the starting circuit. Crank the engine with ignition switch in OFF position. Bump crankshaft over until valve tappet is on base circle of camshaft lobe. At this
point, valve tappet will be in its lowest position. If checking during engine assembly, turn
crankshaft using a socket or ratchet.
6. Zero the dial indicator. Continue to rotate crankshaft slowly until valve tappet is in fully- raised
position (highest indicator reading).
7. NOTE: If lift on any lobe is below specified service limits, install a new camshaft, and new valve
tappets.
Remove the Dial Indicator with Holding Fixture, Dial Indicator Gauge Adapter, and auxiliary
starter switch.
8. Install rocker arm seats, rocker arms and rocker arm seat bolts.
9. Install valve covers.
10. Install spark plugs.
Valve Train Analysis— Engine Running, Valve Tappet
Valve tappet noise can be caused by any of the following:
zexcessive valve tappet gap (collapsed) Klj . 16 ba
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4. Inspect for normal burning.
zCheck for light tan or gray deposits on the firing tip.
5. Inspect for pre- ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect
ignition timing, wrong type of fuel or the unauthorized installation of a heli- coil insert in place of
the spark plug threads.
zInstall a new spark plug.
6. Inspect for overheating, identified by a white or light gray spots and with bluish- burnt
appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark
plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition
timing.
zInstall a new spark plug. Klj . 2 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head
Disassembly and Assembly
CAUTION: If the components are to be reinstalled, they must be installed in the same
position. Mark the components removed for location.
1. Remove the spark plugs (12405) if necessary.
2. Using the special tool, compress the valve springs (6513).
3. Remove the following: 1. The valve spring retainer key (6518).
2. The valve spring retainers (6514).
3. The valve springs (6513).
4. The valve stem seals and seats (6A517).
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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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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4. Remove the bolts and the eight ignition coils.
5.
NOTE: Use compressed air to remove any foreign material from the spark plug wells before
removing the spark plugs.
Remove the spark plugs.
6. NOTE: Rotate the camshaft to the base circle of the camshaft lobe before removing the
followers. Keep the roller followers in order when removing.
Using the special tool, remove the 16 roller followers.
zRotate the crankshaft and camshaft as necessary. Klj . 2 ba
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16. Remove the paper clip from the RH and the LH timing chain tensioners.
17.
NOTE: Rotate the camshaft to the base circle of the camshaft lobe before installing the roller
followers.
NOTE: Keep all the roller followers in order when installing.
Using the special tool, install the 16 roller followers.
18. Install the eight spark plugs. Klj . 11 ba
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39.
NOTE: Use compressed air to remove any foreign material from the spark plug well before
removing the spark plugs.
NOTE: One spark plug shown, others are similar.
Remove the spark plugs.
40. Install the special tool between the valve spring coils to prevent valve stem seal damage.
41. NOTE: Rotate the camshaft to see the base circle of the camshaft's lobe before removing the
followers. Keep roller followers in order when removing.
Use the special tool to compress the valve springs and remove the 16 camshaft roller followers.
Rotate the camshaft and crankshaft as necessary.
42. Remove the crankshaft pulley bolt. Klj . 13 ba
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43.
NOTE: Use compressed air to remove any foreign material from the spark plug well before
removing the spark plugs (12405).
NOTE: One spark plug is shown; others are similar.
Remove the spark plugs.
44. NOTE: Rotate the camshaft to the base circle of the camshaft lobe before removing followers.
Keep roller followers in order when removing.
Use special tool to compress the valve springs (6513) and remove the 16 camshaft roller
followers.
zRotate the camshaft and the crankshaft as necessary.
45. Remove the crankshaft pulley bolt.
46. Using the special tool, remove the crankshaft pulley. Klj . 15 ba
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68. Install the camshaft roller followers.
1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft follower.
69. NOTE: One spark plug shown, others similar.
Install spark plugs.
70. NOTE: The RH side is shown, the LH side is similar. Klj . 26 ba
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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
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