lock FORD MUSTANG 2003 Workshop Manual

Cylinder Block and Lower End Components 9 18801 Radio ignition interference capacitor
10 12281 Ignition wire set —
LH 11 18696 Tube assembly
12 9424 Intake manifold (lower)
13 9439 Intake manifold gasket —
RH 14 9439 Intake manifold gasket —
LH 15 9A424 Intake manifold seal (rear)
16 6A008 Cylinder head-
to-block dowel 17 6010 Cylinder block
18 6A373 Engine rear plate (automatic transmission)
19 6375 Flywheel (automatic transmission)
20 6375 Flywheel (manual transmission)
21 6A372 Engine rear plate (manual transmission)
22 6723 Oil pan rear seal
23 6675 Oil pan
24 7120 Pilot bushing
25 9278 Oil pressure sensor
26 9B339 Oil pressure sensor fitting
27 9A424 Intake manifold seal (front)
28 18663 Heater water outlet tube
29 8255 Thermostat housing-
to-intake manifold gasket 30 8592 Water outlet connection
31 9875 Water thermostat
32 9D475 EGR valve
33 9H465 Vacuum control solenoid
34 9723 Accelerator cable bracket
35 9E936 Throttle body gasket
36 9J433 EGR transducer
37 9E498 Vacuum hose
38 12280 Ignition wire set —
RH Klj . 5 ba
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9 6A333 Balance shaft front and rear bearing
10 6010 Cylinder block
11 6K564 Tappet guide plate and retainer —
RH 12 6K564 Tappet guide plate and retainer —
LH 13 6500 Valve tappet
14 376958 Balance shaft cover plug
15 6337 Crankshaft thrust main bearing
16 6701 Crankshaft rear oil seal
17 6A338 Crankshaft main bearing (lower)
18 6A339 Crankshaft thrust main bearing
19 6325 Rear main bearing cap
20 6327 Main bearing cap
21 6687 Oil pan baffle
22 6622 Oil pump screen cover and tube
23 6625 Oil pump inlet tube gasket
24 6334 Main bearing cap
25 6329 Main bearing cap
26 6303 Crankshaft
27 388907 Woodruff key
28 6333 Crankshaft main bearing (upper)
29 6284 Timing chain vibration damper
30 6263 Camshaft rear bearing
31 6262 Camshaft center bearing
32 6250 Camshaft
33 6265 Camshaft sprocket spacer
34 6269 Camshaft thrust plate
35 6256 Camshaft sprocket
36 6303 Crankshaft sprocket
37 6150 Piston ring
38 6152 Piston ring
39 6161 Piston ring
40 6159 Piston ring
41 6135 Piston pin
42 6200 Connecting rod
43 6211 Connecting rod bearing
44 6210 Connecting rod cap
45 6200 Connecting rod assembly
46 6100 Piston and connecting rod assembly
47 6108 Piston Klj . 7 ba
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IN-
VEHICLE REPAIR
Lower Intake Manifold
Removal 1. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in
this section.
2. Partially drain the cooling system. For additional information, refer to Section 303 - 03A .
3. Relieve the fuel system pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the fuel rail pressure (FRP) sensor electrical connector and vacuum hose.
5. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to Section 310 - 00 .
6. Disconnect and position the engine wire harness aside.
7. Disconnect the intake manifold runner control (IMRC) electrical connector.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Metal Surface Cleaner
F4AZ-
19A536- RA or
equivalent WSE-
M5B392- A Klj . 1 ba
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11. Install the heater bypass tube. For additional information, refer to
Section 303 - 03A .
12. Connect the IMRC electrical connector.
13. Position and connect the engine wire harness. Install the pin- type retainers.
14. Connect the fuel supply tube spring lock coupling. For additional information, refer to Section 310 - 00 .
15. Connect the FRP sensor electrical connector and the vacuum hose. Klj . 8 ba
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16.
CAUTION: The cap screw is hidden; make sure to remove it or the engine front
cover will be damaged.
NOTE: Record the location, type and size of the fasteners.
Remove the engine front cover. zSlide the engine front cover off the two dowels.
z Remove and discard the engine front cover gasket.
Installation 1. CAUTION: In order to prevent foreign material from contaminating the engine block
or the engine front cover it is necessary to seal the coolant and oil passages of both
components. Failure to follow these directions will result in engine damage.
CAUTION: Do not use a surface conditioning pad or any other type of fibrous
abrasive disc to clean the gasket surfaces. Failure to follow these directions will result in
engine damage.
Clean and inspect the engine block and front cover as follows:
zPack the exposed portion of the oil pan with clean shop towels.
z Plug the oil and coolant passages.
z Clean the gasket surfaces.
z Clean all surfaces requiring gasket sealant with metal surface cleaner.
z Using compressed air, remove any remaining foreign material from the engine block and
engine front cover.
z Remove the shop towels from the oil pan.
z Remove the plugs or seals from the engine block and engine front cover. Klj . 4 ba
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1. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic
balance shaft assembly into the cylinder block (6010). Turn the engine balance shaft driven
gear so that the timing mark lines up with the timing mark on the engine balance shaft drive
gear (6A303).
2. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and
the camshaft keyway will be at 6 o'clock on the camshaft.
Install the bolts.
3. Install the radiator fan and shroud assembly.
4. Connect the connector and install the pin- type retainer. Klj . 2 ba
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6. Remove the timing chain tensioner.
1. Remove the bolts.
2. Remove the timing chain tensioner.
Installation 1. Install the timing chain tensioner. 1. Position the timing chain tensioner.
2. Install the bolts.
2. Rotate the crankshaft so the number one piston (6108) is at top dead center (TDC) and the key is at the 12 o'clock position. Klj . 2 ba
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Remove the cylinder head. Discard the cylinder head bolts.
Installation
NOTE: Do not use a fiber disc to clean the surfaces. Fibers from the disc can get into the oil pan and
oil and clog the oil bypass valve.
1. Clean and inspect the cylinder head for flatness. For additional information, refer to Section 303 - 00 .
2. Install a new head gasket on the cylinder block with the small hole to the front of the engine.
3. Position the cylinder head.
4. CAUTION: Always use new bolts.
NOTE: Lubricate the bolts with clean engine oil.
Install new bolts. Refer to the location note made during removal and make sure the bolts are
installed the correct location. 1. Install the new long bolts.
2. Install the new short bolts. Klj . 3 ba
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10. Remove the three exhaust manifold studs.
11.
NOTE: Discard the cylinder head gasket.
NOTE: Record the location of the long bolts and the short bolts.
Remove the cylinder head. Discard the cylinder head bolts.
Installation
NOTE: Do not use a fiber disc to clean the surfaces. Fibers from the disc can get into the oil pan and
oil and clog the oil bypass valve.
1. Clean and inspect the cylinder head for flatness. For additional information, refer to Section 303 - 00 .
2. Install a new head gasket on the cylinder block with the small hole to the front of the engine and position the cylinder head. Klj . 2 ba
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2. Using the special tools, remove the crankshaft rear seal.
Installation 1. Clean and inspect the mating surface.
2. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.
Assemble the special tools and the crankshaft rear seal.
3. Install the special tools on the rear of the crankshaft.
4. Install the crankshaft rear seal. Tighten the center jack screw (303- S560) until the spacer (303-561) contacts the engine block. Klj . 2 ba
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