belt FORD MUSTANG 2003 Owner's Guide

GENERAL PROCEDURES
Sprockets
1. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do
not operate the engine with the hood open until the fan blade has been examined for
possible cracks and separation.
NOTE: Specifications show the expected minimum or maximum condition. Refer to the
appropriate section in Group 303 for the procedure.
NOTE: If a component fails to meet the specifications, it is necessary to install a new
component or refinish. If the component can be refinished, wear limits are provided as an aid to
making a decision. A new component must be installed for any component that fails to meet
specifications and cannot be refinished.
Inspect the timing chain/belt and the sprockets.
zInstall new components as necessary. Refer to the appropriate section in Group 303 for
the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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IN-
VEHICLE REPAIR
Crankshaft Pulley
Removal 1. Remove the drive belt (8620). For additional information, refer to Section 303 - 05 .
2. Remove the radiator coolant recovery reservoir (8A080).
3. Raise the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
4. Remove the crankshaft pulley bolt. SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Remover, Crankshaft Vibration
Damper
303-
009 (T58P-6316- D) Remover, Crankshaft Vibration
Damper
303-
176 (T82L-6316- B) Installer, Crankshaft
Damper/Crankshaft Front Oil
Seal
303-
175 (T82L-6316- A)
Material Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323- A4 Klj . 1 ba
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4. Install the radiator coolant recovery reservoir.
5. Install the drive belt. For additional information, refer to
Section 303 - 05 . Klj . 3 ba
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IN-
VEHICLE REPAIR
Timing Chain
Removal 1. Remove the timing cover. For additional information, refer to Engine Front Cover in this section.
2. Remove the camshaft position sensor drive gear. 1. Remove the bolt.
2. Remove the camshaft position sensor drive gear.
3. Rotate the crankshaft (6303) until the timing marks and keyways align.
4. Compress and install a retaining pin to hold the timing chain tensioner (6L266).
5. Remove the camshaft sprocket (6256), the crankshaft sprocket (6306) and the timing chain/belt (6268) as an assembly.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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IN-
VEHICLE REPAIR
Cylinder Head LH
Removal 1. Disconnect the battery negative cable. For additional information, refer to Section 414 - 01 .
2. Drain the engine cooling system. For additional information, refer to Section 303 - 03A .
3. Remove the LH exhaust manifold. For additional information, refer to Exhaust Manifold — LH in
this section.
4. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in
this section.
5. Remove the push rods. For additional information, refer to Push Rod in this section.
6. Remove the drive belt. For additional information, refer to Section 303 - 05 .
7. Using the special tool, remove the power steering pump pulley.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Remover, Power Steering
Pump Pulley
211-
016 (T69L-10300- B) Installer, Power Steering Pump
Pulley
211-
009
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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9. Install the support bracket.
10. Using the special tool, install the power steering pump pulley.
11. Install the drive belt. For additional information, refer to Section 303 - 05 .
12. Install the push rods. For additional information, refer to Push Rod in this section.
13. Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
14. Install the LH exhaust manifold. For additional information, refer to Exhaust Manifold — LH in this
section.
15. Connect the battery ground cable. For additional information, refer to Section 414 - 01 .
16. CAUTION: Correct cooling system bleeding is critical for correct engine cooling.
Fill and bleed the engine cooling system. For additional information, refer to Section 303 - 03A . Klj . 5 ba
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IN-
VEHICLE REPAIR
Cylinder Head RH
Removal 1. Disconnect the battery negative cable. For additional information, refer to Section 414 - 01 .
2. Drain the engine cooling system. For additional information, refer to Section 303 - 03A .
3. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold RH in
this section.
4. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in
this section.
5. Remove the push rods. For additional information, refer to Push Rod in this section.
6. Remove the drive belt. For additional information, refer to Section 303 - 05 .
7. Disconnect the A/C manifold and tube assembly. For additional information, refer to Section 412 - 03 .
8. Disconnect the A/C compressor clutch electrical connector.
9. Remove the A/C compressor bracket.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual 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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9. Connect the A/C manifold and tube assembly. For additional information, refer to
Section 412 -
03 .
10. Install the accessory drive belt. For additional information, refer to Section 303 - 05 .
11. Install the push rods. For additional information, refer to Push Rod in this section.
12. Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
13. Install the RH exhaust manifold. For additional information, refer to Exhaust Manifold RH in this
section.
14. Connect the battery ground cable. For additional information, refer to Section 414 - 01 .
15. CAUTION: Correct cooling system bleeding is critical for correct engine cooling.
Fill and bleed the engine cooling system. For additional information, refer to Section 303 - 03A .
16. Recharge the A/C refrigerant system. For additional information, refer to Section 412 - 00 . Klj . 5 ba
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27. Remove the heater water outlet tube.
28.
NOTE: Record the location of the long bolts and the short bolts.
Remove the lower intake manifold and the intake manifold gasket.
29. Remove the accessory drive belt.
30. Remove the water pump pulley. Klj . 8 ba
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50. Install the A/C compressor bracket and the bolts.
51. Install the accessory drive belt.
52. Refer to the illustration for intake manifold sealing components.
Item Part Number Description
1 9439 Intake manifold gasket, RH
2 9441 Intake manifold gasket, LH
3 9A424 Intake manifold rear end seal (part of 9439) Klj . 17 ba
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