FORD MUSTANG 2003 Workshop Manual

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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2.
NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed
and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of
wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future
oil leakage.
Apply a small amount of silicone gasket and sealant as shown.
3. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed
and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of
wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future
oil leakage.
Install the engine front cover gasket and apply silicone gasket and sealant as shown.
4. Install the engine front cover and bolts.
5. Install the water pump. Install the nuts and bolts. Klj . 5 ba
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6.
NOTE: The number 12 bolt is not part of the tightening sequence.
Tighten the fasteners to 26 Nm (19 lb- ft) in the sequence shown.
7. Install a new oil filter.
8. Install the wiring harness pin- type retainer. Klj . 6 ba
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9. Connect the crankshaft position sensor electrical connector.
10. Connect the lower radiator hose.
11. Install the camshaft synchronizer assembly. For additional information, refer to Section 303 - 14 .
12. Install the heater water outlet tube. For additional information, refer to Section 303 - 13 .
13. Install the camshaft position (CMP) sensor, and connect the electrical connector. Klj . 7 ba
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14. Connect the bypass hose and the upper radiator hose.
15. Connect the EGR tube.
16. Install the power steering pump.
17. Install the water pump pulley.
18. Install the crankshaft pulley. For additional information, refer to
Crankshaft Pulley in this section. Klj . 8 ba
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19. Drain the engine oil and fill with clean engine oil.
20. Fill the engine cooling system. For additional information, refer to
Section 303 - 03A .
21. Connect the battery ground cable. For additional information, refer to Section 414 - 01 . Klj . 9 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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Klj . 2 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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Klj . 2 ba
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