FORD MUSTANG 2003 Workshop Manual

REMOVAL
Cylinder Heads
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Special Tool(s)
Remover, Crankshaft Vibration
Damper
303-
009 (T58P-6316- D) Remover, Crankshaft Front Oil
Seal
303-
107 (T74P-6700- A) Engine Lift Bracket Set
303-
DS086 (D93P-6001- A) Compressor, Valve Spring
(Exhaust)
303-
567 (T97P-6565- AH) Compressor Spacer, Valve
Spring
303-
382 (T91P-6565- AH) Remover/Installer, Cylinder
Head
303-
572 (T97T-6000- A)
Material Item Specification
Motorcraft Silicone Gasket
Remover
ZC-
30 —
Motorcraft Metal Surface Prep — Klj . 1 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Removal
Both cylinder heads
1. Remove the engine. For additional information, refer to Engine in the Removal portion of this
section.
2. Remove the flywheel.
3. Remove the separator plate.
4. Mount the engine on a suitable engine stand.
5. NOTE: RH shown, LH similar.
Remove the RH and LH lifting eyes. ZC-
31 Klj . 2 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

6. Remove the breather tube.
7. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) electrical
connector.
8. Disconnect the hoses from the differential pressure feedback EGR transducer.
9. Remove the EGR vacuum regulator solenoid. 1. Remove the vacuum lines.
2. Remove the electrical connector.
3. Remove the bolts. Klj . 3 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

10. Disconnect the EGR tube from the EGR valve.
11. Disconnect the positive crankcase ventilation (PCV) hose from the base of the throttle body.
12. Remove the PCV valve and hose as an assembly.
13. Remove the engine wiring harness. Klj . 4 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

14. Disconnect the vacuum line from the fuel pressure sensor. Item Part Number Description
1 — To crankshaft position sensor
2 — To A/C compressor
3 — To radio ignition interference capacitor (2)
4 — To fuel injectors (8)
5 — To ignition coils (8)
6 — To engine coolant temperature sensor
7 — To throttle position sensor
8 — To idle air control valve
9 — To EGR vacuum regulator
10 — To differential pressure feedback EGR
11 — To fuel pressure regulator
12 — Fuel injection ground
13 — To generator
14 — To camshaft position sensor
15 — To body
16 — To heated oxygen sensor (2)
17 — Engine bulkhead connector
18 — To low coolant sensor
19 — To body
20 — To power distribution box
21 — To body Klj . 5 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

15. Remove the throttle body bolts.
16.
NOTE: The gasket is reusable if not damaged.
Remove the throttle body and adapter as an assembly. zInspect and clean the sealing surfaces.
17. Remove the ignition coils.
18. Remove the radio interference capacitors. Klj . 6 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

19. Remove the accessory drive belt.
20. Remove the power steering reservoir and bracket as an assembly.
1. Disconnect the supply line from the pump.
2. Remove the (3) bolts and the reservoir and bracket.
21. Remove the upper generator support bracket.
22. Remove the bolts and the generator. Klj . 7 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

23. Remove the coolant outlet adapter.
24. Remove the thermostat and O-
ring.
25. Remove the bolts in the sequence shown, and remove the intake manifold.
26. Remove the intake manifold gaskets. Klj . 8 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

27.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean sealing surfaces. These tools will cause scratches and gouges
which make leak paths.
Clean the sealing surfaces.
28. Remove the coolant bypass tube. 1. Remove the nut.
2. Remove the coolant bypass tube.
29. Remove the RH engine mount. Klj . 9 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

30.
NOTE: LH shown; RH similar.
Using a suitable container, drain coolant from the engine block. zInstall the drain plugs when finished.
31. Remove the four bolts and the power steering pump.
RH cylinder head 32. Remove the RH exhaust manifold. 1. Remove the RH exhaust manifold nuts.
2. Remove the RH exhaust manifold.
3. Remove the RH exhaust manifold gasket and discard. Klj . 10 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...