FORD MUSTANG 2003 Workshop Manual

LH cylinder head
33. Disconnect the EGR tube at the exhaust manifold.
34. Remove the LH exhaust manifold. 1. Remove the LH exhaust manifold nuts.
2. Remove the LH exhaust manifold.
3. Remove the LH exhaust manifold gasket and discard.
35. Remove the oil level indicator tube bolt. Klj . 11 ba
212003 Mustang Workshop Manual
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36. Remove the oil level indicator tube.
Both cylinder heads 37. Clean and inspect the exhaust manifolds. For additional information, refer to Section 303 - 00 .
38. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: The bolts are part of the valve cover and should not be removed. RH valve cover
shown, LH valve cover similar.
Remove the RH and LH valve covers.
zFully loosen the bolts and remove the valve covers.
z Clean the valve cover mating surface of the cylinder heads with silicone gasket remover
and metal surface prep. Follow the directions on the packaging.
z Inspect the valve cover gasket(s). If the gasket(s) is damaged, remove and discard the
gasket(s). Clean the valve cover gasket groove(s) with soap and water or a suitable
solvent. Klj . 12 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
212003 Mustang Workshop Manual
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43. Using the special tool, remove the crankshaft pulley.
44. Remove the coolant pump pulley.
1. Remove the coolant pump pulley bolts.
2. Remove the coolant pump pulley.
45. Remove the bolts and belt idler pulleys.
46. Using the special tool, remove the engine front cover seal. Klj . 14 ba
212003 Mustang Workshop Manual
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47. Remove the bolts.
48. Remove the bolts, the studs, and the engine front cover.
zDiscard the gaskets, clean and inspect the sealing surfaces.
CAUTION: Since the engine is not free- wheeling, if the crankshaft or the camshafts are
moved in any manner during removal and installation, the crankshaft and the camshafts must
be re- synchronized. 49. Remove the crankshaft sensor ring from the crankshaft. Klj . 15 ba
212003 Mustang Workshop Manual
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50. Position the crankshaft with the keyway at the 12 o'clock position.
51. Remove the RH and LH timing chain tensioning system from both timing chains.
1. Remove the bolts.
2. Remove the timing chain tensioners.
3. Remove the timing chain tensioner arms.
52. Remove the LH and RH timing chains and the crankshaft sprocket. zRemove the RH timing chain from camshaft sprocket.
z Remove the RH timing chain from the crankshaft sprocket.
z Remove the LH timing chain from the camshaft sprocket.
z Remove the LH timing chain and crankshaft sprocket. Klj . 16 ba
212003 Mustang Workshop Manual
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53.
NOTE: LH shown; RH similar.
Remove the bolts and the timing chain guides.
54. NOTE: LH shown; RH similar.
Install the lifting handles to the RH and LH cylinder heads. Klj . 17 ba
212003 Mustang Workshop Manual
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55.
NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the
hydraulic lash adjuster locations.
Remove the hydraulic lash adjusters.
RH cylinder head 56. CAUTION: The cylinder head must be cool before removing it from the engine.
Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove
the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They
are tighten- to-yield designed and cannot be reused.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the
cylinder head gasket surface, unprotected, on a bench surface.
Remove the bolts and the RH cylinder head.
zDiscard the cylinder head gasket.
z Discard the cylinder head bolts. Klj . 18 ba
212003 Mustang Workshop Manual
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LH cylinder head
57. CAUTION: The cylinder head must be cool before removing it from the engine.
Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove
the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They
are tighten- to-yield designed and cannot be reused.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the
cylinder head gasket surface, unprotected, on a bench surface.
Remove the bolts and the LH cylinder head.
zDiscard the cylinder head gasket.
z Discard the cylinder head bolts. Klj . 19 ba
212003 Mustang Workshop Manual
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Both cylinder heads
58. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all application directions
contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean
and prepare the surfaces.
Clean the cylinder head- to-cylinder block mating surfaces of both the cylinder head and the
cylinder block. 1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material
remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt
to make the metal shiny. Some staining of the metal surfaces is normal.
59. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the
deck face with a straightedge, paying particular attention to the oil pressure feed area. The
cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm
(1.5 in) square area, or scratches more than 0.0254 mm (0.001 in) . Klj . 20 ba
212003 Mustang Workshop Manual
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