engine FORD MUSTANG 2003 Workshop Manual

13. Install the engine air cleaner outlet pipe. For additional information, refer to
Section 303 - 12 .
14. Connect the battery ground cable. For additional information, refer to Section 414 - 01 . Klj . 8 ba
82003 Mustang Workshop Manual
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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
92003 Mustang Workshop Manual
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16. Install the upper intake manifold. For additional information, refer to
Upper Intake Manifold in
this section.
17. CAUTION: Correct cooling system bleeding is critical for correct engine cooling.
Fill and bleed the cooling system. For additional information, refer to Section 303 - 03A . Klj . 9 ba
92003 Mustang Workshop Manual
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IN-
VEHICLE REPAIR
Valve Cover — LH
Removal and Installation 1. Position the ignition wires (12281) aside.
2. Disconnect the positive crankcase ventilation (PCV) valve (6758).
3. Remove the ignition coil and position aside. 1. Disconnect the electrical connector.
2. Disconnect the accelerator control cable retainer.
3. Remove the bolts.
4. Remove the LH valve cover (6A565). zInspect the gasket (6584) and install a new gasket if necessary.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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IN-
VEHICLE REPAIR
Valve Cover RH
Removal and Installation 1. Remove the throttle body. For additional information, refer to Section 303 - 04A .
2. Disconnect the crankcase vent hose.
3. Remove the differential feedback exhaust gas recirculation (EGR) system vacuum hoses and the bracket bolts. Position the bracket assembly aside.
4. Disconnect the EGR tube.
5. Remove the EGR tube.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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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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IN-
VEHICLE REPAIR
Crankshaft Front Seal
Removal 1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this
section.
2. Using the special tool, remove and discard the crankshaft front seal.
Installation SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Installer, Front Cover Oil Seal
303-
335 (T88T-6701- A) Installer, Crankshaft Front Oil
Seal
303-
474 (T94P-6701- AH) Remover, Oil Seal
303-
409 (T92C-6700- CH)
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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1.
NOTE: Lubricate the crankshaft front seal with clean engine oil before assembly.
Using the special tool, install the crankshaft front seal.
2. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section. Klj . 2 ba
22003 Mustang Workshop Manual
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IN-
VEHICLE REPAIR
Engine Front Cover
Removal 1. Disconnect the battery ground 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 crankshaft pulley. For additional information, refer to Crankshaft Pulley in this
section.
4. Remove the water pump pulley.
5. Remove the retainers and position the power steering pump aside.
6. Disconnect the exhaust gas recirculation (EGR) tube.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
92003 Mustang Workshop Manual
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