engine 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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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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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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IN-
VEHICLE REPAIR
Valve Springs
Removal 1. Remove the LH and the RH valve covers. For additional information, refer to Valve Cover — LH
and
Valve Cover RH in this section.
2. Rotate the crankshaft until the piston for the valve being worked on is at the top of its stroke with both the intake valve and the exhaust valve closed.
3. Hold the valve in the cylinder head. zRemove the spark plug. For additional information, refer to Section 303 - 07A .
z Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
4. CAUTION: If the components are to be reinstalled, they must be installed in the
same position. Mark the components for location.
NOTE: If a valve drops into the cylinder, remove the cylinder head. For additional information,
refer to Cylinder Head LH or
Cylinder Head RH in this section.
Remove the rocker arms. 1. Remove the bolts.
2. Remove the rocker arms.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Compressor, Valve Spring
303-
163 (T81P-6513- A)
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 parts with clean engine oil.
To install, reverse the removal procedure. Tighten the rocker arm bolts in two stages. zStage 1: Tighten to 5 Nm (44 lb- in).
z Stage 2: Tighten to 35 Nm (26 lb- ft). Klj . 3 ba
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IN-
VEHICLE REPAIR
Valve Tappets
Removal CAUTION: If removing more than one valve tappet, mark the components removed for
correct location.
1. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in
this section.
2. Remove the push rods. For additional information, refer to Push Rod .
3. Remove the eight valve tappets. 1. Remove the bolts.
2. Remove the tappet guide plate and retainer.
3. Remove the valve tappets.
Installation 1. NOTE: Lubricate the valve tappet with clean engine oil before installing. To install, reverse the removal procedure. 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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IN-
VEHICLE REPAIR
Camshaft
Removal 1. Remove the valve tappets. For additional information, refer to Valve Tappets in this section.
2. Remove the timing chain. For additional information, refer to Timing Chain in this section.
3. Position the wire harness aside.
4. Remove the radiator fan and shroud assembly.
5. Remove the engine balance shaft drive gear from the camshaft. 1. Remove the camshaft key.
2. Remove the engine balance shaft drive gear.
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
32003 Mustang Workshop Manual
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6. Remove the camshaft.
1. Remove the bolts.
2. Remove the camshaft thrust plate.
3. Remove the spacer.
4. Remove the camshaft.
Installation 1. NOTE: Lubricate the camshaft with clean engine oil prior to installation.
To install, reverse the removal procedure. Klj . 2 ba
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