engine FORD MUSTANG 2003 Workshop Manual

10. Remove the three exhaust manifold studs.
11.
NOTE: Discard the cylinder head gasket.
NOTE: Record the location of the long bolts and the short bolts.
Remove the cylinder head. Discard the cylinder head bolts.
Installation
NOTE: Do not use a fiber disc to clean the surfaces. Fibers from the disc can get into the oil pan and
oil and clog the oil bypass valve.
1. Clean and inspect the cylinder head for flatness. For additional information, refer to Section 303 - 00 .
2. Install a new head gasket on the cylinder block with the small hole to the front of the engine and position the cylinder head. Klj . 2 ba
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3.
CAUTION: Always use new bolts.
NOTE: Lubricate the bolts with clean engine oil.
Install new bolts. Refer to the location note made during removal and make sure the bolts are
installed the correct location. 1. Install the new long bolts.
2. Install the new short bolts.
4. Tighten the bolts in three stages in the sequence shown. zStage 1: Tighten to 20 Nm (15 lb- ft).
z Stage 2: Tighten to 40 Nm (30 lb- ft).
z Stage 3: Tighten to 50 Nm (37 lb- ft).
5. CAUTION: Do not loosen all of the bolts at one time. Each bolt must be loosened
and final- tightened prior to working on the next bolt in the sequence.
NOTE: The short bolts are numbered 2, 4, 6 and 8 and the long bolts are numbered 1, 3, 5 and
7. Klj . 3 ba
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9. Connect the A/C manifold and tube assembly. For additional information, refer to
Section 412 -
03 .
10. Install the accessory drive belt. For additional information, refer to Section 303 - 05 .
11. Install the push rods. For additional information, refer to Push Rod in this section.
12. Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
13. Install the RH exhaust manifold. For additional information, refer to Exhaust Manifold RH in this
section.
14. Connect the battery ground cable. For additional information, refer to Section 414 - 01 .
15. CAUTION: Correct cooling system bleeding is critical for correct engine cooling.
Fill and bleed the engine cooling system. For additional information, refer to Section 303 - 03A .
16. Recharge the A/C refrigerant system. For additional information, refer to Section 412 - 00 . Klj . 5 ba
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IN-
VEHICLE REPAIR
Oil Level Indicator and Tube
Removal and Installation 1. Remove the oil level indicator tube (6754). zRemove the bolt.
z Remove the oil level indicator tube.
z Remove and discard the oil level indicator tube O- ring.
2. 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
Oil Pan
Removal 1. Disconnect the battery ground cable.
2. Remove the air cleaner outlet pipe. For additional information, refer to Section 303 - 12 .
3. Remove the radiator sight shield.
4. Remove the coolant recovery reservoir. 1. Disconnect the hose.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
3 Bar Engine Support Kit
303-
F072 Lifting Bracket Set, Engine
303-
D095 (D94L-6001- A) or
equivalent
Material Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Klj . 1 ba
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9. Remove the LH engine mount nut.
10. Remove the RH engine mount nut.
11. Lower the vehicle.
12. Raise the engine.
13. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
14. Remove the oil pan drain plug and drain the engine oil. Klj . 3 ba
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11. Install the bracket.
12. Install the starter motor. For additional information, refer to
Section 303 - 06 .
13. Lower the vehicle.
14. Lower the engine.
15. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
16. Install the RH engine mount nut. Klj . 10 ba
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17. Install the LH engine mount nut.
18. Lower the vehicle.
19. Remove the special tools.
20. Install the coolant recovery reservoir.
21. Install the radiator sight shield. Klj . 11 ba
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22. Install the air cleaner outlet pipe. For additional information, refer to
Section 303 - 12 .
23. Connect the battery ground cable. For additional information, refer to Section 414 - 01 .
24. Fill the engine with clean engine oil.
25. CAUTION: Correct coolant bleeding is critical for correct engine cooling.
Fill and bleed the engine cooling system. For additional information, refer to Section 303 - 03A . Klj . 12 ba
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IN-
VEHICLE REPAIR
Oil Pan Baffle
Removal and Installation 1. Remove the oil pump screen cover and tube (6622). For additional information, refer to Oil Pump Screen and Pickup Tube in this section.
2. Remove the oil pan baffle (6687). zRemove the nuts.
3. To install, reverse the removal procedure.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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