ECU FORD MUSTANG 2003 Owner's Manual

40. Install the crankshaft pulley bolt.
41. Install the camshaft synchronizer. For additional information, refer to
Section 303 - 14 .
42. Install the water pump pulley and the retaining bolts.
43. NOTE: If the oil pan 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.
Clean and apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal.
1. Apply silicone gasket and sealant to the rear main bearing cap.
2. Install the oil pan rear seal.
3. Clean the oil pan mating surfaces with metal surface cleaner and apply silicone gasket and sealant to the oil pan mating surface. Klj . 14 ba
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53.
NOTE: If the lower intake manifold 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 lower intake manifold front and rear end seals. 1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as indicated.
2. Install the lower intake manifold front and rear end seals.
54. Install the intake manifold gaskets.
55. NOTE: If the lower intake manifold 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.
Position the lower intake manifold. 1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the
points indicated.
2. Position the lower intake manifold. 4 9A425 Intake manifold front end seal (part of 9439) Klj . 18 ba
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Installation
1. 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.
Clean and inspect the mating surfaces.
2. NOTE: If the oil pan 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 result in future oil
leakage.
Apply the silicone gasket and sealant at the rear oil seal retainer- to-cylinder block sealing
surface.
3. NOTE: If the oil pan 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 result in future oil
leakage.
Apply the silicone gasket and sealant at the engine front cover- to-cylinder block mating surface. 4. Install the oil pan and gasket and loosely install the bolts. Klj . 5 ba
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Install the oil pump screen cover and tube.
26. NOTE: If not secured within four minutes, sealant must be removed and sealing area cleaned
with metal surface cleaner. Allow to dry until there are no signs of wetness, or four minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.
If the retainer plate was removed, apply a 4 mm (0.16 in) bead of silicone gasket and sealant
around the rear oil seal retainer sealing surface.
27. Install the rear main seal retainer plate. Tighten the bolts in the sequence shown. zTighten bolts 1- 6 to 10 Nm (89 lb- in).
z Hand- tighten bolts 7 and 8.
z Tighten bolts 7 and 8 to 20 Nm (15 lb- ft).
z Tighten bolts 7 and 8 an additional 60 degrees.
28. Install the oil pan and gasket and loosely install the bolts. Klj . 12 ba
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25.
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 bead of sealant along the head- to-block surface as shown.
26. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger- tight.
27. Tighten the front cover fasteners in the sequence shown. Klj . 10 ba
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39.
NOTE: Lubricate the camshaft roller followers using clean engine oil.
NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing
each camshaft roller follower.
Install the camshaft roller followers. 1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft roller followers in their original locations.
40. Remove the special tool.
41. NOTE: One spark plug shown, others similar.
Install the spark plugs.
42. NOTE: RH side shown, LH side similar.
NOTE: If not secured within four minutes, the sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow
the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant in the locations shown. Klj . 15 ba
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11. Remove the RH valve cover.
z 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.
Remove and discard the gasket, clean and inspect the sealing surfaces.
12. Inspect the valve cover spark plug hole gaskets. Install new gaskets, if necessary. Make sure the gaskets are correctly seated on the valve cover.
13. NOTE: If the valve 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 result in
future oil leakage.
Apply a bead of silicone gasket and sealant in two places where indicated. Klj . 3 ba
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16. Inspect the valve cover spark plug hole gaskets. Install new gaskets, if necessary. Make sure
the gaskets are correctly seated on the valve cover.
17. NOTE: If the valve 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 result in
future oil leakage.
Apply a bead of silicone gasket and sealant in two places where indicated.
18. To install, reverse the removal procedure. zTighten the valve cover in the sequence shown. Klj . 5 ba
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29.
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.
Remove and discard the gasket, clean and inspect the sealing surfaces.
Installation 1. NOTE: If the valve 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 result in
future oil leakage.
Apply silicone gasket and sealant in the locations shown.
2. Install the engine front cover and tighten the fasteners in the sequence shown, to 25 Nm (18 lb- in). Klj . 7 ba
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22.
NOTE: Be careful when removing the oil pan gasket. It is reusable.
Remove the oil pan and gasket. zInspect the oil pan gasket for damage.
Installation 1. 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.
Clean and inspect the mating surfaces.
2. NOTE: If the oil pan 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 may result in future oil
leakage.
Apply silicone gasket and sealant at the engine front cover- to-cylinder block mating surface.
3. NOTE: If the oil pan 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, Klj . 5 ba
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