engine FORD MUSTANG 2003 Workshop Manual

27.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean sealing surfaces. These tools will cause scratches and gouges
which make leak paths.
Clean the sealing surfaces.
28. Remove the coolant bypass tube. 1. Remove the nut.
2. Remove the coolant bypass tube.
29. Remove the RH engine mount. Klj . 9 ba
212003 Mustang Workshop Manual
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30.
NOTE: LH shown; RH similar.
Using a suitable container, drain coolant from the engine block. zInstall the drain plugs when finished.
31. Remove the four bolts and the power steering pump.
RH cylinder head 32. Remove the RH exhaust manifold. 1. Remove the RH exhaust manifold nuts.
2. Remove the RH exhaust manifold.
3. Remove the RH exhaust manifold gasket and discard. Klj . 10 ba
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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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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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REMOVAL
Engine
Removal
1. Remove the hood.
2. Remove the battery. For additional information, refer to Section 414 - 01 .
3. Remove the air cleaner and outlet tube. For additional information, refer to Section 303 - 12 .
4. Drain the engine cooling system. For additional information, refer to Section 303 - 03A or
Section 303 - 03B .
5. Remove the degas bottle. For additional information, refer to Section 303 - 03A or
Section 303 -
03B .
6. Recover the A/C system. For additional information, refer to Section 412 - 00 .
7. Disconnect the fuel lines. For additional information, refer to Section 310 - 00 .
8. Disconnect the upper radiator hose from the water outlet connector.
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Special Tool(s)
Support Bracket, Engine
303-
639 Spreader Bar
303-
D089 (D93P-6001- A3) Lifting Bracket Set, Engine
303-
D074 (D91P-6001- A) Klj . 1 ba
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13. Disconnect the engine bulkhead connector.
14. Separate the harness in three locations.
15. Disconnect the electrical connector.
16. Remove the safety clip from the manifold suction tube. Klj . 3 ba
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29. Raise and support the vehicle. For additional information, refer to
Section 100 - 02 .
30. Drain the engine oil.
31. Disconnect the RH heated oxygen sensor connector.
32. Disconnect the LH heated oxygen sensor connector.
33. Remove the four exhaust manifold flange nuts. Klj . 7 ba
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50.
NOTE: This step will allow removal of the exhaust manifold through the bottom and access for
the installation of the engine lift brackets.
Using a suitable floor crane, raise the engine to remove the exhaust manifold.
51. Install the RH and LH special tool.
52. NOTE: Before carrying out this step it will be necessary to support the transmission with a floor
jack and a block of wood.
Install the special tool. Klj . 11 ba
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