Cylinder head removal FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Ignition Switch Lock Cylinder —
Non-Functional
Removal and Installation 1. NOTE: Make sure the front wheels are in the straight- ahead position.
Disconnect the battery ground cable (14301) and wait at least one minute to allow the depletion
of the restraint system backup power supply. For additional information, refer to Section 414 -
01 .
2. WARNING: To avoid the risk of serious personal injury, read and follow all
warnings, cautions, notes and instructions in the deactivation procedure.
Deactivate the supplemental restraint system (SRS). For additional information, refer to
Supplemental Restraint System (SRS) Deactivation and Reactivation in this section.
3. WARNING: To reduce the risk of serious personal injury, read and follow all
warnings, cautions, notes and instructions in the steering wheel removal and installation
procedure.
Remove the steering wheel assembly. For additional information, refer to Wheel in this section.
4. Twist off the cap from the ignition switch cylinder.
5. NOTE: The lock cylinder is repaired by discarding the inoperative lock cylinder and building a
new lock cylinder using the appropriate lock repair package (F85Z-11582- AA). The lock repair
package includes a detailed instruction sheet to build the new lock cylinder to the current key
code of the vehicle.
SECTION 211-
04: Steering Column 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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IN-
VEHICLE REPAIR
Cylinder Head LH
Removal 1. Disconnect the battery negative 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 LH exhaust manifold. For additional information, refer to Exhaust Manifold — LH in
this section.
4. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in
this section.
5. Remove the push rods. For additional information, refer to Push Rod in this section.
6. Remove the drive belt. For additional information, refer to Section 303 - 05 .
7. Using the special tool, remove the power steering pump pulley.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Remover, Power Steering
Pump Pulley
211-
016 (T69L-10300- B) Installer, Power Steering Pump
Pulley
211-
009
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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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.
3. Position the cylinder head.
4. 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. Klj . 3 ba
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IN-
VEHICLE REPAIR
Cylinder Head RH
Removal 1. Disconnect the battery negative 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 RH exhaust manifold. For additional information, refer to Exhaust Manifold RH in
this section.
4. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in
this section.
5. Remove the push rods. For additional information, refer to Push Rod in this section.
6. Remove the drive belt. For additional information, refer to Section 303 - 05 .
7. Disconnect the A/C manifold and tube assembly. For additional information, refer to Section 412 - 03 .
8. Disconnect the A/C compressor clutch electrical connector.
9. Remove the A/C compressor bracket.
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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6. Raise and support the vehicle. For additional information, refer to
Section 100 - 02 .
7. Remove the bolt and position the transmission filler tube aside.
8. Remove the bolts, studs and the valve cover in the sequence shown. zClean and inspect the sealing surfaces.
9. NOTE: Apply an eight millimeter bead of silicone gasket and sealant at the intersection of the
engine front cover and the cylinder head.
To install, reverse the removal procedure. Klj . 2 ba
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4. Disconnect the engine wiring harness retainer and position it aside.
5. Remove the bolts, studs and the valve cover in the sequence shown.
zInspect and clean the sealing surfaces.
6. NOTE: Apply an eight millimeter bead of silicone gasket and sealant at the intersection of the
engine front cover and the cylinder head.
To install, reverse the removal procedure. Klj . 2 ba
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REMOVAL
Cylinder Heads
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Special Tool(s)
Remover, Crankshaft Vibration
Damper
303-
009 (T58P-6316- D) Remover, Crankshaft Front Oil
Seal
303-
107 (T74P-6700- A) Engine Lift Bracket Set
303-
DS086 (D93P-6001- A) Compressor, Valve Spring
(Exhaust)
303-
567 (T97P-6565- AH) Compressor Spacer, Valve
Spring
303-
382 (T91P-6565- AH) Remover/Installer, Cylinder
Head
303-
572 (T97T-6000- A)
Material Item Specification
Motorcraft Silicone Gasket
Remover
ZC-
30 —
Motorcraft Metal Surface Prep — Klj . 1 ba
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Removal
Both cylinder heads
1. Remove the engine. For additional information, refer to Engine in the Removal portion of this
section.
2. Remove the flywheel.
3. Remove the separator plate.
4. Mount the engine on a suitable engine stand.
5. NOTE: RH shown, LH similar.
Remove the RH and LH lifting eyes. ZC-
31 Klj . 2 ba
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Both cylinder heads
1. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block
must be clean. For additional information, refer to Cylinder Heads in the Removal portion
of this section.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not
permitted. The gasket must be installed dry.
CAUTION: The new gasket has a film coating which is crucial to the gasket's ability
to seal correctly. Do not scratch the gasket.
NOTE: RH head gasket shown; LH head gasket similar.
Install the head gasket over the dowel pins. 303-
382 (T91P-6565- AH) Remover/Installer, Cylinder
Head
303-
572 (T97T-6000- A)
Material Item Specification
Motorcraft Silicone Gasket
Remover
ZC-
30 —
Motorcraft Metal Surface Prep
ZC-
31 —
Hydraulic Chain Tensioner
Retaining Clip
1L3Z-6P250-
AA —
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Super Premium SAE 5W-20
Engine Oil
XO- 5W20- QSP or equivalent WSS-
M2C153-
H Klj . 2 ba
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