radiator FORD MUSTANG 2003 Workshop Manual

1. If compression improves considerably, piston rings are faulty.
2. If compression does not improve, valves are sticking or seating incorrectly.
3. If two adjacent cylinders indicate low compression pressures and squirting oil on each piston
does not increase compression, the head gasket may be leaking between cylinders. Engine oil
or coolant in cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the
lowest reading is within 75 percent of the highest reading.
Cylinder Leakage Detection
When a cylinder produces a low reading, use of the Engine Cylinder Leak Detection/Air Pressurization
Kit will be helpful in pinpointing the exact cause.
The leakage detector is inserted in the spark plug hole, the piston is brought up to dead center on the
compression stroke, and compressed air is admitted.
Once the combustion chamber is pressurized, a special gauge included in the kit will read the
percentage of leakage. Leakage exceeding 20 percent is excessive.
While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake
valve (6507) will be heard in the throttle body (9E926). A leak at the exhaust valve (6505) can be
heard at the tail pipe. Leakage past the piston rings will be audible at the positive crankcase ventilation
(PCV) connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will
be evident at the spark plug hole of the cylinder into which the air is leaking. Cracks in the cylinder
block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator
(8005).
Oil Consumption Test
The following diagnostic procedure is used to determine the source of excessive internal oil
consumption. 1. NOTE: Oil use is normally greater during the first 16,100 km (10,000 miles) of service. As
mileage increases, oil use generally decreases. Vehicles in normal service should get at least
1,450 km per liter (900 miles per quart) after 16,000 km (10,000 miles) of service. High speed
driving, towing, high ambient temperature and other factors may result in greater oil use.
Define excessive oil consumption, such as the number of miles driven per liter (quart) of oil
used. Also determine customer's driving habits, such as sustained high speed operation,
towing, extended idle and other considerations.
2. Verify that the engine has no external oil leak as described under Engine Oil Leaks in the Diagnosis and Testing portion of this section.
3. Verify that the engine has the correct oil level dipstick (6750).
4. Verify that the engine is not being run in an overfilled condition. Check the oil level at least five minutes after a hot shutdown with the vehicle parked on a level surface. In no case should the
level be above MAX or the letter F in FULL. If significantly overfilled, carry out Steps 6a through
6d.
5. Verify the spark plugs are not oil saturated. If the spark plugs are oil saturated and compression is good it can be assumed the valve seals or valve guides are at fault. Klj . 9 ba
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a
20- 200 seconds to leakdown 3.18 mm (0.125 in) with 225 Newtons (50 pounds) load and tappet filled
with leak- down fluid. —
desired Connecting rod bearing-
to-crankshaft clearance
— allowable 0.022-
0.069 mm (0.00086- 0.0027 in) Connecting rod side clearance 0.11-
0.49 mm (0.0047- 0.0193 in) Balance Shaft
Journal diameter 52.108-
52.082 mm (2.0515- 2.0505 in) Bore inside diameter 55.689-
55.664 mm (2.192- 2.191 in) Maximum runout 0.025 mm (0.001 in)
End play 0.075-
0.200 mm (0.003- 0.008 in)
Torque Specifications Description Nm lb-
ft lb-
in EGR transducer bracket-
to-intake manifold bolts 10 — 89
Ignition coil-
to-intake manifold bolts 6 — 53
Water outlet tube-
to-intake manifold stud bolt 10 — 89
EGR tube-
to-EGR valve nut 40 30 —
Water outlet tube-
to-front water pump bolt 10 — 89
Fuel supply manifold bolts 10 — 89
LH valve cover-
to-cylinder head bolts 10 — 89
LH valve cover-
to-cylinder head stud bolts 10 — 89
EGR tube-
to-exhaust manifold nut 40 30 —
RH valve cover-
to-cylinder head bolts 10 — 89
RH valve cover-
to-cylinder head stud bolts 10 — 89
Coolant recovery reservoir-
to-cylinder head stud bolts 10 — 89
Coolant recovery reservoir-
to-bracket bolts 5 — 44
Crankshaft pulley bolt 160 118 —
Camshaft position sensor bolts 3 — 27
Camshaft synchronizer-
to-front cover bolt 25 18 —
Front cover-
to-cylinder block bolts 25 18 —
Radiator fan shroud-
to-radiator bolts 9 — 80
Camshaft thrust plate-
to-cylinder block bolts 12 9 —
Camshaft synchronizer drive gear-
to-camshaft bolt 45 33 —
Timing chain tensioner-
to-cylinder block bolts 12 9 —
Exhaust manifold-
to-cylinder head nuts 33 24 —
Power steering pump bracket-
to-water pump nuts 20 15 —
Power steering pump bracket-
to-generator bracket bolts 20 15 —
Generator bracket-
to-cylinder head bolts 40 30 —
Exhaust manifold studs 8 — 71
A/C compressor bracket-
to-cylinder head bolts 48 35 —
A/C compressor bracket-
to-cylinder head nut 48 35 — Klj . 4 ba
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8. Remove the heater bypass tube. For additional information, refer to
Section 303 - 03A .
9. Disconnect the heater hose.
10. Disconnect the exhaust gas recirculation (EGR) vacuum tube.
11. Disconnect the EGR tube from the EGR valve.
12. Disconnect the radiator upper hose and coolant bypass hose. Klj . 2 ba
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IN-
VEHICLE REPAIR
Crankshaft Pulley
Removal 1. Remove the drive belt (8620). For additional information, refer to Section 303 - 05 .
2. Remove the radiator coolant recovery reservoir (8A080).
3. Raise the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
4. Remove the crankshaft pulley bolt. SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Remover, Crankshaft Vibration
Damper
303-
009 (T58P-6316- D) Remover, Crankshaft Vibration
Damper
303-
176 (T82L-6316- B) Installer, Crankshaft
Damper/Crankshaft Front Oil
Seal
303-
175 (T82L-6316- A)
Material Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323- A4 Klj . 1 ba
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4. Install the radiator coolant recovery reservoir.
5. Install the drive belt. For additional information, refer to
Section 303 - 05 . Klj . 3 ba
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7. Disconnect the upper radiator hose and the bypass hose.
8. Remove the camshaft position (CMP) sensor.
9. Remove the heater water outlet tube. For additional information, refer to
Section 303 - 03A .
10. Remove the camshaft synchronizer assembly.
11. Disconnect the lower radiator hose. Klj . 2 ba
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9. Connect the crankshaft position sensor electrical connector.
10. Connect the lower radiator hose.
11. Install the camshaft synchronizer assembly. For additional information, refer to Section 303 - 14 .
12. Install the heater water outlet tube. For additional information, refer to Section 303 - 13 .
13. Install the camshaft position (CMP) sensor, and connect the electrical connector. Klj . 7 ba
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14. Connect the bypass hose and the upper radiator hose.
15. Connect the EGR tube.
16. Install the power steering pump.
17. Install the water pump pulley.
18. Install the crankshaft pulley. For additional information, refer to
Crankshaft Pulley in this section. Klj . 8 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
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IN-
VEHICLE REPAIR
Engine Dynamic Balance Shaft
Removal 1. Remove the timing chain (6268). For additional information, refer to Timing Chain in this
section.
2. Disconnect and position the wire harness aside.
3. Remove the radiator fan and shroud assembly (8146).
4. Remove the engine dynamic balance shaft (6A311). zRemove the bolts.
z Remove the balance shaft driver gear, thrust plate and engine dynamic balance shaft as
an assembly. Installation SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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