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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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19. Drain the engine oil and fill with clean engine oil.
20. Fill the engine cooling system. For additional information, refer to
Section 303 - 03A .
21. Connect the battery ground cable. For additional information, refer to Section 414 - 01 . Klj . 9 ba
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IN-
VEHICLE REPAIR
Rocker Arm
Removal CAUTION: If removing more than one rocker arm (6564), mark the components removed
for correct location.
1. Remove the valve covers. For additional information, refer to Valve Cover — LH and
Valve Cover RH in this section.
2. Remove the rocker arm assembly. zRemove the bolt.
Installation 1. Install the rocker arms, tighten the bolts in two stages. zStage 1: tighten to 5 Nm (44- lb-in).
z Stage 2: tighten to 35 Nm (26 lb- ft).
2. Install the valve covers. For additional information, refer to Valve Cover — LH and
Valve Cover RH in this section.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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Klj . 2 ba
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IN-
VEHICLE REPAIR
Push Rod
Removal CAUTION: Mark the components removed for correct location.
1. Remove the rocker arms (6564). For additional information, refer to Rocker Arm in this section.
2. Remove the push rods (6565).
3. Inspect the components. For additional information, refer to Section 303 - 00 .
Installation 1. To install, reverse the removal procedure.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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Klj . 2 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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5. Using the special tool, compress the valve springs.
6. Remove the valve spring assembly.
1. Remove the valve spring retainer key.
2. Remove the valve spring retainer.
3. Remove the valve spring.
4. Remove and discard the valve stem seal and spring seat assembly.
7. Inspect the components. For additional information, refer to Section 303 - 00 .
Installation Klj . 2 ba
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