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IN-
VEHICLE REPAIR
Exhaust Manifold RH
Removal and Installation 1. Disconnect the battery negative cable. For additional information, refer to Section 414 - 01 .
2. Remove the air cleaner outlet pipe. For additional information, refer to Section 303 - 12 .
3. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system electrical and vacuum connections.
4. Disconnect the EGR tube.
5. Remove the EGR tube. 6. Raise and support the vehicle. For additional information, refer to Section 100 - 02 . SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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7. Remove the LH exhaust manifold flange nuts.
8. Remove the RH exhaust manifold flange nuts.
9. Lower the vehicle.
10. NOTE: Discard the exhaust manifold gasket.
Remove the RH exhaust manifold retaining nuts and the RH exhaust manifold.
11. To install, reverse the removal procedure. Tighten the exhaust manifold nuts in the sequence shown. Klj . 2 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-
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8. Remove the power steering pump bracket.
9. Remove the generator bracket.
10. Remove the three exhaust manifold studs.
11. NOTE: Discard the cylinder head gasket. NOTE: Record the location of the long bolts and the short bolts. Klj . 2 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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