2003 FORD MUSTANG rocker

GENERAL PROCEDURES
Rocker Arms —
Inspection
CAUTION: Do not attempt to true surfaces by grinding. Check the rocker arm pad, side
rails and seat for excessive wear, cracks, nicks or burrs. Check the rocker arm seat bolt for
stripped or broken threads. Install new components as ncessary or possible damage may
occur.
1. Inspect the rocker arm push rod bore for nicks, scratches, scores or scuffs. Install new components as necessary. Refer to the appropriate section in Group 303 for the procedure.
2. Inspect the pad at the valve end of the rocker arm for indications of scuffing or abnormal wear. If the pad is grooved, install a new rocker arm. Refer to the appropriate section in Group 303 for
the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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Valve seat angle 44.75 degrees
Valve spring free length —
Valve spring squareness —
Valve spring compression pressure —
valve
open (without damper) 1000 N (224 lbs) @ 29.2 mm (1.16 in)
Valve spring compression pressure —
valve
closed (without damper) 350 N (79 lbs) @ 40.7 mm (1.62 in)
Valve spring installed height 40.7 mm (1.62 in)
Valve spring installed pressure —
Rocker arm ratio 1.73
Hydraulic Lash Adjuster
Diameter 22.195-
22.212 mm (0.8738- 0.8745 in) Clearance-
to-bore 0.018-
0.068 mm (0.0007- 0.0027 in) Service limit 0.127 mm (0.005 in)
Hydraulic leakdown rate a
Collapsed lash adjuster gap —
Camshaft
Theoretical valve lift @ 0 lash —
intake 11.30 mm (0.45 in)
Theoretical valve lift @ 0 lash —
exhaust 11.47 mm (0.45 in)
Lobe lift —
intake 6.53 mm (0.257 in)
Lobe lift —
exhaust 6.57 mm (0.259 in)
Allowable lobe lift loss 0.127 mm (0.005 in)
Journal diameter 52.082-
52.108 mm (2.0505- 2.0515 in) Camshaft journal bore inside diameter —
No. 1 55.689-
55.664 mm (2.192- 2.191 in) Camshaft journal bore inside diameter —
No. 2
and No. 3 55.308-
55.283 mm (2.177- 2.176 in) Camshaft journal bore inside diameter —
No. 4 55.684-
55.664 mm (2.192- 2.191 in) Camshaft journal-
to-bearing clearance 0.025-
0.076 mm (0.001- 0.003 in) Runout 0.05 mm (0.002 in) runout of No. 2 or No. 3
relative to No. 1 and No. 4 End play 0.025-
0.150 mm (0.001- 0.006 in) Cylinder Block
Cylinder bore diameter 96.813 mm (3.81 in)
Cylinder bore maximum taper 0.050 mm (0.002 in)
Cylinder bore maximum out-of-
round 0.050 mm (0.002 in)
Main bearing bore inside diameter 68.905 mm (2.713 in)
68.885 mm (2.712 in)
Camshaft bearing bore inside diameter —
intake 47.097 mm (1.8542 in) max. 47.072 mm (1.8532
in) min. Camshaft bearing bore inside diameter —
exhaust 39.739 mm (1.5645 in) max. 39.714 mm (1.5635
in) min. Head gasket surface flatness 0.08 mm (0.003 in) in 152.0 mm (6.00 in)
Crankshaft
Main bearing journal diameter 63.983-
64.003 mm (2.5190- 2.5198 in) Klj . 2 ba
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A/C compressor bracket-
to-cylinder head stud bolt 25 18 —
Oil level indicator tube-
to-cylinder head bolt 10 — 89
Coolant recovery reservoir bracket-to-
GOP bolts 9 — 80
Motor mount-
to-subframe nuts 115 85 —
Oil pan drain plug 26 19 —
Wire harness bracket to motor mount nut 27 20 —
Steering column pinch bolt 47 35 —
Front subframe-
to-body bolts 90 66 —
Front subframe-
to-shock tower bolts 115 85 —
Oil pan-to-
cylinder block bolts a — — —
Oil pan-to-
transmission bell housing 45 33 —
Main bearing bridge nuts 32 24
Oil pump cover-
to-engine front cover bolts 25 18 —
Oil pump cover-
to-engine front cover bolt 10 89 —
Oil pickup tube-
to-cylinder block bolts 25 18 —
Oil pickup tube-
to-oil pan baffle nut 48 35 —
Flywheel-
to-crankshaft bolts 80 59 —
Wire harness bracket-
to-motor mount stud- nut 27 20 —
Engine ground strap-
to-motor mount nut 27 20 —
Motor mount-
to-motor mount bracket bolts 70 52 —
RH motor mount-
to-motor mount bracket nut 70 52 —
Hood ground strap-
to-hood hinge bolt 12 9 —
Hood hinge nuts 12 9 —
Generator mounting bracket 25 18 —
Power steering pump bracket nuts 8 — 71
Power steering pump bolts 25 18 —
Valve tappet guide plate bolts 12 9 —
Generator positive cable nut 10 — 89
Power steering pressure tube to pump nut 40 30 —
Accelerator cable bracket-
to-intake manifold bolts 10 — 89
42-
pin connector bolt 10 — 89
Transmission oil cooler tube bracket-
to-motor mount bracket nut 27 20
Torque converter-
to-flywheel nuts 36 27 —
Engine-
to-transmission bolts 40 30 —
Engine mount bracket-
to-engine bolts 70 52 —
Engine mount bracket-
to-engine nuts 70 52 —
Water pump pulley bolts 25 18 —
Oil filter
b — — —
Upper intake manifold-
to-lower intake manifold bolts a — — —
Lower intake manifold-
to-cylinder head bolts a — — —
Rocker arm pivot-
to-cylinder head bolts a — — — Klj . 5 ba
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Engine Front Cover Components 9 6A666 Positive crankcase ventilation valve
10 6565 Push rod
11 6564 Rocker arm
12 6A528 Rocker arm seat
13 N807699 Bolt
14 6518 Valve spring retainer key
15 6514 Valve spring retainer
16 6513 Valve spring
17 6A517 Valve stem seal
18 611497 Bolt
19 6049 Cylinder head —
LH 20 9448 Exhaust manifold gasket —
LH 21 17A084 Engine lifting eye
22 6754 Oil level indicator tube
23 9430 Exhaust manifold —
LH 24 6507 Intake valve
25 6505 Exhaust valve
26 6051 Head gasket —
LH 27 6051 Head gasket —
RH 28 9448 Exhaust manifold gasket —
RH 29 9430 Exhaust manifold —
RH 30 17A084 Engine lifting eye Klj . 2 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
22003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

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
22003 Mustang Workshop Manual
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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
32003 Mustang Workshop Manual
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1.
NOTE: Lubricate the parts with clean engine oil.
To install, reverse the removal procedure. Tighten the rocker arm bolts in two stages. zStage 1: Tighten to 5 Nm (44 lb- in).
z Stage 2: Tighten to 35 Nm (26 lb- ft). Klj . 3 ba
32003 Mustang Workshop Manual
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