2003 FORD MUSTANG water pump

Engine Components Item Part Number Description
1 6B288 Camshaft position sensor
2 8507 Water pump housing gasket
3 12A362 Camshaft synchronizer
4 6A618 Oil pump intermediate shaft
5 6020 Engine front cover gasket
6 6010 Cylinder block
7 6019 Engine front cover
8 6714 Oil bypass filter
9 6C315 Crankshaft position sensor
10 8501 Water pump
11 6312 Crankshaft pulley Klj . 3 ba
82003 Mustang Workshop Manual
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IN-
VEHICLE REPAIR
Engine Front Cover
Removal 1. Disconnect the battery ground 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 crankshaft pulley. For additional information, refer to Crankshaft Pulley in this
section.
4. Remove the water pump pulley.
5. Remove the retainers and position the power steering pump aside.
6. Disconnect the exhaust gas recirculation (EGR) tube.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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12. Disconnect the crankshaft position sensor electrical connector.
13. Remove the wiring harness pin-
type retainer.
14. Remove the oil filter.
15. Remove the retainers and the water pump. Klj . 3 ba
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2.
NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed
and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of
wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future
oil leakage.
Apply a small amount of silicone gasket and sealant as shown.
3. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed
and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of
wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future
oil leakage.
Install the engine front cover gasket and apply silicone gasket and sealant as shown.
4. Install the engine front cover and bolts.
5. Install the water pump. Install the nuts and bolts. Klj . 5 ba
92003 Mustang Workshop Manual
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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
92003 Mustang Workshop Manual
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27. Remove the heater water outlet tube.
28.
NOTE: Record the location of the long bolts and the short bolts.
Remove the lower intake manifold and the intake manifold gasket.
29. Remove the accessory drive belt.
30. Remove the water pump pulley. Klj . 8 ba
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z
Install the valve tappets.
z Install the tappet guide plates and retainers.
z Install the bolts.
34. NOTE: Lubricate the push rods with clean engine oil prior to installation.
Install the 12 push rods.
35. Install the 12 rocker arms. For additional information, refer to Rocker Arm in this section.
36. NOTE: Use pipe sealant with Teflon® on studs No. 4 and 6, and bolt No. 12.
Using a new gasket, install the engine front cover. Tighten the nuts and the bolts in the
sequence shown. zInstall a 135.5 mm (5.42 in) stud at location No. 5 and tighten to 7 Nm (62 lb- in).
z Install a 137 mm (5.48 in) stud at locations No. 4, 6, 7 and 10, and tighten to 7 Nm (62 lb-
in).
z Using a new gasket, install the water pump.
z Tighten bolt No. 12 to 10 Nm (89 lb- in). All other nuts and bolts are to be tightened to 28 Klj . 12 ba
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40. Install the crankshaft pulley bolt.
41. Install the camshaft synchronizer. For additional information, refer to
Section 303 - 14 .
42. Install the water pump pulley and the retaining bolts.
43. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the
sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness,
or four minutes, whichever is longer. Failure to follow this procedure can cause future oil
leakage.
Clean and apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal.
1. Apply silicone gasket and sealant to the rear main bearing cap.
2. Install the oil pan rear seal.
3. Clean the oil pan mating surfaces with metal surface cleaner and apply silicone gasket and sealant to the oil pan mating surface. Klj . 14 ba
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