2003 FORD MUSTANG rocker

39. Remove the bolts and the oil pan.
40.
CAUTION: If the components are to be reinstalled, they must be installed into the
same position. Mark the components for location.
Remove the LH rocker arms. 1. Remove the bolts.
2. Remove the rocker arms. 41. Remove the LH push rods. Klj . 11 ba
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42.
NOTE: Record the location of the long bolts and the short bolts.
Remove and discard the LH cylinder head bolts.
43. Remove the LH cylinder head and gasket. Discard the gasket.
44. Remove the RH rocker arms. 1. Remove the bolts.
2. Remove the rocker arms. Klj . 12 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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N806155 Bolt (2 req'd)
92 6C315 Crankshaft position sensor
93 N806300 Stud bolt (5 req'd)
94 6C086 Engine front cover
95 N806155 Bolt
96 6B288 Camshaft position sensor
97 N606543 Bolt (4 req'd)
98 6L266 Timing chain tensioner
99 6268 Timing chain belt
100 6K297 Timing chain cover
101 6M269 Timing chain tensioner
102 6L253 Timing chain tensioner arm
103 N806184 Bolt (3 req'd)
104 19D629 A/C compressor
105 8501 Water pump
106 N806177 Bolt (4 req'd)
107 N806183 Bolt (4 req'd)
108 6621 Oil pump
109 N806201 Woodruff key
110 6333 Crankshaft main bearing (5 req'd)
111 6A341 Crankshaft thrust washer (3 req'd)
112 6C357 Crankshaft main bearing side bolt (10 req'd)
113 6010 Cylinder block
114 9439 Intake manifold gasket (2 req'd)
115 6083 Head gasket
116 6505 Exhaust valve (8 req'd)
117 6507 Intake valve (8 req'd)
118 87838 Pipe plug (8 req'd)
119 12405 Spark plug (8 req'd)
120 6F087 Dowel
121 9431 Exhaust manifold
122 6C501 Valve tappet (16 req'd)
123 6529 Rocker arm (16 req'd)
124 6049 Cylinder head, RH
125 W701681 Stud (8 req'd)
126 9Y431 Exhaust manifold gasket
127 9F485 EGR valve tube to manifold connector
128 W701706 Nut (8 req'd)
129 181198A Engine lifting eye
130 6A517 Valve stem seal (16 req'd)
131 6513 Valve spring (16 req'd)
132 Klj . 6 ba
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DESCRIPTION AND OPERATION
Body Sealer Types And Applications
Liquid Butyl Sealer
HB Fuller E709-19554-
B or equivalent meeting Ford Specification ESB-M4G162- A:
z Does not run.
z Is fast drying.
z Remains semi-elastic.
z Can be used for seam sealing on the floorpan, wheelhouse, body rocker panels, door openings,
and drip rails.
Caulking Cord
3M Strip Caulk- Black 051135-08578 or equivalent meeting Ford specification ESB-M4G32- A:
z Is a heavy- bodied, plastic base with a filler.
z Is commonly known as perma-gum.
z Is used on spot- welds holes, around moulding clips, and between surfaces not sealed with a
gasket.
Weatherstrip Adhesive
Weatherstrip and Rubber Adhesive E8AZ-19552- A or equivalent meeting Ford specification ESB-
M2G14- A:
z Is a quick drying, strong adhesive designed to hold weatherstripping onto all body panels and
surrounding metal.
Silicone Lubricant
Silicone Lubricant C0AZ-19553-AA meeting Ford specification ESR- M13P4-A:
z Is used to keep the door and the window weatherstrip pliable and soft.
z Should be applied to the weatherstrip at every lubrication period.
z Makes the door easier to close.
z Retards weatherstrip squeaks.
z Retards weatherstrip wear.
z Helps retain door window alignment by reducing friction between the glass frame and the rubber
weatherstrip.
z Should not be used prior to painting.
SECTION 501-
00: Body System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Fender
Removal and Installation
1. On the RH fender, remove the antenna base. 1. Remove the antenna base cap.
2. Remove the screws.
3. Remove the antenna base.
4. Disconnect the antenna cable from the antenna base.
2. Remove the front bumper cover. For additional information, refer to Section 501 - 19 .
3. Remove the screw, the two pin- type retainers and the front rocker panel moulding.
4. Remove the fender splash shield screw. 5. NOTE: Position the fender splash shield aside. SECTION 501-
02: Front End Body Panels 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
SECTION 501-
03: Body Closures 2003 Mustang Workshop Manual General Specifications
Item Specification
Premium Long Life Grease XG-1-
C or
XG -1-K ESA-
M1C75- B Silicone Lubricant (Aerosol) F5AZ-
19553-
AA ESR-
M13P4-A Multi-
Purpose Grease Spray XL-5 ESB-
M1C93- B Flowable air dry paintable caulk ESB-
M4G24- A Door clearance: bottom of the door to
the rocker panel 3.0-
7.0 mm (0.118- 0.275 in) parallel top to bottom within
2.0 mm (0.08 in) Door clearance: front and rear of the
door to the body 3.0-
7.0 mm (0.118- 0.275 in) parallel with the body opening
within 1.0 mm (0.04 in) Door flushness: door to the front fender -
1.0- 0.00 mm (- 0.04-0.00 in)
Torque Specifications Description Nm lb-
ft lb-
in Door latch striker plate bolts 25 18 —
Door hinge nuts and bolts 30 22 —
Luggage compartment lid hinge bolts 30 22 —
Luggage compartment lid hinge nuts 13 10 —
Rear spoiler nuts/screws 9 — 80 Klj . 1 ba
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DESCRIPTION AND OPERATION
Exterior Trim and Ornamentation
The exterior trim and ornamentation consists of the following components:
zbody side scoop
z hood scoop (if equipped)
z front spoiler (Mach 1)
z radiator grille
z rear spoiler (if equipped)
z rocker panel moulding
z roof side moulding
SECTION 501-
08: Exterior Trim and Ornamentation 2003 Mustang Workshop Manual Klj . 1 ba
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