2003 FORD MUSTANG fuel

4. Inspect for normal burning.
zCheck for light tan or gray deposits on the firing tip.
5. Inspect for pre- ignition, identified by melted electrodes and a possibly damaged insulator.
Metallic deposits on the insulator indicate engine damage. This may be caused by incorrect
ignition timing, wrong type of fuel or the unauthorized installation of a heli- coil insert in place of
the spark plug threads.
zInstall a new spark plug.
6. Inspect for overheating, identified by a white or light gray spots and with bluish- burnt
appearance of electrodes. This is caused by engine overheating, wrong type of fuel, loose spark
plugs, spark plugs with an incorrect heat range, low fuel pump pressure or incorrect ignition
timing.
zInstall a new spark plug. Klj . 2 ba
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a
20- 200 seconds to leakdown 3.18 mm (0.125 in) with 225 Newtons (50 pounds) load and tappet filled
with leak- down fluid. —
desired Connecting rod bearing-
to-crankshaft clearance
— allowable 0.022-
0.069 mm (0.00086- 0.0027 in) Connecting rod side clearance 0.11-
0.49 mm (0.0047- 0.0193 in) Balance Shaft
Journal diameter 52.108-
52.082 mm (2.0515- 2.0505 in) Bore inside diameter 55.689-
55.664 mm (2.192- 2.191 in) Maximum runout 0.025 mm (0.001 in)
End play 0.075-
0.200 mm (0.003- 0.008 in)
Torque Specifications Description Nm lb-
ft lb-
in EGR transducer bracket-
to-intake manifold bolts 10 — 89
Ignition coil-
to-intake manifold bolts 6 — 53
Water outlet tube-
to-intake manifold stud bolt 10 — 89
EGR tube-
to-EGR valve nut 40 30 —
Water outlet tube-
to-front water pump bolt 10 — 89
Fuel supply manifold bolts 10 — 89
LH valve cover-
to-cylinder head bolts 10 — 89
LH valve cover-
to-cylinder head stud bolts 10 — 89
EGR tube-
to-exhaust manifold nut 40 30 —
RH valve cover-
to-cylinder head bolts 10 — 89
RH valve cover-
to-cylinder head stud bolts 10 — 89
Coolant recovery reservoir-
to-cylinder head stud bolts 10 — 89
Coolant recovery reservoir-
to-bracket bolts 5 — 44
Crankshaft pulley bolt 160 118 —
Camshaft position sensor bolts 3 — 27
Camshaft synchronizer-
to-front cover bolt 25 18 —
Front cover-
to-cylinder block bolts 25 18 —
Radiator fan shroud-
to-radiator bolts 9 — 80
Camshaft thrust plate-
to-cylinder block bolts 12 9 —
Camshaft synchronizer drive gear-
to-camshaft bolt 45 33 —
Timing chain tensioner-
to-cylinder block bolts 12 9 —
Exhaust manifold-
to-cylinder head nuts 33 24 —
Power steering pump bracket-
to-water pump nuts 20 15 —
Power steering pump bracket-
to-generator bracket bolts 20 15 —
Generator bracket-
to-cylinder head bolts 40 30 —
Exhaust manifold studs 8 — 71
A/C compressor bracket-
to-cylinder head bolts 48 35 —
A/C compressor bracket-
to-cylinder head nut 48 35 — Klj . 4 ba
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DESCRIPTION AND OPERATION
Engine
The 3.8L engine has:
za V- block with six cylinders and splayed crankpins.
z a distributorless ignition system.
z a multiport, sequential fuel injection (SFI) system.
z overhead valves.
z hydraulic valve tappets for automatic lash adjustment.
z connecting rod parting faces that are unique with an interference fit.
z an engine dynamic balance shaft.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
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IN-
VEHICLE REPAIR
Lower Intake Manifold
Removal 1. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in
this section.
2. Partially drain the cooling system. For additional information, refer to Section 303 - 03A .
3. Relieve the fuel system pressure. For additional information, refer to Section 310 - 00 .
4. Disconnect the fuel rail pressure (FRP) sensor electrical connector and vacuum hose.
5. Disconnect the fuel supply tube spring lock coupling. For additional information, refer to Section 310 - 00 .
6. Disconnect and position the engine wire harness aside.
7. Disconnect the intake manifold runner control (IMRC) electrical connector.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Material
Item Specification
Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 Metal Surface Cleaner
F4AZ-
19A536- RA or
equivalent WSE-
M5B392- A Klj . 1 ba
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13. Disconnect the electrical connector.
14.
NOTE: Remove the fuel injection supply manifold and fuel injectors as an assembly.
Remove the bolts and the fuel injection supply manifold.
15. NOTE: For ease in installation, record the location of the short bolts and the long bolts.
Remove the lower intake manifold. 1. Remove the eight short bolts.
2. Remove the six long bolts.
3. Remove the lower intake manifold. Klj . 3 ba
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4.
NOTE: Refer to the location note made during removal and make sure the bolts are installed in
the correct location.
Tighten the bolts in two stages in the sequence shown:
zStage 1: Tighten the bolts to 5 Nm (44 lb- in).
z Stage 2: Tighten the bolts to 10 Nm (89 lb- in).
5. NOTE: Install the fuel injection supply manifold and fuel injectors as an assembly.
Install the fuel injector supply manifold and bolts. Klj . 6 ba
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11. Install the heater bypass tube. For additional information, refer to
Section 303 - 03A .
12. Connect the IMRC electrical connector.
13. Position and connect the engine wire harness. Install the pin- type retainers.
14. Connect the fuel supply tube spring lock coupling. For additional information, refer to Section 310 - 00 .
15. Connect the FRP sensor electrical connector and the vacuum hose. Klj . 8 ba
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REMOVAL
Engine
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel related components. Highly flammable mixtures are always present
and may be ignited, resulting in possible personal injury.
All vehicles
1. Drain the engine cooling system. For additional information, refer to Section 303 - 03A .
2. Recover the A/C refrigerant. For additional information, refer to Section 412 - 00 .
3. Disconnect the battery negative cable (14301). For additional information, refer to Section 414 -
01 .
4. Relieve the fuel pressure. For additional information, refer to Section 310 - 00 .
5. Disconnect the hood ground strap. SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Lifting Bracket Set, Engine
303-
D095 (D94L-6001- A) or
equivalent Spreader Bar
303-
D089 (D93P-6001- A3) or
equivalent Heavy Duty Floor Crane
014-
00071 or equivalent Klj . 1 ba
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