2003 FORD MUSTANG Oil pan

Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean and inspect the mating surfaces.
2. 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 result in future oil
leakage.
Apply the silicone gasket and sealant at the rear oil seal retainer- to-cylinder block sealing
surface.
3. 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 result in future oil
leakage.
Apply the silicone gasket and sealant at the engine front cover- to-cylinder block mating surface. 4. Install the oil pan and gasket and loosely install the bolts. Klj . 5 ba
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5. Tighten the bolts in the sequence shown in three stages.
zStage 1: Tighten to 2 Nm (18 lb- in).
z Stage 2: Tighten to 20 Nm (15 lb- ft).
z Stage 3: Tighten an additional 60 degrees.
6. Install the oil pan drain plug.
7. Raise the front subframe into position. Klj . 6 ba
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47. Remove the water pump pulley.
1. Remove the water pump pulley bolts.
2. Remove the water pump pulley.
48. Remove the bolts and belt idler pulleys.
49. NOTE: The gasket can be reused if not damaged.
Remove the oil pan. zRemove the bolts.
z Remove the oil pan. Klj . 16 ba
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2. Press the piston into the piston and connecting rod assembly.
3. Install the piston rings.
1. Using a suitable ring expander tool install the upper compression ring with the top side identification mark towards the dome.
2. Using a suitable ring expander tool install the lower compression ring with the top side
identification mark towards the dome.
3. NOTE: Assemble with end gaps up.
Using a suitable tool install the piston oil control segment ring spacer.
4. NOTE: Install one segment ring above and one segment ring below the spacer.
Using a suitable tool install the piston oil control segment rings.
5. Orient the upper compression ring gap to the center line at the rear of the piston, parallel to the wrist pin bore.
6. Orient the oil control ring gaps as shown.
7. Orient the expander ring gap and lower compression ring gap as shown. Klj . 2 ba
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Install the oil pump screen cover and tube.
26. NOTE: If not secured within four minutes, sealant must be removed and sealing area cleaned
with metal surface cleaner. Allow to dry until there are no signs of wetness, or four minutes,
whichever is longer. Failure to follow this procedure can cause future oil leakage.
If the retainer plate was removed, apply a 4 mm (0.16 in) bead of silicone gasket and sealant
around the rear oil seal retainer sealing surface.
27. Install the rear main seal retainer plate. Tighten the bolts in the sequence shown. zTighten bolts 1- 6 to 10 Nm (89 lb- in).
z Hand- tighten bolts 7 and 8.
z Tighten bolts 7 and 8 to 20 Nm (15 lb- ft).
z Tighten bolts 7 and 8 an additional 60 degrees.
28. Install the oil pan and gasket and loosely install the bolts. Klj . 12 ba
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55. Tighten the four oil pan bolts in the sequence shown in three stages.
zStage 1: Tighten to 2 Nm (18 lb- in).
z Stage 2: Tighten to 20 Nm (15 lb- ft).
z Stage 3: Tighten an additional 60 degrees.
56. Install the belt idler pulleys. 57. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil. 8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
11 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 12 W706560 Stud and Washer, Hex-
Head Pilot, M8 x 1.25 x 65
— M8 x 1.25 x 16 13 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 14 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 15 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 —
M8 x 1.25
x 26 Klj . 22 ba
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2.
CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor
Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm
(1.5 in) square area.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not
permitted. The gasket must be installed dry.
CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder
head during cylinder head installation.
NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a
few minutes prior to installation.
NOTE: RH head gasket shown; LH head gasket similar.
Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.
NOTE: Position the cylinder head(s) over the dowels on the head gasket(s).
3. NOTE: LH shown, RH similar.
Tighten the bolts in six stages in the sequence shown. zStage 1: Tighten to 40 Nm (30 lb- ft).
z Stage 2: Tighten an additional 90 degrees.
z Stage 3: Loosen the bolts a minimum of one full turn.
z Stage 4: Tighten to 40 Nm (30 lb- ft).
z Stage 5: Tighten an additional 90 degrees.
z Stage 6: Tighten an additional 90 degrees. Klj . 3 ba
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b
P=Primary, S=Secondary, E=Exhaust
c Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in
tappet.
Torque Specifications Description Nm lb-
ft lb-
in A/C compressor bolts 25 18 —
A/C peanut fittings 8 — 71
A/C muffler nut 25 18 —
Accelerator bracket bolts 10 — 89
Battery tray bolts 11 8 —
Belt idler support bracket assembly fasteners 25 18 —
Camshaft sprocket bolt 115 85 —
Coolant bypass tube studs 25 18 —
Coolant bypass tube bolts 25 18 —
Coolant hose and tube assembly bolt 25 18 —
Cooling fan motor and shroud bolts 10 — 89
Connecting rod bolt
a — — —
Engine front cover bolt a a a
Drive belt tensioner bolts 25 18 —
Cylinder head bolt
a — — —
Idler pulley bracket 25 18 —
Power steering pump bolts 25 18 —
Power steering hose fitting 65 48 —
Power steering hose bracket bolt 10 — 89
Pulley to crankshaft bolt
a — — —
EGR valve to intake manifold
a — — —
Engine coolant degas bottle bolts 10 — 89
Exhaust manifold studs 25 18 —
Generator bolts 25 18 —
Generator support bracket bolts 25 18 —
Hood prop bolt 10 — 89
Hood mounting nuts 12 9 —
Heater water inlet tube 10 — 89
Heater water outlet tube 24 18 —
Lower intake manifold-
to-cylinder head bolt a — — —
Main bearing cap bolt
a — — —
Oil filter adapter bolt 25 18 —
Oil bypass filter to adapter 50 37 —
Oil pump screen cover and tube-
to-oil pump bolt 10 — 89
Oil pan-to-
cylinder block bolt a — — — Klj . 4 ba
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