FORD MUSTANG 2003 Workshop Manual

56. Remove the engine dynamic balance shaft.
zRemove the bolts.
z Remove the balance shaft driven gear, thrust plate and engine dynamic balance shaft as
an assembly.
57. Remove the valve tappets. 1. Remove the bolts.
2. Remove the tappet guide plates and retainers.
3. Remove the valve tappets.
58. Remove the engine balance shaft drive gear. 1. Remove the camshaft keyway.
2. Remove the gear. Klj . 16 ba
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59. Remove the camshaft.
1. Remove the bolts.
2. Remove the camshaft thrust plate.
3. Remove the spacer.
4. Remove the camshaft.
60. Remove the bearing covers. 1. Remove the engine dynamic balance shaft bearing cover.
2. Remove the camshaft bearing cover.
61. Remove the oil pump screen cover and tube. Klj . 17 ba
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62. Remove the oil pan bridge and baffle assembly.
63.
CAUTION: The connecting rods and bearings are matched to the crankshaft
journals. Make sure the components are marked and installed in the correct location.
CAUTION: Each connecting rod and connecting rod cap are matched sets. They will
fit together only one way. Mark them before removing.
CAUTION: Care should be taken not to damage the connecting rod and the
connecting rod cap fractured joint face surface or engine damage may occur.
NOTE: Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove
the ridge or carbon deposits from each cylinder, using a cylinder ridge reamer and following the
manufacturer's instructions.
Remove the pistons. 1. Make sure the piston being removed is at the bottom of the cylinder bore.
2. Remove the bolts.
3. Remove the connecting rod cap and the lower connecting rod bearing.
4. CAUTION: Be careful to avoid damage to the cylinder wall when removing the
piston.
Push the piston and the connecting rod out of the cylinder.
64. Repeat the removal steps for the remaining pistons.
65. CAUTION: The crankshaft main bearings and the main bearing caps are matched to
the crankshaft journals. Make sure the components are marked for position. NOTE: The crankshaft main bearing located at the rear main bearing cap is the thrust bearing. Klj . 18 ba
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Remove the four main bearing caps and lower crankshaft main bearings.
1. Remove the stud bolts.
2. Remove the main bearing cap and the lower crankshaft main bearing.
66. Repeat the main bearing cap and the lower bearing removal steps for the remaining main bearing caps and the crankshaft lower main bearings.
67. CAUTION: The crankshaft journals must be protected from damage when the
crankshaft is removed.
Remove the crankshaft and the crankshaft rear seal.
68. NOTE: For ease in assembly, record the location of the crankshaft upper thrust bearing.
Remove the crankshaft upper main bearings and the crankshaft upper thrust bearing.
69. Using the camshaft bearing service set, remove the camshaft bearings. Klj . 19 ba
212003 Mustang Workshop Manual
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70. Using the camshaft bearing service set, remove the engine dynamic balance shaft bearings.
71. If equipped, remove the engine block heater. For additional information, refer to
Section 303 -
03A .
72. NOTE: For cleaning purposes, the plugs should be removed.
If necessary, remove the following: 1. the cylinder block dowels.
2. the oil gallery plugs.
3. the water jacket plugs. Klj . 20 ba
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Klj . 21 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head
Disassembly and Assembly
CAUTION: If the components are to be reinstalled, they must be installed in the same
position. Mark the components removed for location.
1. Remove the spark plugs (12405) if necessary.
2. Using the special tool, compress the valve springs (6513).
3. Remove the following: 1. The valve spring retainer key (6518).
2. The valve spring retainers (6514).
3. The valve springs (6513).
4. The valve stem seals and seats (6A517).
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
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4. Inspect the components. For additional information, refer to
Section 303 - 00 .
5. CAUTION: Lubricate the parts with clean engine oil before installing.
To assemble, reverse the disassembly procedure. Klj . 2 ba
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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Piston
Disassembly
1. Using the special tool, press the piston pin out from the connecting rod and piston assembly.
2. Remove the connecting rod from the piston.
3. Clean and inspect the connecting rod and piston. For additional information, refer to Section 303 - 00 .
Assembly SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Piston Pin Tool or equivalent
303-
D034 (D81L- 6135-A)
Material Item Specification
SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Klj . 1 ba
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1. Lubricate the piston pin and piston pin bore with clean engine oil.
2.
NOTE: The connecting rod can be installed in either direction.
Position the piston pin in the bore aligned with the connecting rod bore.
3. Using the special tool, press the piston pin into the piston and rod assembly. Klj . 2 ba
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