engine FORD MUSTANG 2003 Workshop Manual

A/C compressor bracket-
to-cylinder head stud bolt 25 18 —
Oil level indicator tube-
to-cylinder head bolt 10 — 89
Coolant recovery reservoir bracket-to-
GOP bolts 9 — 80
Motor mount-
to-subframe nuts 115 85 —
Oil pan drain plug 26 19 —
Wire harness bracket to motor mount nut 27 20 —
Steering column pinch bolt 47 35 —
Front subframe-
to-body bolts 90 66 —
Front subframe-
to-shock tower bolts 115 85 —
Oil pan-to-
cylinder block bolts a — — —
Oil pan-to-
transmission bell housing 45 33 —
Main bearing bridge nuts 32 24
Oil pump cover-
to-engine front cover bolts 25 18 —
Oil pump cover-
to-engine front cover bolt 10 89 —
Oil pickup tube-
to-cylinder block bolts 25 18 —
Oil pickup tube-
to-oil pan baffle nut 48 35 —
Flywheel-
to-crankshaft bolts 80 59 —
Wire harness bracket-
to-motor mount stud- nut 27 20 —
Engine ground strap-
to-motor mount nut 27 20 —
Motor mount-
to-motor mount bracket bolts 70 52 —
RH motor mount-
to-motor mount bracket nut 70 52 —
Hood ground strap-
to-hood hinge bolt 12 9 —
Hood hinge nuts 12 9 —
Generator mounting bracket 25 18 —
Power steering pump bracket nuts 8 — 71
Power steering pump bolts 25 18 —
Valve tappet guide plate bolts 12 9 —
Generator positive cable nut 10 — 89
Power steering pressure tube to pump nut 40 30 —
Accelerator cable bracket-
to-intake manifold bolts 10 — 89
42-
pin connector bolt 10 — 89
Transmission oil cooler tube bracket-
to-motor mount bracket nut 27 20
Torque converter-
to-flywheel nuts 36 27 —
Engine-
to-transmission bolts 40 30 —
Engine mount bracket-
to-engine bolts 70 52 —
Engine mount bracket-
to-engine nuts 70 52 —
Water pump pulley bolts 25 18 —
Oil filter
b — — —
Upper intake manifold-
to-lower intake manifold bolts a — — —
Lower intake manifold-
to-cylinder head bolts a — — —
Rocker arm pivot-
to-cylinder head bolts a — — — Klj . 5 ba
62003 Mustang Workshop Manual
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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
12003 Mustang Workshop Manual
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DESCRIPTION AND OPERATION
Engine Component View
Cylinder Heads and Valve Train Components
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Item Part Number Description
1 9D477 EGR valve-to-
exhaust manifold tube 2 6C342 Crankcase ventilation hose
3 6582 Valve cover —
RH 4 12405 Spark plug
5 6049 Cylinder head —
RH 6 6582 Valve cover —
LH 7 6766 Oil fill cap
8 6758 Crankcase ventilation tube Klj . 1 ba
82003 Mustang Workshop Manual
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Engine Front Cover Components 9 6A666 Positive crankcase ventilation valve
10 6565 Push rod
11 6564 Rocker arm
12 6A528 Rocker arm seat
13 N807699 Bolt
14 6518 Valve spring retainer key
15 6514 Valve spring retainer
16 6513 Valve spring
17 6A517 Valve stem seal
18 611497 Bolt
19 6049 Cylinder head —
LH 20 9448 Exhaust manifold gasket —
LH 21 17A084 Engine lifting eye
22 6754 Oil level indicator tube
23 9430 Exhaust manifold —
LH 24 6507 Intake valve
25 6505 Exhaust valve
26 6051 Head gasket —
LH 27 6051 Head gasket —
RH 28 9448 Exhaust manifold gasket —
RH 29 9430 Exhaust manifold —
RH 30 17A084 Engine lifting eye Klj . 2 ba
82003 Mustang Workshop Manual
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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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Item Part Number Description
1 9F797 Engine wire harness
2 9E926 Throttle body
3 9F670 Idle air control gasket
4 9F715 Idle air control valve
5 9E498 Emissions vacuum harness
6 9424 Intake manifold (upper)
7 9H486 Intake manifold gasket (upper)
8 12029 Ignition coil Klj . 4 ba
82003 Mustang Workshop Manual
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Cylinder Block and Lower End Components 9 18801 Radio ignition interference capacitor
10 12281 Ignition wire set —
LH 11 18696 Tube assembly
12 9424 Intake manifold (lower)
13 9439 Intake manifold gasket —
RH 14 9439 Intake manifold gasket —
LH 15 9A424 Intake manifold seal (rear)
16 6A008 Cylinder head-
to-block dowel 17 6010 Cylinder block
18 6A373 Engine rear plate (automatic transmission)
19 6375 Flywheel (automatic transmission)
20 6375 Flywheel (manual transmission)
21 6A372 Engine rear plate (manual transmission)
22 6723 Oil pan rear seal
23 6675 Oil pan
24 7120 Pilot bushing
25 9278 Oil pressure sensor
26 9B339 Oil pressure sensor fitting
27 9A424 Intake manifold seal (front)
28 18663 Heater water outlet tube
29 8255 Thermostat housing-
to-intake manifold gasket 30 8592 Water outlet connection
31 9875 Water thermostat
32 9D475 EGR valve
33 9H465 Vacuum control solenoid
34 9723 Accelerator cable bracket
35 9E936 Throttle body gasket
36 9J433 EGR transducer
37 9E498 Vacuum hose
38 12280 Ignition wire set —
RH Klj . 5 ba
82003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Item Part Number Description
1 6255 Distributor drive gear
2 6268 Timing chain
3 6A303 Engine balance shaft drive gear
4 6A304 Engine balance shaft driven gear
5 6C341 Balance shaft thrust plate
6 6A311 Engine dynamic balance shaft
7 W705934 Woodruff key
8 6261 Camshaft bearing Klj . 6 ba
82003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

DIAGNOSIS AND TESTING
Engine
Refer to
Section 303 - 00 for basic mechanical concerns or refer to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual for driveability concerns. SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

IN-
VEHICLE REPAIR
Upper Intake Manifold
Removal 1. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 .
2. Remove the engine air cleaner outlet pipe. For additional information, refer to Section 303 - 12 .
3. Disconnect the vacuum hose and the idle air control (IAC) valve electrical connector.
4. Disconnect the throttle position (TP) sensor electrical connector and the evaporative emissions (EVAP) return tube.
5. Disconnect the accelerator and the speed control cables from the throttle body cam. 6. Remove the bolts and position the accelerator cable bracket assembly aside. SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
82003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...