engine FORD MUSTANG 2003 Workshop Manual

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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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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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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ASSEMBLY
Engine
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Special Tool(s)
Slide Hammer
307-
005 (T59L- 100-B) Remover Adapter, Vibration
Damper
303-
176 (T82L-6316- B) Installer, Crankshaft Front Seal
303-
474 (T94P-6701- AH) Replacer, Steering Pump
Pulley
211-
009 (T65P-3A733- C) Engine Lift Bracket Set
303-
D095 (D94L-6001- A) Replacer, Rear Crankshaft
Seal
303-
516 (T95P-6701- BH) Spacer, Rear Crank Seal
Replacer
303-
561 (T96T-6701- B) Adapter, Crankshaft Rear Seal
(Use only the adapter retaining
bolts)
303-
518 (T95P-6701- DH) Klj . 1 ba
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CAUTION: The moving components must be lubricated with clean engine oil before
assembly.
CAUTION: The components with oil holes must be correctly aligned with the oil feed
holes.
1. If necessary, install the following: 1. the cylinder block dowels.
2. the oil gallery plugs.
3. the water jacket plugs.
2. If equipped, install the engine coolant heater. For additional information refer to Section 303 -
03A .
3. Using the camshaft bearing service set, install the engine dynamic balance shaft bearings. Adapter, Crankshaft Rear Seal
(Use only the adapter and the
center jack screw)
303-
S560 (T96T-6701- A) Spreader Bar
303-
D089 (D93P-6001- A3)
Material Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA or equivalent WSE-
M5B392-
A Silicone Gasket and Sealant
F7AZ-
19554- EA or equivalent WSE-
M4G323-
A4 SAE 5W-
20 Premium Synthetic
Blend Motor Oil
XO- 5W20-QSP or equivalent WSS-
M2C153-
H Pipe Sealant with Teflon®
XW7Z-19554-
AA WSK-
M2G350-
A2 Klj . 2 ba
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4. Using the camshaft bearing service set, install the camshaft bearings.
5. Install the following:
1. the engine dynamic balance shaft bearing cover.
2. the camshaft bearing cover.
6. CAUTION: Do not damage the camshaft lobes when installing the camshaft.
Install the camshaft and the camshaft spacer. Klj . 3 ba
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