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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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Klj . 3 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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7. Install the camshaft thrust plate.
1. Position the camshaft thrust plate.
2. Install the bolts.
8. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic balance shaft assembly into the cylinder block. Turn the engine balance shaft driven gear so
that the timing mark aligns up with the timing mark on the engine balance shaft drive gear.
9. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and
the camshaft keyway will be at 6 o'clock on the camshaft.
Install the bolts.
10. CAUTION: Make sure the components are installed in the correct location.
NOTE: Lubricate the crankshaft main bearings prior to installation.
Install the crankshaft upper main bearings and the crankshaft upper thrust main bearing. Klj . 4 ba
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11.
CAUTION: The crankshaft journals must be protected from damage when installing
the crankshaft.
Position the crankshaft.
CAUTION: The main bearings are precision selective fit. Inspect the bearing clearance.
For additional information, refer to Section 303 - 00 .
12. NOTE: If the rear main bearing cap 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 cause
future oil leakage.
Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket
and sealant to the rear main bearing cap- to-cylinder block parting line. Klj . 5 ba
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