Section 03-01A: Engine, 3.8L
1994 Mustang Workshop Manual
REMOVAL AND INSTALLATION

Engine Assembly

 

Removal

  1. Drain engine cooling system. Refer to Section 03-03.
  1. Disconnect battery ground cable (14301).
  1. Disconnect underhood lamp wiring connector.
  1. Mark position of hood hinge (16796) and remove hood (16612) .
  1. Disconnect generator to voltage regulator wiring assembly.
  1. Remove radiator upper sight shield (8C291).
  1. Release drive belt tensioner (6B209) and remove drive belt (8620) as outlined in Section 03-05.
  1. Remove air cleaner outlet tube (9B659). Refer to Section 03-12.
  1. Disconnect electric fan motor (8C607) .
  1. Disconnect constant control relay module (CCRM) (12B581) at wiring connector and remove radiator coolant recovery reservoir (8A080). Refer to Section 03-03.
  1. Remove radiator electric motor (8K621), fan blade (8600) and fan shroud (8146) as an assembly. Refer to Section 03-03.
  1. Remove upper radiator hose (8260).
  1. Disconnect transmission oil cooler inlet and outlet tubes (automatic transmission).
  1. Disconnect heater inlet and heater return tube hoses.
  1. Disconnect lower radiator hose (8286) at water pump (8501) .
  1. Remove radiator retaining bolts and radiator (8005) . Refer to Section 03-03.
  1. Disconnect power steering pressure hose (3A719).
  1. Remove power steering pump (3A674) and power steering pump bracket (10A313) and position aside.
  1. Remove mass airflow sensor (MAF sensor) (12B579) as outlined in Section 03-14.
  1. Disconnect power steering pressure switch (PSP switch) (3N824) at wiring connector.
  1. Disconnect A/C clutch (2884) from fuel charging wiring (9D930) .
  1. Discharge A/C system. Refer to Section 12-00.
  1. Disconnect A/C compressor lines. Cap or plug open lines.
  1. Remove A/C compressor retaining bolts and remove A/C compressor (19703) .
  1. Remove wiring shield.
  1. Disconnect accelerator cable (9A758) and speed control actuator (9A825) from throttle body (9E926) .
  1. Remove accelerator cable bracket (9723) and position aside with cables.
  1. Release fuel system pressure and disconnect fuel supply hose as outlined in Section 10-01.
  1. Disconnect fuel return hose as outlined in Section 10-01.
  1. Disconnect fuel charging wiring from engine control sensor wiring (12A581) at 40-pin connector.
  1. Disconnect main vacuum source hose.
  1. Disconnect ignition control module (ICM) (12A297) at wiring connector.
  1. Disconnect fuel vapor hose.
  1. Remove A/C compressor mounting bracket (2882) with drive belt tensioner attached.
  1. Raise vehicle on hoist. Refer to Section 00-02.
  1. Position drain pan beneath engine oil pan (6675) .
  1. Drain engine oil.
  1. Remove oil bypass filter (6714).



  1. Position drain pan away from vehicle.
  1. Disconnect heated oxygen sensors (HO2S) (9F472).
  1. Remove dual converter and pipe. Refer to Section 09-00.
  1. Remove inspection plug from engine rear plate (7007) and remove torque converter bolts (automatic transmission).
  1. Remove engine-to-transmission bolts.
  1. Remove transmission oil cooler line retainers from RH front engine support insulator (6038) , if equipped.
  1. Remove nuts retaining front engine support insulator to crossmember (5025) .
  1. Remove starter motor (11002). Refer to Section 03-06.
  1. Remove ground cable and remove starter motor wire harness retainers (LH and RH sides).
  1. Partially lower vehicle.
  1. Position floor jack under transmission.
  1. Position engine lifting equipment.
  1. Remove engine assembly from vehicle.
  1. Place engine on a work stand.
 

Installation

NOTE: Lightly oil all bolt and stud threads before installation except those specifying special sealant.

  1. Install engine lifting equipment and remove engine assembly from work stand.
  1. Position engine assembly in vehicle.
  1. Install two engine-to-transmission bolts.

    NOTE: Seat LH side front engine support insulator locating pin before RH side front engine support insulator.

  1. Lower engine onto front engine support insulators and remove lifting equipment.
  1. Remove floor jack from under transmission.
  1. Tighten two engine-to-transmission bolts.
  1. Raise vehicle.
  1. Install remaining engine-to-transmission bolts. On automatic transmission, tighten all bolts to 55-68 Nm (40-50 lb-ft). On manual transmission, tighten all bolts to 38-51 Nm (28-38 lb-ft).
  1. Install torque converter bolts and tighten to 27-46 Nm (20-34 lb-ft). Install inspection plug to engine rear plate .
  1. Install and tighten front engine support insulator retaining nuts to 97-133 Nm (72-98 lb-ft).


3.8L Front Engine Support Insulators





Item Part Number Description
1A N80398-S36 Bolt (2 Req'd)
2 6038 Front Engine Support Insulator
3A N805803-S36 Stud Bolt (4 Req'd)
4 5025 Crossmember
5B N803226-S60 Nut (2 Req'd)
A Tighten to 59-81 Nm (44-60 Lb-Ft)
B Tighten to 97-133 Nm (72-98 Lb-Ft)
  1. Install starter motor. Refer to Section 03-06.
  1. Install transmission oil cooler line bracket, if equipped.
  1. Install dual converter and pipe. Refer to Section 09-00.
  1. Connect heated oxygen sensor.
  1. Install oil bypass filter.
  1. Lower vehicle.
  1. Install A/C compressor mounting bracket with drive belt tensioner attached.
  1. Connect fuel vapor hose.
  1. Install radiator coolant recovery reservoir. Connect constant control relay module at wiring connector. Refer to Section 03-03.
  1. Connect main vacuum source hose.
  1. Connect fuel charging wiring to engine control sensor wiring at 40-pin connector.
  1. Connect ignition control module at wiring connector.
  1. Remove plugs from fuel supply and return lines and connect lines as outlined in Section 10-01.
  1. Install accelerator cable bracket.
  1. Connect accelerator cable and speed control actuator to throttle body .
  1. Install wiring shield.
  1. Install A/C compressor and retaining bolts. Tighten to 41-61 Nm (30-45 lb-ft).
  1. Remove caps or plugs on A/C compressor lines and connect lines to A/C compressor .
  1. Connect A/C clutch to fuel charging wiring .
  1. Connect power steering pressure switch at wiring connector.
  1. Install mass airflow sensor as outlined in Section 03-14.
  1. Install power steering pump and bracket.
  1. Connect power steering hoses.
  1. Install radiator as outlined in Section 03-03.
  1. Connect lower radiator hose to water pump .
  1. Install heater inlet and heater return tube hoses.
  1. Install transmission cooler lines (automatic transmission).
  1. Install upper radiator hose.
  1. Install radiator electric motor, fan blade and fan shroud as an assembly. Refer to Section 03-03.
  1. Connect electric fan motor to engine control sensor wiring .
  1. Install radiator coolant recovery reservoir and connect constant control relay module at wiring connector. Refer to Section 03-03.
  1. Position drive belt. Refer to Section 03-05.
  1. Install radiator upper sight shield.
  1. Install air cleaner outlet tube to throttle body as outlined in Section 03-12.
  1. Install hood to previously marked position.
  1. Connect underhood lamp wiring.
  1. Connect battery ground cable.
  1. Refill crankcase to proper level with specified engine oil.
  1. Refill engine cooling system. Refer to Section 03-03.
  1. Drain, evacuate, pressure test and recharge A/C system. Refer to Section 12-00.
  1. Start engine and check for leaks.