Rebuilding a 2002 3.8L mustang engine - Mustang Evolution

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Old 08-09-2015, 11:20 PM   #1
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Rebuilding a 2002 3.8L mustang engine

Hello guys. I've never been the type to start a thread on any forums because I've never done anything too exciting with my car. But now I'm actually making a huge step!!! I'm deciding to rebuild an engine! I own a 2003 3.8L silver mustang. Appearance wise, my mustang stays under the radar, which I really like... It has smoked headlights, blue under lights on the interior, and chrome 18" wheels that are 9" wide all around (Honestly not a big fan of the wheels imo... But don't want to mess with it till after this is finished). But performance wise it has little to nothing... It has a dual catback magnaflow exhaust system and high performance flowmaster midpipes. But recently I've bought a really nice engine for super cheap and I HAD to get it! So I'm going to post how this build will go on here, that way later on I can come back to these videos and pictures to see how a certain thing went on. So here's the list of things I want to do. I may forget something's but if I do you guys can let me know, or just let me know if you don't think a certain thing I do will work out. But I've been doing a lot of research the past couple of years and I've rebuilt a couple engines but not a ford engine. But I'm very open minded so if you think something will be easier or don't think something will work please let me know! So here's the list:

- bbk shorty headers
- comp cams
- 03/04 cobra CAI
- m112 supercharger adapter
- eaton m112 supercharger
- 39# fuel injectors
- 90 mm lightening MAF
- IAT sensor
- IAT pigtail
- idler pulley and mounting bracket
- ported lower intake manifold

Then we have things that might go on as well but I'm still debating whether to do it or not:

- 4.2l crankshaft
- 4.2l pistons
- ported cylinder heads

After all this I would get a tune to bring everything together and I would probably want to run premium after the guild also and use e85 when I go to the tracks.

Now that I look at the list... It seems a little small... Haha!!! I know I'm forgetting a couple things but now for pictures!

Here's my mustang
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And here's my engine that I have for her
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Like I said, I'll try my best to post every time I do something with the engine. So far I've only taken hoses, belts, spark plug wires, alternator, headers, egr and upper intake manifold off. They were all pretty straight forward on how to take off. There's 12 bolts holding down the manifold and I think 3 connectors that need to be disconnected from the manifold before removing it. Only thing I'll have to remember is that the the upper intake manifold bolts had 4 that were on the back that were longer than the rest of them. Also I removed the iac valve and the throttle body... I believe that's all I've removed so far. Well??? so far everything is running smoothly and if something does come up and confuse me, I hope you guys will be able to help me out! Thanks for looking!
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Old 08-10-2015, 10:01 AM   #2
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That's where I get the most enjoyment out of my Mustangs, rebuilding, restoring and buying new goodies for it. I look forward to seeing your progress and finished product.

I've got a couple build threads on here. One for my 03 3.8 (SOLD), and my current one on my 04 gt and wife's 99 3.8. Lots of pictures and info, worth taking a look at for inspiration, tips, and lessons learned during my builds. I'd also encourage you to check out other members builds.

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Old 08-10-2015, 07:42 PM   #3
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I was about to ask why a 3.8l but after seeing your plans i wanna see the end result, you should also do all of the things your debating on doing
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Old 08-10-2015, 08:25 PM   #4
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hey swc, i have a 2001 3.8 thats modded to hell and back just short of a procharger.alot of people will ask you"why a v6?"but i'm like you...you have to stay true to the car.born a v6 always v6.the vin# will always prove that.but why not make it a kick a$$ 3.8 and have something alot of people don't have but will talk about.can't send any pictures of mine right now but if you want to see my motor you can go to 3.8 forums under show us those v6 pics and im about page 7 under newedge01 of course.if your gonna do all this to the motor you will have to update to a better fuel pump as well.bought mine thru Steeda for about $250.00 or if you can get your hands on an older 2000 svt focus fuel pump but you will have to rewire pump.Steeda/Walbro pump hooks right up ready to go.i'm runnin 3.73 gears now with t-loc limited slip but still using 7.5 housing.works pretty good.cars barely broke in so it hasn't made it out to raceway park yet but next summer we'll see what she does before adding boost.i went with shorty headers also,long tube headers are just a pain in the butt.better maybe but a big pain.did i mention mine was silver too.
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Old 08-11-2015, 01:25 AM   #5
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hey swc, i have a 2001 3.8 thats modded to hell and back just short of a procharger.alot of people will ask you"why a v6?"but i'm like you...you have to stay true to the car.born a v6 always v6.the vin# will always prove that.but why not make it a kick a$$ 3.8 and have something alot of people don't have but will talk about.can't send any pictures of mine right now but if you want to see my motor you can go to 3.8 forums under show us those v6 pics and im about page 7 under newedge01 of course.if your gonna do all this to the motor you will have to update to a better fuel pump as well.bought mine thru Steeda for about $250.00 or if you can get your hands on an older 2000 svt focus fuel pump but you will have to rewire pump.Steeda/Walbro pump hooks right up ready to go.i'm runnin 3.73 gears now with t-loc limited slip but still using 7.5 housing.works pretty good.cars barely broke in so it hasn't made it out to raceway park yet but next summer we'll see what she does before adding boost.i went with shorty headers also,long tube headers are just a pain in the butt.better maybe but a big pain.did i mention mine was silver too.

Yea it's not as big of a headache either with the whole suspension thing haha. But yea the fuel pump was already on the list just forgot to add it... Haha... But yea I was thinking of getting gears but not sure whether I want a 3.73 gears or 4.10 gears. That's a whole new topic though...

Hope to see the numbers for your stang!
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Old 08-11-2015, 01:41 AM   #6
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Rebuilding a 2002 3.8L mustang engine

Ok so tonight I got a lot more off the engine. Here are some pictures:

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Not sure what this is... It's connected on the back of the engine behind the fuel rail... The part number reads pet-gf30. Not sure what it is. Any ideas?
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Also this connector connected to the front driver side corner of the fuel rail... Anyone know? Maybe fuel regulator?
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A hidden connector behind the power steering pump....
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Disconnected the connectors to the fuel injectors too
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After all that the wire harness came right off
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Next thing to go was the fuel rail and the injectors. It was pretty simple to remove. Just had to pull the pins off the injectors and removed the 4 bolts that connect the fuel rail to the lower intake manifold.
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After taking those things off, with a little bit of patience the fuel rail came right off. Some injectors stayed on some came off.
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Then I started taking off miscellaneous parts off
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Then started taking off a little bigger things...
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And that's all I have for now! I wish I could video tape all this but my video camera isn't working... Pictures will have to do for now I guess! I'll post more later!
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Old 08-20-2015, 08:25 AM   #7
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Is this a tough task? Like could some one with intermediate skill take this motor apart and rebuild it? Maybe with help from youtube or internet. And if i worked on it 5-6 hours a day how long would it take?

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Old 08-20-2015, 08:41 AM   #8
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Old 08-20-2015, 08:45 AM   #9
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A big factor will be the work space available, and the tools you have. An engine stand is strongly recommended. Having not done it before, I would plan on it taking a few days providing you have all the parts and fluids on hand. More time if your going to take the heads and or block to a shop for work. It's really hard to narrow down a time. I've done it in a weekend, or when building a motor I've had it take a few weeks. Pick up a repair manual for the car and that will help a lot. A proper set of tools will save you a lot of headache as well.

Tip: Take pictures of everything. Also bag and clearly label every nut and bolt as you pull it off. This will save time when it's time to put everything back together. The pictures will be a good reference to use to make sure it all goes back together correctly.

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Old 08-20-2015, 09:48 AM   #10
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Ok so I haven't been on for a while because of work but here's where I'm at now...
I took off the 8 bolts holding on the cylinder head
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....not sure if I explained how I took off the rocker arms and push rods.... Either way they're pretty self explanatory and they're in their own separate labeled sandwich bags.

Here's a picture of it with the driver side cylinder head off...
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Then did the same thing for the other side
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And here's where I'm at now!
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So basically all I have now is the bottom end of the engine to pull off and the crankshaft pulley.... Basically I'm stuck at trying to pull the crankshaft pulley off... I just don't want to buy the stupid loaner tool haha... I know I know I'll get my money back but still... But I'll probably do it this weekend when I'm off. Other than that everything is going pretty smoothly! Figured out the impact wrench is the best tool I've ever used. Without it I would of had a hard time disassembling this engine.

So yeeeaaaa..... there's no videos for the disassembly.... Sorry guys.... My video camera is being a ****** and won't cooperate... But I'm going to try to fix it or get a new one and record the reassembly and maybe the disassembly of the bottom end... I'll be sure to post more later on! Thanks for looking!
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Old 08-20-2015, 10:00 AM   #11
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Is this a tough task? Like could some one with intermediate skill take this motor apart and rebuild it? Maybe with help from youtube or internet. And if i worked on it 5-6 hours a day how long would it take?

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Ok so first off!!! I'm not a professional mechanic.... Haha. But I was able to get to where I'm at now in less than 5 hours. You will hit some roadblocks on the way but as long as you have the right tools, it should go smoothly! I've read through my Haynes manual a couple times to understand the whole rebuild so that definitely helped me a lot! I would say that you wouldn't know how long it would really take until you fully disassemble it, because there's going to be some parts you'll need to replace and some parts you will need to get machined. And usually the reassembly takes twice as long as the disassembly because you have to make sure everything has good clearance, everything goes in smoothly without it being forced, and everything is torqued to its specifications. For me I listed it as a 2 year project max because I want to go through EVERYTHING and make sure everything is good. And also it's going to take me a while to find the right forged internals and order them for the build. For right now I'm focusing on the bottom end. I've noticed SSM had forged internals for the bottom end and was thinking of getting those (if anyone has any other places please let me know). They said nothing had to be adjusted on the block which is good because it's less of a headache for me. So yea... Couldn't give you a specific time but you should now when you've disassembled it yourself.
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Old 08-20-2015, 11:46 AM   #12
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all the top end stuff i used was from Comp Cam.they should offer everything you need.sounds like your REALLY getting serious on this build.tuned mine for race yesterday for the first time after break in and took it for a test drive.WOW!what a difference from street tune to race tune and your going beyond what ive done to mine.yours should be a rocket.after yesterday i do have to give kudos to BBK Gripp upper/lower control arms.they hook.
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Old 08-20-2015, 12:30 PM   #13
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all the top end stuff i used was from Comp Cam.they should offer everything you need.sounds like your REALLY getting serious on this build.tuned mine for race yesterday for the first time after break in and took it for a test drive.WOW!what a difference from street tune to race tune and your going beyond what ive done to mine.yours should be a rocket.after yesterday i do have to give kudos to BBK Gripp upper/lower control arms.they hook.

Yea I was actually looking into comp cams! I was just going to get the ca shafts there but it's a good idea to just get the entire top end there I guess. If anything I'll probably just build the bottom end and work on the top end later. Yea I'll have to figure out where to get mine tuned. It's probably going to be the most expensive part haha! Yea I'll have to focus on everything else once this engine is done...
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Old 08-20-2015, 03:05 PM   #14
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super six motorsports is a good place to check out if you haven't heard of them.they offer all the serious goodies for our motors.and speaking of tune,do you plan on boost right away on that motor or will there be a period of time you'll be driving prior to installing?Bama tune worked for me for about $400.00 bucks and after test drive yesterday it was well worth the money.alot of people have different opinions on who to use but Bama sure woke my v6 up.woke my a$$ up too when i hit 2nd.lol!
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Old 08-20-2015, 08:56 PM   #15
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super six motorsports is a good place to check out if you haven't heard of them.they offer all the serious goodies for our motors.and speaking of tune,do you plan on boost right away on that motor or will there be a period of time you'll be driving prior to installing?Bama tune worked for me for about $400.00 bucks and after test drive yesterday it was well worth the money.alot of people have different opinions on who to use but Bama sure woke my v6 up.woke my a$$ up too when i hit 2nd.lol!

Yea super six motorsports is my first option. And no I don't want to boost it right away cz that's a lot of money. So I'll probably leave the motor alone till I can slap a procharger on there. But I'll first need to figure out can what the compression needs to be in order for it to work with the procharger. But yea! I've heard of Bama tuners! But will they be able to tune my procharged motor with forged internals? Wasn't sure if they were capable of doing a big tune like that... Always just figured that I would have to take it to a shop to get it tuned then dyno'd. Idk! I'm not sure how it works with the whole tuning process haha
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Old 08-20-2015, 09:24 PM   #16
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super six motorsports is a good place to check out if you haven't heard of them.they offer all the serious goodies for our motors.and speaking of tune,do you plan on boost right away on that motor or will there be a period of time you'll be driving prior to installing?Bama tune worked for me for about $400.00 bucks and after test drive yesterday it was well worth the money.alot of people have different opinions on who to use but Bama sure woke my v6 up.woke my a$$ up too when i hit 2nd.lol!

Yea super six motorsports is my first option. And no I don't want to boost it right away cz that's a lot of money. So I'll probably leave the motor alone till I can slap a procharger on there. But I'll first need to figure out can what the compression needs to be in order for it to work with the procharger. But yea! I've heard of Bama tuners! But will they be able to tune my procharged motor with forged internals? Wasn't sure if they were capable of doing a big tune like that... Always just figured that I would have to take it to a shop to get it tuned then dyno'd. Idk! I'm not sure how it works with the whole tuning process haha
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Old 08-21-2015, 09:51 AM   #17
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they would be a good source to contact and they'd be able to tell ya or not but i agree about the procharger.pro dyno tune at shop.i'm not 100% positive but if you go with the stage ll procharger it should handle it,stage l will not.they say stage ll will handle any mods you throw at it.
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Old 08-31-2015, 12:10 PM   #18
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Bama can tune just about everything
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Old 08-31-2015, 12:12 PM   #19
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Bama can tune just about everything
And do an average to crappy job.
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Old 08-31-2015, 01:05 PM   #20
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With a fairly long list of things they won't tune. Which looks to be most the mods that really give our cars gains.

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