length FORD MUSTANG 2003 Owner's Manual

a
With installation of a new filter. Head gasket surface flatness 0.15 mm (0.006 in) max. overall
Crankshaft
Main bearing journal diameter 67.493 mm
Main bearing journal maximum taper 0.05 mm
Main bearing journal maximum out-
of round 0.05 mm
Main bearing journal-
to-cylinder block clearance 0.023-
0.055 mm Connecting rod journal diameter 56.866-
56.886 mm Connecting rod journal maximum taper 0.004 mm (0.0002 in)
Connecting rod journal maximum out-of-
round 0.004 mm (0.0002 in)
Crankshaft maximum end play 0.130-
0.301 mm Thrust bearing journal diameter 67.493 mm
Thrust bearing journal maximum out-
of round 0.05 mm
Thrust bearing journal maximum taper 0.05 mm
Thrust bearing journal length 17.725-
17.775 mm Piston and Connecting Rod
Piston diameter 90.180-
90.191 mm Piston-
to-cylinder bore clearance -
0.010/+0.026 mm Piston ring end gap —
compression (top) 0.30 mm
Piston ring end gap —
compression (bottom) 0.50 mm
Piston ring end gap —
compression (oil ring) 0.65 mm
Piston ring groove width —
compression (top) 1.53-1.549 mm
Piston ring groove width —
compression (bottom) 1.519-
1.539 mm Piston ring groove width —
oil ring 3.031-
3.055 mm Piston ring width —
compression (top) 1.47-
1.49 mm Piston ring width —
compression (bottom) 1.47-
1.49 mm Piston ring width —
oil ring 2.854-
2.984 mm Piston ring-
to groove clearance — compression (top) 0.04-0.079 mm
Piston ring-
to groove clearance — compression (bottom) 0.029-
0.069 mm Piston ring-
to groove clearance — oil ring 0.047-
0.201 mm Piston pin bore diameter 22.0042-
21.998 mm Piston pin diameter 21.991-
29.994 mm Piston pin length 61.60-
62.03 mm Piston pin-
to-piston fit 0.0058-
0.0132 mm Connecting rod-
to-pin clearance 0.018-
0.033 mm Connecting rod pin bore diameter 22.012-
22.024 mm Connecting rod length 150.7 mm
Connecting rod maximum allowed bend 0.038 mm per 25 mm
Connecting rod maximum allowed twist 0.050 mm per 25 mm
Connecting rod bearing bore diameter 56.866-
56.886 mm Connecting rod bearing-
to-crankshaft clearance 0.027-
0.069 mm Connecting rod side clearance 0.15-
0.45 mm Klj . 3 ba
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7.
CAUTION: The bolts are different lengths and must be returned to their original
location.
NOTE: RH shown; LH similar.
Remove the bolts and the timing chain guides (6K297).
Installation 1. CAUTION: Timing chain procedures must be followed exactly or damage to the
pistons or valves will result.
Compress the tensioner plunger, using a soft- jawed vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation. zRemove the tensioner from the vise. Klj . 3 ba
72003 Mustang Workshop Manual
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Valve Head Diameter
·
Intake 37 mm (1.46 inch)
·
Exhaust 30 mm (1.18 inch)
·
Gauge Diameters 35.0 and 28.0 mm (1.378-
1.102 inch) Valve Face Runout Limit 0.05 mm (0.002 inch)
Valve Face Angle 45.5 degrees
Valve Stem Diameter (Std)
·
Intake 6.975-
6.995 mm (0.2754- 0.2746 inch) ·
Exhaust 6.949-
6.970 mm (0.2744- 0.2736 inch) Valve Springs
·
Compression Pressure (N (Lb) @ Spec
Length) ·
Intake 711.47 N @ 26.19 mm (159.9 Lb-
Ft @ 1.031
inch) ·
Exhaust 711.47 N @ 26.19 mm (159.9 Lb-
Ft @ 1.031
inch) ·
Free Length (Approximate) ·
Intake 42.16 mm (1.6598 inch)
·
Exhaust 42.16 mm (1.6598 inch)
·
Installed Pressure (N (Lb- Ft) @ Spec. Length) ·
Intake 289.1 N @ 36.14 mm (64.99 Lb-
Ft @ 1.4228
inch) ·
Exhaust 289.1 N @ 36.14 mm (64.99 Lb-
Ft @ 1.4228
inch) ·
Service Limit 10% Pressure Loss @ 28.02 mm (1.103 inch)
Roller Follower
·
Ratio 1.8:1
Hydraulic Lash Adjuster
·
Diameter (Std) 16.000-
15.988 mm (0.6299- 0.6294 inch) ·
Clearance to Bore 0.018-
0.069 mm (0.000709- 0.002717 inch) ·
Service Limit 0.016 mm (1.0006299 inch)
·
Hydraulic Leakdown Rate d 5-
25 seconds ·
Collapsed Lash Adjuster Gap— Desired 0.80-
1.20 mm (0.0315- 0.0472 inch) CAMSHAFT
Theoretical Valve Lift @ Zero Lash
·
Intake (Primary) 10.0 mm (0.3937 inch)
·
Intake (Secondary) 10.0 mm (0.3937 inch)
·
Exhaust 10.0 mm (0.3937 inch)
End Play 0.025-
0.165 mm (0.00098- 0.00649 inch) ·
Service Limit 0.190 mm (0.007480 inch)
Journal to Bearing Clearance 0.025-
0.076 mm (0.00098- 0.002992 inch) ·
Service Limit 0.100 mm (0.003937 inch) MAX
Journal Diameter (All) 26.962-
26.936 mm (1.0615- 1.0605 inch) Klj . 2 ba
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Bearing Inside Diameter (All) 27.012-
26.987 mm (1.0635- 1.0625 inch) Front Bearing Location e
CYLINDER BLOCK
·
Head Gasket Face Flatness 0.15 mm (0.006 in) MAX overall
·
Head Gasket Surface Finish b Main Bearing Bore Diameter 72.400-
72.424 mm (2.8504- 2.8513 inch) CRANKSHAFT
Main Bearing Journal Diameter 67.481-
67.505 mm (2.6567269- 2.6576718 inch) Connecting Rod Journal
·
Diameter 52.983-
53.003 mm (2.085941- 2.086728 inch) Crankshaft Free End Play 0.130-
0.301 mm (0.005118- 0.011850 inch) Crankshaft Runout to Rear Face of Block 0.050 mm (0.01969 inch) MAX
Connecting Rod Bearings
Clearance to Crankshaft
·
Desired 0.027-
0.069 mm (0.0010629- 0.0027165 inch) ·
Allowable 0.027-
0.069 mm (0.0010629- 0.0027165 inch) Bearing Wall Thickness (Std)
f 1.920-
1.928 mm (0.075591- 0.075905 inch) Main Bearings
Clearance to Crankshaft
·
Desired 0.025-
0.045 mm (0.00098- 0.00177 inch) ·
Allowable 0.025-
0.050 mm (0.00098- 0.00197 inch) Bearing Wall Thickness (Std)
f 2.451 mm (0.0965 inch)
Connecting Rod
·
Pin Bore Diameter 22.012-
22.024 mm (0.86661- 0.86708 inch) ·
Crankshaft Bearing Bore Diameter 56.866-
56.886 mm (2.23881- 2.23960 inch) ·
Length (Center- to-Center) 150.7 mm (5.933 inch)
Alignment (Bore-To-
Bore Max. Diff.) g ·
Twist 0.050 per 25 mm (0.00197 per 0.9843 inch)
·
Bend 0.038 per 25 mm (0.00150 per 0.9843 inch)
Side Clearance (Assembled to Crank)
·
Standard 0.15-
0.45 mm (0.00591- 0.01772 inch) ·
Service Limit 0.50 mm (0.01969 inch) MAX
CYLINDER BORE AND PISTON
Cylinder Bore
Diameter
h ·
Surface Finish (RMS) 0.2-
0.6 Microns ·
Out- of-Round Limit 0.015 mm
·
Out- of-Round Service Limit 0.020 mm
·
Taper Service Limit 0.006 mm
Piston
·
Diameter i .028 mm (.0010 inch) Klj . 3 ba
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a
Newly Installed— Refers to the condition of the "NEW" drive belt before the engine has made no more
than one rotation and before the belt has had a chance to stretch or seat into the pulley grooves.
c P=Primary, S=Secondary, E=Exhaust
d Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in
tappet.
e Distance front edge of bearing is installed below front face of cylinder block.
f 0.050 Undersize— add 0.025 to standard thickness.
g Pin bore and crank bearing bore must be parallel and in same vertical plane within the specified total
difference when measured at the ends of a 203 mm bar, 101.5 mm on each side of rod centerline.
h Cylinder Bore Diameter
Red— 90.200-90.213
Blue— 90.213-90.226
Yellow— 90.226-90.239 ·
Coded Red 1 90.167-
90.188 mm (3.299- 3.5505 inch) ·
Coded Blue 2 90.180-
90.195 mm (3.5504- 3.5510 inch) ·
Coded Yellow 3 90.198-
90.208 mm Coated Piston-
to-Bore Clearance -
0.010/+0.026 mm (- 0.0003937/+0.0010236 inch) Pin Bore Diameter 21.9985-
22.0025 mm (0.866081- 0.866238 inch) Ring Groove Width
·
Compression (Top) 1.230-
1.250 mm (0.484- 0.0492 inch) ·
Compression (Bottom) 1.520-
1.540 mm (0.05984- 0.06062 inch) ·
Oil Ring 3.030-
3.055mm Piston Pin
·
Length 61.601-
62.030 mm (2.42523- 2.44212 inch) ·
Diameter 22.0005-
22.0030 mm (0.8661596- 0.8662581
inch) Pin to Piston Fit
j -
0.0045/+0.002 mm (- 0.000177/+0.0000787 inch) Pin to Rod Clearance
·
Standard 0.004-
0.0175 mm (0.000157- 0.00689 inch) ·
Service Limit 0.035 mm (0.001378 inch)
Oil Ring 1.15 mm (0.04528 inch) MAX
·
Side Clearance .075
-.1000 mm (.0030 -.0040 inch) ·
Compression (Top) 0.0090-
0.0235 mm (0.000354- 0.000925 inch) ·
Compression (Bottom) 0.030-
0.080 mm (0.00118- 0.00315 inch) ·
Oil Ring Snug Fit
Ring Gap
k ·
Compression (Top) .150
-.300 mm (.006- 0.0018 inch) ·
Compression (Bottom) 0.300-
0.550 mm (0.0018- 0.0022 inch) ·
Oil Ring (Steel Rail) 0.15-
0.66 mm (0.00591- 0.02598 inch) Piston Rings
·
Ring Gap ·
Compression (Top) 1.00 mm (0.03937 inch) MAX
·
Compression (Bottom) 1.00 mm (0.03937 inch) MAX
·
Service Limit 1.15 mm (0.04528 inch) MAX
LUBRICATION SYSTEM
Oil Capacity (Quarts U.S.)
6 ±
0.25 l Klj . 4 ba
62003 Mustang Workshop Manual
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7.
CAUTION: The bolts are different lengths and must be returned to their original
location.
NOTE: RH shown; LH similar.
Remove the bolts and the timing chain guides.
Installation 1. CAUTION: Timing chain procedures must be followed exactly or damage to the
pistons or valves will result.
Compress the tensioner plunger, using a soft- jawed vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation. zRemove the tensioner from the vise. Klj . 3 ba
72003 Mustang Workshop Manual
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42. Install the 1-
2 accumulator retaining ring.
43. NOTE: This is not an ordinary installation procedure and does not compensate for band wear.
When new piston and rod assembly installation becomes necessary, or when a new reverse
band has been installed, the reverse piston and rod length must be adjusted.
NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal.
NOTE: Do not install the reverse servo piston cover and seal at this time.
Install the reverse servo piston and rod assembly.
44. Install the special tool. zTighten the bolt. Klj . 15 ba
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1. Using the special tool, install the input shaft seal.
2.
NOTE: In installing a new input shaft seal as part of a transmission overhaul, do not install the
end play selective shims at this time.
Instal the end play selective shims and the bearing race.
3. Using a press and a capped length of pipe, install the input bearing. Klj . 2 ba
32003 Mustang Workshop Manual
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13. Install the output shaft rear bearing.
14. Lubricate the splines of the fifth speed driven gear with petroleum jelly.
15.
CAUTION: Align the output shaft splines and the splines of the fifth speed driven
gear or damage will occur.
Position the fifth speed driven gear on the output shaft. Using a press and a capped length of
pipe 31.7 mm (1.26 in) inside diameter X 356 mm (14.24 in) long, install the fifth speed driven
gear.
16. Install the snap ring. Klj . 8 ba
102003 Mustang Workshop Manual
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tool to prevent axial scratches which may cause future leaks.
Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and
free of scratches or foreign material.
7. Clean the fitting with a lint- free cloth.
8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component.
9. Clean the O- ring seal grooves with a 300 mm (12 inch) length of natural fiber string.
z Loop the string around the grooves and pull the string back and forth.
10. Remove any foreign material from the grooves with a lint- free cloth.
Connect 1. Install the A/C tube lock coupling spring.
2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R- 134a Systems) or
equivalent. Klj . 4 ba
62003 Mustang Workshop Manual
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