FORD MUSTANG 2003 Workshop Manual

7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or
blisters. These are caused by sudden acceleration.
zClean the spark plug. Klj . 3 ba
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GENERAL PROCEDURES
Exhaust Manifold —
Inspection
1. Place a straight edge across the exhaust manifold flanges and check for warping with a feeler gauge.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Straight Edge
303-
D039 (D83L-4201- A) or
equivalent Klj . 1 ba
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GENERAL PROCEDURES
Bearing —
Inspection
1. Inspect bearings for the following defects. Possible causes are shown: 1. Cratering — fatigue failure.
2. Spot polishing — incorrect seating.
3. Imbedded dirt engine oil.
4. Scratching — dirty engine oil.
5. Base exposed — poor lubrication.
6. Both edges worn — journal damaged.
7. One edge worn — journal tapered or bearing not seated.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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Klj . 2 ba
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SPECIFICATIONS
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
SAE 5W-
20 Premium Synthetic Blend Motor Oil
XO- 5W20- QSP WSS-
M2C153- H Gasket and Trim Adhesive F3AZ-19B508-
AA ESE-
M2G52- A Pipe Sealant with Teflon® D8AZ-19554-
A WSK-
M2G350- A2 Silicone Gasket and Sealant F7AZ-19554-
EA WSE-
M4G323- A4 Metal Surface Cleaner F4AZ-19A536-
RA WSE-
M5B392- A Engine
Displacement 3.8L
Number of cylinders 6
Bore 96.8325 mm (3.81 in)
Stroke 86.0 mm (3.39 in)
Firing order 1-4-2-5-3-
6 Oil pressure (hot 2,500 rpm) 40-
125 psi Oil capacity 5 quarts w/filter change
Compression ratio —
Cylinder Head and Valve Train
Cylinder head gasket surface flatness 0.18 mm (0.007 in)
Combustion chamber volume 61.5-
64.5 cc Valve arrangement (front to rear) —
Valve guide bore diameter 7.015-
7.044 mm (0.276- 0.277 in) Valve stem diameter —
intake 6.955-
6.988 mm (0.2738- 0.2751 in) Valve stem diameter —
exhaust 6.929-
6.962 mm (0.2728- 0.2741 in) Valve stem diameter —
oversize (intake) 9.075-
9.055 mm (0.3573- 0.3565 in) Valve stem diameter —
oversize (exhaust) 9.063-
9.043 mm (0.3568- 0.3560 in) Valve stem diameter —
oversize (intake) 9.456-
9.436 mm (0.3723- 0.3715 in) Valve stem diameter —
oversize (exhaust) 9.444-
9.424 mm (0.3718- 0.3710 in) Valve stem-
to-guide clearance — intake 0.020-
0.069 mm (0.045- 0.090 in) Valve stem-
to-guide clearance — exhaust 0.038-
0.083 mm (0.0015- 0.0033 in) Valve head diameter —
intake 47.27 mm (1.86 in)
Valve head diameter —
exhaust 37.1 mm (1.46 in)
Valve face runout 0.05 mm (0.002 in)
Valve face angle 45.675 degrees
Valve seat width 1.5-
2.0 mm (0.06- 0.08 in) Valve seat runout (T.I.R.) 0.076 mm (0.003 in) Klj . 1 ba
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Valve seat angle 44.75 degrees
Valve spring free length —
Valve spring squareness —
Valve spring compression pressure —
valve
open (without damper) 1000 N (224 lbs) @ 29.2 mm (1.16 in)
Valve spring compression pressure —
valve
closed (without damper) 350 N (79 lbs) @ 40.7 mm (1.62 in)
Valve spring installed height 40.7 mm (1.62 in)
Valve spring installed pressure —
Rocker arm ratio 1.73
Hydraulic Lash Adjuster
Diameter 22.195-
22.212 mm (0.8738- 0.8745 in) Clearance-
to-bore 0.018-
0.068 mm (0.0007- 0.0027 in) Service limit 0.127 mm (0.005 in)
Hydraulic leakdown rate a
Collapsed lash adjuster gap —
Camshaft
Theoretical valve lift @ 0 lash —
intake 11.30 mm (0.45 in)
Theoretical valve lift @ 0 lash —
exhaust 11.47 mm (0.45 in)
Lobe lift —
intake 6.53 mm (0.257 in)
Lobe lift —
exhaust 6.57 mm (0.259 in)
Allowable lobe lift loss 0.127 mm (0.005 in)
Journal diameter 52.082-
52.108 mm (2.0505- 2.0515 in) Camshaft journal bore inside diameter —
No. 1 55.689-
55.664 mm (2.192- 2.191 in) Camshaft journal bore inside diameter —
No. 2
and No. 3 55.308-
55.283 mm (2.177- 2.176 in) Camshaft journal bore inside diameter —
No. 4 55.684-
55.664 mm (2.192- 2.191 in) Camshaft journal-
to-bearing clearance 0.025-
0.076 mm (0.001- 0.003 in) Runout 0.05 mm (0.002 in) runout of No. 2 or No. 3
relative to No. 1 and No. 4 End play 0.025-
0.150 mm (0.001- 0.006 in) Cylinder Block
Cylinder bore diameter 96.813 mm (3.81 in)
Cylinder bore maximum taper 0.050 mm (0.002 in)
Cylinder bore maximum out-of-
round 0.050 mm (0.002 in)
Main bearing bore inside diameter 68.905 mm (2.713 in)
68.885 mm (2.712 in)
Camshaft bearing bore inside diameter —
intake 47.097 mm (1.8542 in) max. 47.072 mm (1.8532
in) min. Camshaft bearing bore inside diameter —
exhaust 39.739 mm (1.5645 in) max. 39.714 mm (1.5635
in) min. Head gasket surface flatness 0.08 mm (0.003 in) in 152.0 mm (6.00 in)
Crankshaft
Main bearing journal diameter 63.983-
64.003 mm (2.5190- 2.5198 in) Klj . 2 ba
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Main bearing journal maximum taper 0.008 mm (0.0003 in) per 25 mm (1.0 in)
Main bearing journal maximum out-of-
round 0.008 mm (0.0003 in) max. in 45 degrees, 0.015
mm (0.006 in) total Main bearing journal-
to-cylinder block clearance
— desired 0.025-
0.035 mm (0.001- 0.0014 in) Main bearing journal-
to-cylinder block clearance
— allowable 0.013-
0.058 mm (0.0005- 0.0023 in) Connecting rod journal diameter 58.682-
58.702 mm (2.3103- 2.3111 in) Connecting rod journal maximum taper 0.008 mm per 25 mm (0.0003 in per in)
Connecting rod journal maximum out-of-
round 0.008 mm (0.0003 in) max. in 45 degrees, 0.015
mm (0.0006 in) total Crankshaft maximum end play 0.10-
020 mm (0.004- 0.008 in) Piston and Connecting Rod
Piston diameter —
code red 96.795-
96.782 mm (3.8108- 3.8103 in) Piston diameter —
code blue 96.808-
96.795 mm (3.8113- 3.8108 in) Piston diameter —
code yellow 96.821-
96.808 mm (3.8118- 3.8113 in) Piston-
to-cylinder bore clearance (undercoated
clearance) 0.018-
0.044 mm (0.0007- 0.0017 in) Piston ring end gap —
compression (top, in
gauge) 0.17-
0.33 mm (0.0067- 0.013 in) Piston ring end gap —
compression (bottom, in
gauge) 0.3-
0.55 mm (0.0118- 0.0217 in) Piston ring end gap —
oil ring (steel rail, in
gauge) 0.15-
0.65 mm (0.0059- 0.0256 in) Piston ring groove width —
compression (top) 1.54-
1.52 mm (0.0606- 0.0598 in) Piston ring groove width —
compression
(bottom) 1.54-
1.52 mm (0.0606- 0.0598 in) Piston ring groove width —
compression (oil) 3.05-
3.03 mm (0.1200- 0.1193 in) Piston ring width —
compression (top and
bottom) 1.460-
1.490 mm (0.0575- 0.0587 in) Piston ring width —
compression (oil) Side seal —
snug fit Piston ring-
to-groove clearance (1st and 2nd
ring) 0.030-
0.080 mm (0.0012- 0.0032 in) Piston pin bore diameter 22.94-
22.98 mm (0.9032- 0.9047 in) Piston pin diameter 23.000-
23.003 mm (0.9055- 0.9056 in) Piston pin length 63.55-
63.05 mm (2.5096- 2.4823 in) Piston pin-
to-piston fit 0.011-
0.018 mm (0.0004- 0.0007 in) Piston-
to-connecting rod clearance —
Connecting rod-
to-pin clearance Press fit 8 kilonewtons (1,800 lbs)
Connecting rod pin bore diameter —
Connecting rod length (center-
to-center) 154.66-
154.74 mm (6.0890- 6.0921 in) Connecting rod maximum allowed bend 0.04 per 25 mm (0.0016 per in)
Connecting rod maximum allowed twist 0.059 per 25 mm (0.002 per in)
Connecting rod bearing bore diameter 61.635-
61.655 mm (2.4266- 2.4274 in) Connecting rod bearing-
to-crankshaft clearance 0.025-
0.035 mm (0.001- 0.0014 in) Klj . 3 ba
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a
20- 200 seconds to leakdown 3.18 mm (0.125 in) with 225 Newtons (50 pounds) load and tappet filled
with leak- down fluid. —
desired Connecting rod bearing-
to-crankshaft clearance
— allowable 0.022-
0.069 mm (0.00086- 0.0027 in) Connecting rod side clearance 0.11-
0.49 mm (0.0047- 0.0193 in) Balance Shaft
Journal diameter 52.108-
52.082 mm (2.0515- 2.0505 in) Bore inside diameter 55.689-
55.664 mm (2.192- 2.191 in) Maximum runout 0.025 mm (0.001 in)
End play 0.075-
0.200 mm (0.003- 0.008 in)
Torque Specifications Description Nm lb-
ft lb-
in EGR transducer bracket-
to-intake manifold bolts 10 — 89
Ignition coil-
to-intake manifold bolts 6 — 53
Water outlet tube-
to-intake manifold stud bolt 10 — 89
EGR tube-
to-EGR valve nut 40 30 —
Water outlet tube-
to-front water pump bolt 10 — 89
Fuel supply manifold bolts 10 — 89
LH valve cover-
to-cylinder head bolts 10 — 89
LH valve cover-
to-cylinder head stud bolts 10 — 89
EGR tube-
to-exhaust manifold nut 40 30 —
RH valve cover-
to-cylinder head bolts 10 — 89
RH valve cover-
to-cylinder head stud bolts 10 — 89
Coolant recovery reservoir-
to-cylinder head stud bolts 10 — 89
Coolant recovery reservoir-
to-bracket bolts 5 — 44
Crankshaft pulley bolt 160 118 —
Camshaft position sensor bolts 3 — 27
Camshaft synchronizer-
to-front cover bolt 25 18 —
Front cover-
to-cylinder block bolts 25 18 —
Radiator fan shroud-
to-radiator bolts 9 — 80
Camshaft thrust plate-
to-cylinder block bolts 12 9 —
Camshaft synchronizer drive gear-
to-camshaft bolt 45 33 —
Timing chain tensioner-
to-cylinder block bolts 12 9 —
Exhaust manifold-
to-cylinder head nuts 33 24 —
Power steering pump bracket-
to-water pump nuts 20 15 —
Power steering pump bracket-
to-generator bracket bolts 20 15 —
Generator bracket-
to-cylinder head bolts 40 30 —
Exhaust manifold studs 8 — 71
A/C compressor bracket-
to-cylinder head bolts 48 35 —
A/C compressor bracket-
to-cylinder head nut 48 35 — Klj . 4 ba
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A/C compressor bracket-
to-cylinder head stud bolt 25 18 —
Oil level indicator tube-
to-cylinder head bolt 10 — 89
Coolant recovery reservoir bracket-to-
GOP bolts 9 — 80
Motor mount-
to-subframe nuts 115 85 —
Oil pan drain plug 26 19 —
Wire harness bracket to motor mount nut 27 20 —
Steering column pinch bolt 47 35 —
Front subframe-
to-body bolts 90 66 —
Front subframe-
to-shock tower bolts 115 85 —
Oil pan-to-
cylinder block bolts a — — —
Oil pan-to-
transmission bell housing 45 33 —
Main bearing bridge nuts 32 24
Oil pump cover-
to-engine front cover bolts 25 18 —
Oil pump cover-
to-engine front cover bolt 10 89 —
Oil pickup tube-
to-cylinder block bolts 25 18 —
Oil pickup tube-
to-oil pan baffle nut 48 35 —
Flywheel-
to-crankshaft bolts 80 59 —
Wire harness bracket-
to-motor mount stud- nut 27 20 —
Engine ground strap-
to-motor mount nut 27 20 —
Motor mount-
to-motor mount bracket bolts 70 52 —
RH motor mount-
to-motor mount bracket nut 70 52 —
Hood ground strap-
to-hood hinge bolt 12 9 —
Hood hinge nuts 12 9 —
Generator mounting bracket 25 18 —
Power steering pump bracket nuts 8 — 71
Power steering pump bolts 25 18 —
Valve tappet guide plate bolts 12 9 —
Generator positive cable nut 10 — 89
Power steering pressure tube to pump nut 40 30 —
Accelerator cable bracket-
to-intake manifold bolts 10 — 89
42-
pin connector bolt 10 — 89
Transmission oil cooler tube bracket-
to-motor mount bracket nut 27 20
Torque converter-
to-flywheel nuts 36 27 —
Engine-
to-transmission bolts 40 30 —
Engine mount bracket-
to-engine bolts 70 52 —
Engine mount bracket-
to-engine nuts 70 52 —
Water pump pulley bolts 25 18 —
Oil filter
b — — —
Upper intake manifold-
to-lower intake manifold bolts a — — —
Lower intake manifold-
to-cylinder head bolts a — — —
Rocker arm pivot-
to-cylinder head bolts a — — — Klj . 5 ba
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a
Refer to the procedure in this section
b Advance one- half turn after gasket contacts the sealing surface. Cylinder head bolts
a — — —
Crankshaft main bearing bolts and studs
a — — —
Connecting rod cap bolts
a — — — Klj . 6 ba
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