2003 FORD MUSTANG Workshop Manual

cruise control brakes reset sun roof fuse diagram height adjustment night vision

Page 937 of 4378

FORD MUSTANG 2003 Workshop Manual 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 beari

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
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Page 938 of 4378

FORD MUSTANG 2003 Workshop Manual 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
— allowab

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
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Page 939 of 4378

FORD MUSTANG 2003 Workshop Manual 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-
t

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
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Page 940 of 4378

FORD MUSTANG 2003 Workshop Manual 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 — —

Page 941 of 4378

FORD MUSTANG 2003 Workshop Manual DESCRIPTION AND OPERATION
Engine
The 3.8L engine has:
�za V- block with six cylinders and splayed crankpins.
�z a distributorless ignition system.
�z a multiport, sequential fuel injection (SFI)

Page 942 of 4378

FORD MUSTANG 2003 Workshop Manual DESCRIPTION AND OPERATION
Engine Component View
Cylinder Heads and Valve Train Components
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Item Part Number Description
1 9D477 E

Page 943 of 4378

FORD MUSTANG 2003 Workshop Manual Engine Front Cover Components 9 6A666 Positive crankcase ventilation valve
10 6565 Push rod
11 6564 Rocker arm
12 6A528 Rocker arm seat
13 N807699 Bolt
14 6518 Valve spring retainer

Page 944 of 4378

FORD MUSTANG 2003 Workshop Manual Engine Components Item Part Number Description
1 6B288 Camshaft position sensor
2 8507 Water pump housing gasket
3 12A362 Camshaft synchronizer
4 6A618 Oil pump intermediate shaft
5 6

Load next 8 pages

Page: < prev 1-10 ... 905-912 913-920 921-928 929-936 937-944 945-952 953-960 961-968 969-976 ... 4384 next >

start stop button cabin filter washer fluid belt air conditioning brake sensor