2003 FORD MUSTANG Workshop Manual

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Page 1129 of 4378

FORD MUSTANG 2003 Workshop Manual 40. Connect the battery negative cable. For additional information, refer to
Section 414 - 01 .
41. Fill the engine with clean engine oil.
42. Fill the engine cooling system. For additional inform

Page 1130 of 4378

FORD MUSTANG 2003 Workshop Manual SPECIFICATIONS
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricants and Sealants
Silicone Gasket and Sealant F7AZ-19554-
EA W

Page 1131 of 4378

FORD MUSTANG 2003 Workshop Manual Valve spring installed height 42.3-
42.9 mm (1.67- 1.69 in) Valve spring installed pressure 283.0-
321.0 N @ 42.56 mm (63.61 lb @ 1.68 in) Roller follower ratio —
intake 2.02:1
Roller follower

Valve spring installed height 42.3-
42.9 mm (1.67- 1.69 in) Valve spring installed pressure 283.0-
321.0 N @ 42.56 mm (63.61 lb @ 1.68 in) Roller follower ratio —
intake 2.02:1
Roller follower ratio —
exhaust 2.03:1
Hydraulic Lash Adjuster
Diameter 16.000-
15.988 mm (0.6299- 0.6294 in) Clearance-
to-bore 0.018-
0.069 mm (0.0007- 0.0027 in) Service limit 15.988 mm
Hydraulic leakdown rate
c 5-
25 seconds Collapsed lash adjuster gap —
desired 0.45-
0.85 mm (0.02- 0.03 in) Camshaft
Theoretical valve lift @ 0 lash —
intake 13.00 mm (0.51 in)
Theoretical valve lift @ 0 lash —
exhaust 13.75 mm (0.54 in)
Lobe lift —
intake 7.11038 mm (0.28 in)
Lobe lift —
exhaust 7.4794 mm (0.30 in)
Allowable lobe lift loss 0 mm (0.0 in)
Journal diameter 26.962-
26.936 mm (1.0615- 1.0605 in) Camshaft journal bore inside diameter 27.012-
26.987 mm (1.0635- 1.0625 in) Camshaft journal-
to-bearing clearance 0.025-
0.076 mm (0.00098- 0.002992 in) Camshaft journal-
to-bearing clearance —
service limit 0.100 mm (0.003937 in) max.
Runout —
Front and rear journals 0.03 mm (0.001 in)
Runout —
four inner journals 0.09 mm (0.003 in)
End play 0.027-
0.190 mm (0.001- 0.007 in) End play —
service limit 0.190 mm (0.007480 in)
Cylinder Block
Cylinder bore diameter 31 mm (1.24 in) from top of block
red — 90.200-90.210
blue — 90.210-90.220
yellow — 90.220-90.230 Cylinder bore maximum taper 0.70 mm (0.027559 in)
Cylinder bore maximum out-of-
round —limit 0.20 mm (0.007874 in)
Cylinder bore maximum out-of-
round —service
limit 0.70 mm (0.027559 in)
Main bearing bore inside diameter 72.400-
72.424 mm (2.8504- 2.8513 in) Crankshaft
Main bearing journal diameter 67.482-
67.504 mm (2.66- 21.661 in) Main bearing journal maximum taper 0.004 mm (0.0002 in)
Main bearing journal maximum out-of-
round 0.05 mm (0.002 in)
Main bearing journal-
to-cylinder block clearance
— desired 0.025-
0.044 mm (0.001- 0.002 in) Main bearing journal-
to-cylinder block clearance
— allowable 0.025-
0.050 mm (0.00098- 0.00197 in) Connecting rod journal diameter 52.983-
53.003 mm (2.085941- 2.086728 in) Klj . 2 ba
62003 Mustang Workshop Manual
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Page 1132 of 4378

FORD MUSTANG 2003 Workshop Manual a
With installation of a new filter.
b Distance front edge of bearing is installed below front face of cylinder block.
c Time necessary for plunger to leak down 1.6 mm of travel with 222 N force

a
With installation of a new filter.
b Distance front edge of bearing is installed below front face of cylinder block.
c Time necessary for plunger to leak down 1.6 mm of travel with 222 N force and leak down fluid in
tappet.
d Measured at 31.5 mm from top of block. Measured at 43 mm from top of piston, at 90 degrees to the
piston pin. Connecting rod journal maximum taper 0.004 mm (0.0002 in)
Connecting rod journal maximum out-of-
round 0.05 mm (0.002 in)
Crankshaft maximum end play 0.075-
0.377 mm (0.003- 0.015 in) Piston and Connecting Rod
Piston diameter —
code red 1 d 90.185-
90.205 mm (3.55- 3.551 in) Piston diameter —
code blue 2 d 90.195-
90.215 mm (3.55- 3.551 in) Piston diameter —
code yellow 3 d 90.205-
90.225 mm (3.551- 3.552 in) Piston-
to-cylinder bore clearance -0.005-
0.025 mm (- 0.002/+0.001 in) Piston ring end gap —
compression (top) e 0.130-
0.280 mm (0.005- 0.011 in) Piston ring end gap —
compression (bottom) e 0.300-
0.550 mm (0.0018- 0.0022 in) Piston ring end gap —
oil ring (steel rail) e 0.150-
0.650 mm (0.006- 0.0256 in) Piston ring groove width —
compression (top) 1.530-
1.550 mm (0.06- 0.061 in) Piston ring groove width —
compression
(bottom) 1.520-
1.540 mm (0.06- 0.061 in) Piston ring groove width —
oil ring 3.030-
3.050 mm (0.12- 0.12 in) Piston ring width —
compression (top) 1.480-
1.500 mm (0.058- 0.059 in) Piston ring width —
compression (bottom) 1.470-
1.490 mm (0.0587- 0.0586 in) Piston ring-
to-groove clearance — compression
(top) 0.050-
0.090 mm (0.002- 0.004 in) Piston ring-
to-groove clearance — compression
(bottom) 0.030-
0.080 mm (0.00118- 0.00315 in) Piston ring-
to-groove clearance — oil ring Snug fit
Piston pin bore diameter
f 21.008-
22.014 mm (0.866- 0.867 in) Piston pin diameter 22.0010-
22.0030 mm (0.87- 0.871 in) Piston pin length 61.601-
62.030 mm (2.42523- 2.44212 in) Piston pin-
to-piston fit -
0.005/+0.0135 mm (- 0.0002/+0.0005 in) Piston-
to-connecting rod clearance — standard 0.009-
0.0235 mm (0.0004- 0.00092 in) Piston-
to-connecting rod clearance — service
limit 0.035 mm (0.001378 in)
Connecting rod-
to-pin clearance 0.009-
0.023 mm (0.0004- 0.0009 in) Connecting rod pin bore diameter 22.012-
22.024 mm (0.86661- 0.86708 in) Connecting rod length (center-
to-center) 150.7 mm (5.933 in)
Connecting rod maximum allowed bend
g 0.038 per 25 mm (0.00150 per 0.9843 in)
Connecting rod maximum allowed twist
c 0.050 per 25 mm (0.00197 per 0.9843 in)
Connecting rod bearing bore diameter 56.866-
56.886 mm (2.23881- 2.23960 in) Connecting rod bearing-
to-crankshaft clearance 0.027-
0.069 mm (0.0010629- 0.0027165 in) Connecting rod side clearance —
standard 0.125-
0.475 mm (0.005- 0.019 in) Connecting rod side clearance —
service limit 0.50 mm (0.01969 in) max. Klj . 3 ba
62003 Mustang Workshop Manual
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Page 1133 of 4378

FORD MUSTANG 2003 Workshop Manual e
Specification in 90.200 mm diameter gauge.
f If applicable, measured vertically, +0.030- 0.050 mm (0.001-0.002 inch) measured horizontally (oval
pin bore).
g Pin bore and crank bearing bore mu

Page 1134 of 4378

FORD MUSTANG 2003 Workshop Manual a
Refer to the procedure in this section. Power steering reservoir bolts 10 — 89
Water outlet connector bolts 25 18 —
Camshaft cap cluster to cylinder head bolts 10 — 89
Torque conver

Page 1135 of 4378

FORD MUSTANG 2003 Workshop Manual Klj . 6 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Page 1136 of 4378

FORD MUSTANG 2003 Workshop Manual DESCRIPTION AND OPERATION
Engine
SECTION 303-
01B: Engine — 4.6L (2V) 2003 Mustang Workshop Manual Klj . 1 ba
92003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocac

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