2003 FORD MUSTANG length

REMOVAL AND INSTALLATION
Brake Caliper Anchor Plate
Removal
1. Remove the pads. For additional information, refer to Pads in this section.
2. Remove the anchor plate (2B292). 1. Remove and discard the anchor plate bolts.
2. Remove the anchor plate.
Installation 1. CAUTION: Use correct type and length bolts.
Follow the removal procedure in reverse order. zInstall new anchor plate bolts.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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Brake Pressure Control Valve
The brake pressure control valve proportions the pressure to the rear brakes.
zWhen the brake pedal is applied, brake fluid pressure passes through the proportioning valves
to the rear brake system until the valve split point is reached.
z Above its split point, the proportioning valve begins to reduce the hydraulic pressure to the rear
brakes, creating a balanced braking condition between the front and rear brakes.
Brake Tubes and Hoses CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion which
could result in brake tube failure.
Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly
double flared to provide strong leakproof connections. When bending the tubing to fit the underbody or
rear axle contours, be careful not to kink or crack the tube.
If a section of brake tube is damaged, the entire section must be removed and a new tube of the same
type, size, shape and length installed.
When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After
installation, bleed the brake system. For additional information, refer to Section 206 - 00 . Klj . 3 ba
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GENERAL PROCEDURES
Valve —
Spring Installed Length
1. Measure the installed length of each valve spring. zRefer to the appropriate section in Group 303 for the procedure.
z If out of specification, install new components. Refer to the appropriate section in Group
303 for the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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GENERAL PROCEDURES
Valve —
Spring Free Length
1. Measure the free length of each valve spring. zRefer to the appropriate section in Group 303 for the procedure.
z If out of specification, install new components as necessary. Refer to the appropriate
section in Group 303 for the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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GENERAL PROCEDURES
Valve Spring Strength
1. Use a Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the specified valve spring length.
zRefer to the appropriate section in Group 303 for the procedure.
z If out of specification, install new components as necessary. Refer to the appropriate
section in Group 303 for the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Pressure Gauge, Valve/Clutch
Spring
303-
006 (TOOL- 6513-DD) or
equivalent Klj . 1 ba
22003 Mustang Workshop Manual
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GENERAL PROCEDURES
Valve —
Seat Width
1. Measure the valve seat width. If necessary, grind the valve seat to specification. zMeasure the intake valve seat width.
z Measure the exhaust valve seat width.
z Recheck the valve spring installed length after the seats have been ground, and shim the
valve springs as necessary to achieve the correct installed spring length.
z Refer to the appropriate section in Group 303 for the procedure.
SECTION 303-
00: Engine System — General Information 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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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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