2003 FORD MUSTANG width

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

SPECIFICATIONS
SECTION 303-
01D: Engine — Mach I 4.6L (4V) 2003 Mustang Workshop Manual General Specifications
Item Specification
Metal Surface Cleaner
F4AZ-
19A536- RA WSE-
M5B392- A Silicone Gasket and Sealant F7AZ-19554-
EA WSE-
M4G323-
A4 Motorcraft Premium Gold Engine Coolant VC-7-
A (in Oregon VC-7-B) (Yellow
Color) WSS-
M97B51- A1 Pipe Sealant with Teflon® D8AZ-19554-
A WSK-
M2G350-
A2 Motorcraft MERCON® Super Premium 5W-
20 Motor Oil XO-5W20-QSP WSS-
M2C153- H Threadlock 262 E2FZ-19554-
B WSK-
M2G351-
A6
Engine Specifications Description Specification
GENERAL SPECIFICATIONS
Displacement 4.6L (4V) (281 CID)
Number of Cylinders 8
Bore and Stroke 90.2 x 90.0 mm (3.55 x 3.54 inch)
Firing Order 1-3-7-2-6-5-4-
8 Oil Pressure (HOT 1500 RPM) 138-
310 kPa Drive Belt Tension a
Combustion Chamber Volume (cc)
52.6±
0.5 cm c Valve Seats
·
Width— Intake 1.8-
2.2 mm (0.071- 0.086 inch) ·
Width— Exhaust 1.8-
2.2 mm (0.071- 0.086 inch) ·
Angle 45 degrees
·
Runout (T.I.R.) Max 0.05 mm (0.002 inch)
Valve Arrangement (Front-
to-Rear) c ·
(Left Hand) Intake: S-P-S-P-S-P-S-P
·
Exhaust: E-E-E-E-E-E-E-E
·
(Right Hand) Intake: P-S-P-S-P-S-P-S
·
Exhaust: (C) E-E-E-E-E-E-E-E
Valve Stem to Guide Clearance
·
Intake 0.020-
0.069 mm (0.00078- 0.00272 inch) ·
Exhaust 0.046-
0.095 mm (0.0018- 0.0037 inch) Klj . 1 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

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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Ignition Coil —
Coil On Plug
The engine uses eight separate coil per plug units. Each coil per plug unit is controlled by the
powertrain control module (PCM).
Each coil per plug unit is mounted directly above each spark plug and activates its own spark plug in
the correct sequence as controlled by the PCM.
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for additional information on the
ignition system.
Intake Air Temperature (IAT) Sensor
The intake air temperature (IAT) sensor provides the sequential fuel injection (SFI) system mixture
temperature information. The IAT sensor is used both as a density corrector for air flow calculation and
to proportion cold enrichment fuel flow. The IAT sensor is installed in the air cleaner inlet tube. The IAT
sensor is also used in determining EPC pressures.
Mass Air Flow (MAF) Sensor
The mass air flow (MAF) sensor measures the mass of air flowing into the engine. The MAF sensor
output signal is used by the powertrain control module to calculate injector pulse width. For
transmission strategies, the mass air flow sensor is used to regulate EPC, shift and torque converter
clutch scheduling.
Transmission Control Switch (TCS) and Transmission Control Indicator Lamp (TCIL)
The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a
signal is sent to the PCM to allow automatic shifts from first through fourth gears or first through third
gears only. The PCM energizes the transmission control indicator lamp (TCIL) when the switch is off.
The TCIL indicates overdrive cancel mode activated (lamp on). When the TCIL is flashing, it indicates
electronic pressure control (EPC) circuit shorted or a monitored sensor failure.
Throttle Position (TP) Sensor
The throttle position (TP) sensor is a potentiometer mounted on the throttle body. The TP sensor
detects the position of the throttle plate and sends this information to the PCM. The TP sensor is used
for shift scheduling, electronic pressure control (EPC) and TCC control.
Digital Transmission Range (TR) Sensor
The digital transmission range (TR) sensor is located on the outside of the transmission at the manual
lever. The digital sensor completes the start circuit in PARK and NEUTRAL, and the back- up lamp
circuit in REVERSE. The digital sensor also opens/closes a set of four switches that are monitored by
the PCM to determine the position of the manual lever (P, R, N, D, 2, 1).
Output Shaft Speed (OSS) Sensor
The output shaft speed (OSS) sensor is a magnetic pickup, located at the output shaft ring gear, that
sends a signal to the powertrain control module (PCM) to indicate transmission output shaft speed.
The OSS sensor is used for torque converter clutch (TCC) control, shift scheduling and to determine
electronic pressure control (EPC).
Electronic Pressure Control (EPC) Solenoid
The EPC solenoid regulates transmission pressure. EPC valve pressure is used to control line
pressure.
Torque Converter Clutch (TCC) Solenoid Klj . 2 ba
42003 Mustang Workshop Manual
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DIAGNOSIS AND TESTING
Daytime Running Lamps (DRL)
Refer to Wiring Diagrams Cell
97 , Daytime Running Lamps for schematic and connector information.
Principles of Operation
Daytime Running Lamps (DRL)
The daytime running lamps (DRL) system operates the low beam headlamps at a reduced intensity.
The DRL module (15A270) supplies pulse width modulated (PWM) voltage, approximately 75%- 92%
of battery voltage, to the low beam headlamps when the following conditions are met:
zThe parking brake control is released.
z The high beam headlamps are disabled.
z The ignition switch (11572) is in the RUN position.
The DRL module remains enabled when the low beam headlamps are turned on.
Inspection and Verification 1. Verify the customer concern by operating the system.
2. Visually inspect for obvious signs of mechanical and electrical damage.
3. Verify the headlamps are operating correctly. Correct any concerns before proceeding to the
SECTION 417-
04: Daytime Running Lamps 2003 Mustang Workshop Manual Special Tool(s)
73III Automotive Meter or
equivalent
105-
R0057
Visual Inspection Chart Mechanical Electrical
z
Damaged DRL module
z Damaged parking brake signal switch and
bracket (15A851) z
Blown battery junction box (BJB) Maxi-
Fuse FOG+DRL (20A)
z Damaged wiring harness
z Loose or corroded connection
z Damaged DRL module
z Damaged parking brake signal switch and
bracket Klj . 1 ba
62003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...