2003 FORD MUSTANG lock

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

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) system.
z overhead valves.
z hydraulic valve tappets for automatic lash adjustment.
z connecting rod parting faces that are unique with an interference fit.
z an engine dynamic balance shaft.
SECTION 303-
01A: Engine — 3.8L 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

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 6020 Engine front cover gasket
6 6010 Cylinder block
7 6019 Engine front cover
8 6714 Oil bypass filter
9 6C315 Crankshaft position sensor
10 8501 Water pump
11 6312 Crankshaft pulley Klj . 3 ba
82003 Mustang Workshop Manual
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Cylinder Block and Lower End Components 9 18801 Radio ignition interference capacitor
10 12281 Ignition wire set —
LH 11 18696 Tube assembly
12 9424 Intake manifold (lower)
13 9439 Intake manifold gasket —
RH 14 9439 Intake manifold gasket —
LH 15 9A424 Intake manifold seal (rear)
16 6A008 Cylinder head-
to-block dowel 17 6010 Cylinder block
18 6A373 Engine rear plate (automatic transmission)
19 6375 Flywheel (automatic transmission)
20 6375 Flywheel (manual transmission)
21 6A372 Engine rear plate (manual transmission)
22 6723 Oil pan rear seal
23 6675 Oil pan
24 7120 Pilot bushing
25 9278 Oil pressure sensor
26 9B339 Oil pressure sensor fitting
27 9A424 Intake manifold seal (front)
28 18663 Heater water outlet tube
29 8255 Thermostat housing-
to-intake manifold gasket 30 8592 Water outlet connection
31 9875 Water thermostat
32 9D475 EGR valve
33 9H465 Vacuum control solenoid
34 9723 Accelerator cable bracket
35 9E936 Throttle body gasket
36 9J433 EGR transducer
37 9E498 Vacuum hose
38 12280 Ignition wire set —
RH Klj . 5 ba
82003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

9 6A333 Balance shaft front and rear bearing
10 6010 Cylinder block
11 6K564 Tappet guide plate and retainer —
RH 12 6K564 Tappet guide plate and retainer —
LH 13 6500 Valve tappet
14 376958 Balance shaft cover plug
15 6337 Crankshaft thrust main bearing
16 6701 Crankshaft rear oil seal
17 6A338 Crankshaft main bearing (lower)
18 6A339 Crankshaft thrust main bearing
19 6325 Rear main bearing cap
20 6327 Main bearing cap
21 6687 Oil pan baffle
22 6622 Oil pump screen cover and tube
23 6625 Oil pump inlet tube gasket
24 6334 Main bearing cap
25 6329 Main bearing cap
26 6303 Crankshaft
27 388907 Woodruff key
28 6333 Crankshaft main bearing (upper)
29 6284 Timing chain vibration damper
30 6263 Camshaft rear bearing
31 6262 Camshaft center bearing
32 6250 Camshaft
33 6265 Camshaft sprocket spacer
34 6269 Camshaft thrust plate
35 6256 Camshaft sprocket
36 6303 Crankshaft sprocket
37 6150 Piston ring
38 6152 Piston ring
39 6161 Piston ring
40 6159 Piston ring
41 6135 Piston pin
42 6200 Connecting rod
43 6211 Connecting rod bearing
44 6210 Connecting rod cap
45 6200 Connecting rod assembly
46 6100 Piston and connecting rod assembly
47 6108 Piston Klj . 7 ba
82003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...