2003 FORD MUSTANG lock

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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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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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 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.
Torque Specifications Description Nm lb-
ft lb-
in Main bearing cap adjusting bolts
a — — —
EGR sensor bracket 10 — 89
Belt idler pulley 25 18 —
Oil filter 15 11 —
Oil filter adapter insert 58 43 —
Camshaft sprocket bolt
a — — —
Connecting rod bolt
a — — —
Engine mount nuts 150 111 —
Engine mount-
to-cylinder block bolts 70 52 —
Exhaust manifolds
a — — —
Engine front cover bolts
a — — —
Drive belt tensioner bolts 25 18 —
A/C muffler 20 15 —
Battery cable support brackets 20 15 —
Cylinder head bolt
a — — —
Pulley-
to-crankshaft bolt a — — —
EGR valve to intake manifold 25 18 —
EGR valve tube to exhaust manifold fittings 40 30 —
Intake manifold-
to-cylinder head bolt 25 18 —
Main bearing cap bolt
a — — —
Oil filter adapter bolts 25 18 —
Oil level indicator tube bolt 10 — 89
Oil pump screen cover and tube-
to-oil pump bolt 10 — 89
Oil pan-to-
cylinder block bolt a — — —
Flywheel 80 59
Oil pan-to-
engine front cover bolts a — — —
Oil pump-
to-cylinder block bolt 10 — 89
Oil pump screen cover and tube-
to-main bearing cap stud spacer bolt 25 18 —
Water pump pulley bolts 25 18 —
Cam cover bolt
a — — —
Water pump-
to-cylinder block bolt 25 18 —
Water bypass tube 25 18 —
EGR tube nuts (2 req'd) 40 30 —
Power steering pump to engine 25 18 — Klj . 4 ba
62003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

N806155 Bolt (2 req'd)
92 6C315 Crankshaft position sensor
93 N806300 Stud bolt (5 req'd)
94 6C086 Engine front cover
95 N806155 Bolt
96 6B288 Camshaft position sensor
97 N606543 Bolt (4 req'd)
98 6L266 Timing chain tensioner
99 6268 Timing chain belt
100 6K297 Timing chain cover
101 6M269 Timing chain tensioner
102 6L253 Timing chain tensioner arm
103 N806184 Bolt (3 req'd)
104 19D629 A/C compressor
105 8501 Water pump
106 N806177 Bolt (4 req'd)
107 N806183 Bolt (4 req'd)
108 6621 Oil pump
109 N806201 Woodruff key
110 6333 Crankshaft main bearing (5 req'd)
111 6A341 Crankshaft thrust washer (3 req'd)
112 6C357 Crankshaft main bearing side bolt (10 req'd)
113 6010 Cylinder block
114 9439 Intake manifold gasket (2 req'd)
115 6083 Head gasket
116 6505 Exhaust valve (8 req'd)
117 6507 Intake valve (8 req'd)
118 87838 Pipe plug (8 req'd)
119 12405 Spark plug (8 req'd)
120 6F087 Dowel
121 9431 Exhaust manifold
122 6C501 Valve tappet (16 req'd)
123 6529 Rocker arm (16 req'd)
124 6049 Cylinder head, RH
125 W701681 Stud (8 req'd)
126 9Y431 Exhaust manifold gasket
127 9F485 EGR valve tube to manifold connector
128 W701706 Nut (8 req'd)
129 181198A Engine lifting eye
130 6A517 Valve stem seal (16 req'd)
131 6513 Valve spring (16 req'd)
132 Klj . 6 ba
92003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

A modular engine is built around four modules:
zthe intake module
z the cylinder head module (RH)
z the cylinder head module (LH)
z the lower engine module
While not all repairs can take advantage of the modular concept, most out-of- vehicle repairs benefit
due to the reduction of necessary time and labor.
The basic engine components consist of the following:
zsingle overhead camshafts
z two valves per cylinder
z sequential multiport fuel injection (SFI)
z aluminum cylinder heads (6049)
z cast iron, 90- degree V-shaped cylinder block
z individual ignition coils for each spark plug
z composite-material intake manifold
z large- bore throttle body N605919 Bolt
174 18663 Heater water tube
175 N806007 Dowel (2 req'd)
176 N807198 Dowel (2 req'd)
177 N806168 Bolt (6 req'd)
178 6375 Flywheel (automatic transmission)
179 6310 Crankshaft oil slinger
180 6701 Crankshaft rear oil seal
181 N806155 Bolt (6 req'd)
182 6K318 Crankshaft rear oil seal and retainer
183 7120 Transmission input shaft pilot bearing
184 N806435 Pipe plug
185 N87836 Dowel (2 req'd) Klj . 8 ba
92003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

Installation
1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean and inspect the mating surfaces.
2. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the
sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness,
or four minutes, whichever is longer. Failure to follow this procedure can result in future oil
leakage.
Apply the silicone gasket and sealant at the rear oil seal retainer- to-cylinder block sealing
surface.
3. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the
sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness,
or four minutes, whichever is longer. Failure to follow this procedure can result in future oil
leakage.
Apply the silicone gasket and sealant at the engine front cover- to-cylinder block mating surface. 4. Install the oil pan and gasket and loosely install the bolts. Klj . 5 ba
92003 Mustang Workshop Manual
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30.
NOTE: LH shown; RH similar.
Using a suitable container, drain coolant from the engine block. zInstall the drain plugs when finished.
31. Remove the four bolts and the power steering pump.
RH cylinder head 32. Remove the RH exhaust manifold. 1. Remove the RH exhaust manifold nuts.
2. Remove the RH exhaust manifold.
3. Remove the RH exhaust manifold gasket and discard. Klj . 10 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...

50. Position the crankshaft with the keyway at the 12 o'clock position.
51. Remove the RH and LH timing chain tensioning system from both timing chains.
1. Remove the bolts.
2. Remove the timing chain tensioners.
3. Remove the timing chain tensioner arms.
52. Remove the LH and RH timing chains and the crankshaft sprocket. zRemove the RH timing chain from camshaft sprocket.
z Remove the RH timing chain from the crankshaft sprocket.
z Remove the LH timing chain from the camshaft sprocket.
z Remove the LH timing chain and crankshaft sprocket. Klj . 16 ba
212003 Mustang Workshop Manual
17. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_4464/S3B~us~en~ ...