Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2003 Ford Excursion 2WD V8-6.0L DSL TurboFACTORY OEM SERVICE PROCEDURE
System Specifications
Cylinder block
Cylinder bore diameter 94.999 - 95.001 mm (3.7401 - 3.7402 inch)
Cylinder bore maximum taper 0.076 mm (0.003 inch)
Cylinder bore maximum out of round 0.05 mm (0.002 inch)
Main bearing bore inside diameter 85.99 - 86.01 mm (3.3854 - 3.3862 inch)
Camshaft bearing bore inside diameter 65.98 - 66.02 mm (2.597 - 2.599 inch)
Head gasket surface flatness Per 50 mm (2 inch): 0.025 mm (0.001 inch)
Crankshaft
Main bearing journal diameter - Standard size 80.9873 - 81.0127 mm (3.188 - 3.150 inch)
Main bearing journal diameter - 0.254 mm (0.010 inch) undersize 80.7333 - 80.7587 mm (3.178 - 3.140 inch)
Main bearing journal diameter - 0.508 mm (0.020 inch) undersize 80.4793 - 80.5047 mm (3.168 - 3.130 inch)
Main bearing journal diameter - 0.762 mm (0.030 inch) undersize 80.2253 - 80.2507 mm (3.158 - 3.120 inch)
Crankshaft maximum end play 0.222 mm (0.0087 inch)
Piston and connecting rod
Piston diameter - Standard size 94.9460 - 94.9186 mm (3.737 - 3.738 inch)
Piston diameter - 0.254 mm (0.010 inch) oversize 95.1738 - 95.1992 mm (3.747 - 3.748 inch)
Piston diameter - 0.508 mm (0.020 inch) oversize 95.4278 - 95.4532 mm (3.757 - 3.758 inch)
Piston diameter - 0.762 mm (0.030 inch) oversize 95.6818 - 95.7072 mm (3.767 - 3.768 inch)
Piston-to-cylinder bore clearance 0.0441 - 0.0909 mm (0.0017 - 0.036 inch)
Piston ring end gap - top compression 0.29 - 0.55 mm (0.011 - 0.021 inch)
Piston ring end gap - intermediate compression 1.40 - 1.66 mm (0.55 - 0.65 inch)
Piston ring end gap - oil control 0.24 - 0.50 mm (0.009 - 0.019 inch)
Piston ring groove width (measured over 2.03 mm (0.08 inch) gauge pins) Upper limit - 94.030 mm (3.702 inch)
Piston ring groove width (measured over 2.03 mm (0.08 inch) gauge pins) Replacement limit - 93.854 mm (3.695 inch)
Piston pin diameter 33.9975 - 34.0025 mm (1.3385 - 1.3387 inch)
Piston pin length 65.073 - 65.327 mm (2.5619 - 2.5719 inch)
Piston pin-to-piston fit 0.013 - 0.022 mm (0.0005 - 0.0009 inch)
Connecting rod length (center to center) 176 mm (6.929 inch)
Connecting rod bearing bore diameter 72.987 - 73.013 mm (2.8735 - 2.8745 inch)
For torque specifications, refer to the service procedure.
Cylinder bore diameter 94.999 - 95.001 mm (3.7401 - 3.7402 inch)
Cylinder bore maximum taper 0.076 mm (0.003 inch)
Cylinder bore maximum out of round 0.05 mm (0.002 inch)
Main bearing bore inside diameter 85.99 - 86.01 mm (3.3854 - 3.3862 inch)
Camshaft bearing bore inside diameter 65.98 - 66.02 mm (2.597 - 2.599 inch)
Head gasket surface flatness Per 50 mm (2 inch): 0.025 mm (0.001 inch)
Crankshaft
Main bearing journal diameter - Standard size 80.9873 - 81.0127 mm (3.188 - 3.150 inch)
Main bearing journal diameter - 0.254 mm (0.010 inch) undersize 80.7333 - 80.7587 mm (3.178 - 3.140 inch)
Main bearing journal diameter - 0.508 mm (0.020 inch) undersize 80.4793 - 80.5047 mm (3.168 - 3.130 inch)
Main bearing journal diameter - 0.762 mm (0.030 inch) undersize 80.2253 - 80.2507 mm (3.158 - 3.120 inch)
Crankshaft maximum end play 0.222 mm (0.0087 inch)
Piston and connecting rod
Piston diameter - Standard size 94.9460 - 94.9186 mm (3.737 - 3.738 inch)
Piston diameter - 0.254 mm (0.010 inch) oversize 95.1738 - 95.1992 mm (3.747 - 3.748 inch)
Piston diameter - 0.508 mm (0.020 inch) oversize 95.4278 - 95.4532 mm (3.757 - 3.758 inch)
Piston diameter - 0.762 mm (0.030 inch) oversize 95.6818 - 95.7072 mm (3.767 - 3.768 inch)
Piston-to-cylinder bore clearance 0.0441 - 0.0909 mm (0.0017 - 0.036 inch)
Piston ring end gap - top compression 0.29 - 0.55 mm (0.011 - 0.021 inch)
Piston ring end gap - intermediate compression 1.40 - 1.66 mm (0.55 - 0.65 inch)
Piston ring end gap - oil control 0.24 - 0.50 mm (0.009 - 0.019 inch)
Piston ring groove width (measured over 2.03 mm (0.08 inch) gauge pins) Upper limit - 94.030 mm (3.702 inch)
Piston ring groove width (measured over 2.03 mm (0.08 inch) gauge pins) Replacement limit - 93.854 mm (3.695 inch)
Piston pin diameter 33.9975 - 34.0025 mm (1.3385 - 1.3387 inch)
Piston pin length 65.073 - 65.327 mm (2.5619 - 2.5719 inch)
Piston pin-to-piston fit 0.013 - 0.022 mm (0.0005 - 0.0009 inch)
Connecting rod length (center to center) 176 mm (6.929 inch)
Connecting rod bearing bore diameter 72.987 - 73.013 mm (2.8735 - 2.8745 inch)
For torque specifications, refer to the service procedure.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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