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.
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HOMESERVICE MANUALSFORD2004MUSTANG BASE, 2D COUPE, 3.9 6, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1205 (ENGINE - 2.3L - (EXCEPT HYBRID))SPECIFICATIONSGENERAL SPECIFICATIONS
2004 Ford Mustang Base, 2D Coupe, 3.9 6, Automatic
General Specifications
2004 Ford Mustang Base, 2D Coupe, 3.9 6, AutomaticSECTION General Specifications
WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
GENERAL SPECIFICATIONS
| Item | Specification | ||
|---|---|---|---|
| Displacement | 2.3L | ||
| No. of cylinders | 4 | ||
| Bore/stroke | 87.5/94.0 | ||
| Firing order | 1-3-4-2 | ||
| Oil pressure (hot @ 2,000 rpm) | 29-39 psi 200-268 kPa |
||
| Oil capacity | 4.1 qts. + 0.4 qt. with filter | ||
| Cylinder Block | |||
| Cylinder bore diameter | 87.5-87.53 mm (3.444-3.446 in.) | ||
| Cylinder bore maximum out-of-round | 0.008 mm (0.0003 in.) | ||
| Main bearing bore diameter | 57.020-57.038 mm (2.244-2.245 in.) | ||
| Head gasket surface flatness | 0.1 mm/general 0.05 mm/200 x 200 (0.004 in./general) (0.0019 in./7.87 x 7.87) |
||
| Piston | |||
| Diameter (1) | 87.5-87.51 mm (3.444-3.445 in.) | ||
| Diameter (2) | 87.51-87.52 mm (3.4452-3.4456 in.) | ||
| Diameter (3) | 87.52-87.53 mm (3.445-3.446 in.) | ||
| Piston-to-bore clearance | 0.025-0.045 mm (0.0009-0.0017 in.) | ||
| Ring groove width - top | 1.203-1.205 mm (0.0473-0.0474 in.) | ||
| Ring groove width - 2nd | 1.17-1.19 mm (0.0460-0.0468 in.) | ||
| Ring groove width - oil | 2.501-2.503 mm (0.0984-0.0985 in.) | ||
| Piston skirt coating thickness | 0.008-0.020 mm (0.0003-0.0007 in.) | ||
| Piston Pin | |||
| Diameter | 20.995-21.0 mm (0.8265-0.8267 in.) | ||
| Length | 59.6-60.4 mm (2.346-2.377 in.) | ||
| Piston-to-pin clearance | 0.008-0.016 mm (0.0003-0.0006 in.) | ||
| Cylinder Head | |||
| Valve lift @ zero lash (exhaust) | 7.4 mm (0.29 in.) | ||
| Valve lift @ zero lash (intake) | 7.9 mm (0.31 in.) | ||
| Valve guide diameter | 5.509-5.539 mm (0.216-0.218 in.) | ||
| Valve seat width - intake/exhaust | 0.99-1.84 mm (0.038-0.072 in.) | ||
| Valve seat angle | 45 degrees | ||
| Valve seat runout | 0.075 mm (0.0029 in.) | ||
| Valve lash adjuster bore diameter | 31.00-31.03 mm (1.220-1.221 in.) | ||
| Cam bore diameter | 25.015-25.040 mm (0.984-0.985 in.) | ||
| Valve | |||
| Valve head diameter - intake | 34.85-35.15 mm (1.372-1.383 in.) | ||
| Valve head diameter - exhaust | 29.85-30.15 mm (1.175-1.187 in.) | ||
| Valve stem diameter - intake | 5.470-5.485 mm (0.2153-0.2159 in.) | ||
| Valve stem diameter - exhaust | 5.465-5.480 mm (0.2151-0.2157 in.) | ||
| Valve stem-to-guide clearance - intake | 0.0027 mm (0.00010 in.) | ||
| Valve stem-to-guide clearance - exhaust | 0.0029 mm (0.00011 in.) | ||
| Valve face runout | 0.05 mm (0.0019 in.) | ||
| Valve face angle | 45 degrees | ||
| Valve Spring - Compression Pressure - | |||
| Intake and exhaust (installed) | 38.667 lb | ||
| Intake (valve open) 8.9 mm (0.35 in.) of lift | 97.032 lb | ||
| Exhaust (valve open) | 7.4 mm of lift 93.338 lb | ||
| Free length | 44.92 mm (1.768 in.) | ||
| Assembled height | 37.9 mm (1.492 in.) | ||
| Crankshaft | |||
| Main bearing journal diameter | 51.980-52.000 mm (2.046-2.047 in.) | ||
| Production repair | 51.730-51.750 mm (2.036-2.037 in.) | ||
| Main bearing clearance | 0.019-0.035 mm (0.0007-0.0013 in.) | ||
| Connecting rod journal diameter | 49.980-50.000 mm (1.967-1.968 in.) | ||
| Production repair | 49.730-49.750 mm (1.957-1.958 in.) | ||
| End play | 0.22-0.43 mm (0.008-0.016 in.) | ||
| Rings | |||
| Width - top | 1.17-1.185 mm (0.0460-0.0466 in.) | ||
| Width - 2nd | 1.197-1.199 mm (0.0471-0.0472 in.) | ||
| Width - oil | 2.38-2.45 mm (0.093-0.096 in.) | ||
| Ring gap (in bore) - top | 0.16-0.31 mm (0.006-0.012 in.) | ||
| Ring gap (in bore) - 2nd | 0.33-0.48 mm (0.012-0.018 in.) | ||
| Ring gap (in bore) - oil | 0.2-0.7 mm (0.007-0.027 in.) | ||
| Valve Tappet | |||
| Diameter | 30.97-30.98 mm (1.2192-1.2196 in.) | ||
| Tappet-to-valve clearance - intake | 0.22-0.28 mm (0.008-0.011 in.) | ||
| Tappet-to-valve clearance - exhaust | 0.27-0.33 mm (0.010-0.013 in.) | ||
| Tappet-to-bore clearance | 0.02-0.06 mm (0.0007-0.0023 in.) | ||
| Camshaft | |||
| Lobe lift - intake | 8.24999 mm (0.324 in.) | ||
| Lobe lift - exhaust | 7.80007 mm (0.307 in.) | ||
| Runout (1)(1) | 0.03 mm (0.001 in.) | ||
| Thrust clearance | 0.09-0.24 mm (0.003-0.009 in.) | ||
| Journal diameter | 24.96-24.98 mm (0.982-0.983 in.) | ||
| Journal-to-bore clearance | 0.035-0.080 mm (0.001-0.003 in.) | ||
| Connecting Rod | |||
| Bearing clearance | 0.027-0.052 mm (0.001-0.002 in.) | ||
| Bearing thickness | 1.496-1.520 mm (0.058-0.059 in.) | ||
| Crank bore diameter | 53.025-53.045 mm (2.087-2.088 in.) | ||
| Pin bore diameter | 20.965-20.985 mm (0.825-0.826 in.) | ||
| Length (center-to-center) | 154.8 mm (6.094 in.) | ||
| Side clearance | 1.95-3.05 mm (0.076-0.120 in.) | ||
| Axial clearance | 0.14-0.36 mm (0.005-0.014 in.) | ||
|
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GENERAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Motorcraft Metal Surface Cleaner ZC-21 |
WSE-M5B392-A |
| Silicone Gasket Remover ZC-30 |
- |
| Motorcraft Metal Surface Prep ZC-31 |
- |
| Silicone Gasket and Sealant TA-30 |
WSE-M4G323-A4 |
| High Temperature 4x4 Front Axle and Wheel Bearing Grease E8TZ-19590-A | ESA-M1C198-A |
| Silicone Brake Caliper Grease and Dielectric Compound XG-3-A |
ESE-M1C171-A |
| Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent |
WSS-M2C930-A |
| Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) or equivalent (yellow color) | WSS-M97B51-A1 |
| Multi-Purpose Grease XL-5, XG-4 | ESB-M1C93-B |
| Thread Sealant with PTFE TA-24 |
WSK-M2G350-A2 |
RENDER: 1.0x
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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.