1994 Mustang Engine Information – 232 cubic inch V6 (3.8L Ford Essex V6)
The Ford Essex V6
The 3.8 L Essex V6 replaced the 3.3 L I6, as the 3.3 L engine had little demand and was dropped after 1982. The 3.8 liter engine was used from 1983 to 1986, it was then dropped from the Mustang line. It reappears as a Mustang engine in 1994 and is used until 2004, replaced by the 4.0 liter engine in 2005.
The engine got multi-point fuel injection (single port) became standard on the 3.8 L (3,797 cc) V6 in 1988. All applications where the engine was used initially put out 145 hp (104 kW) at 3800 rpm and 215 lb⋅ft (292 N⋅m) of torque at 2400 rpm and this was what was offered in the 1994 Mustang.
Engine Basics
| Year | 1994 |
| Cylinders | 6 |
| Displacement | 232 cu / 3.8 liters |
| Power (hp) | 145 hp @ 3,800 RPM |
| Torque (lb/ft) | 215 lb/ft @ 2,400 RPM |
| Compression | |
| Bore x Stroke | 3.81 × 3.39 |
3.8 Liter Engine Specs
- Firing Order: 1-4-2-5-3-6
- LH cylinders front to rear: 1-2-3
- RH cylinders front to rear: 4-5-6
- Valve order left head: E-I-E-I-E-I
- Valve order right head: I-E-I-E-IE
- Cylinder compression pressure 101 PSI minimum
- Spark plugs 1994 & 1995 AWSF44-PP @0.052″
- Spark plugs 1996 & 1997 SP-482 @ 0.052-0.056
- Spark plugs 1998 SP-482 @ 0.054
- Spark plugs 1999 to 2002 SP-482 @ 0.054
- Spark plugs 2003 & 2004 SP-482 @ 0.054
- Thermostat starts to open 193-200 degrees
- Thermostat fully open
- Radiator cap pressure: 16
Engine & Other Torque Specifications
All torque specifications provided in this table are those recommended by FORD. If you use special bolts, follow the torque specifications provided by the manufacturer. I recommend that you use the 3 step torque technique where you torque down the bolts in three equal steps. Once you have reached the maximum recommended torque setting, go around one more time. Do not torque in a circular pattern. Always torque cross to cross.
| Head bolts 1984 & up | 35-45-55-60 |
| Head bolts 1983 | 45-55-65-75 |
| Rod end caps | 31-36 |
| Intake bolts | 5-10-18 |
| Exhaust manifold bolts | 15-22 |
| Harmonic damper | 93-121 |
| A/C Compressor mounts | |
| pressure plate to flywheel | 12-24 |
| Motor mounts to engine | |
| Bellhousing to engine bolts | 28-38 |
| Trans to bellhousing | |
| Flywheel to Crankshaft | 54-64 |
| Auto Transmission to motor block 4 & 6 cylinders | 28-38 |
| Auto Transmission to motor block 8 cylinders | 40-50 |
| Crankshaft pulley to Harmonic balancer | 20-28 |
| Vibration dampner bolt | |
| Camshaft Sprocket | 15-22 |
| Timing chain cover bolts | 15-22 |
| fuel pump to block 12-15 | |
| neutral start switch C3 1979-1981 | 12-15 |
| neutral start switch C3 1982 – 1986 | 7-10 |
| neutral start switch C4 | 6-8 |
| neutral start switch C5 | 55-75 “/lbs |
| neutral start switch C3 1982 – 1986 | 84-120 “/lbs |
| neutral start switch AOD | 8-11 lbs |
| Auto transmission pan bolts C3 | 12-17 |
| Auto transmission pan bolts C4 & C5 | 12-16 |
| Auto transmission pan bolts A4LD | 8-10 |
| Auto transmission pan bolts AOD | 6-10 |
| Oil pan bolts | 12 |
| Valve cover bolts | 10 |
| Carburetor mount bolts | |
| Oil pump | 18-22 |
| Oil pan drain plug | 8-12 |
| Trans. inspection plate | |
| Water pump bolts | 15-22 |
| Clutch pressure plate | |
| Spark plugs | 7-14 |
| engine block drain plug | 5-8 |
| Rocker arms | 8 -18 to 25 |
| Main cap bolts | 65-81 |
| Rocker arm cover to cylinder head (screw) | 31-61 inch pounds |
| Rocker arm cover to cylinder head (bolt/stud | 80-106 inch pounds |
| Carb to intake 5200/6500 | 10-14 |
| Carb to intake model YFA 1v | 13-14 |
| Carb to intake 2150 2V | 14-16 |
| Carb to intake model 7200 VV | 12-15 |
| Carb to intake 4180-C 4V | 14-20 |
| Automatic transmission oil pan | 10-12 |
| Driveshaft flange bolts | 70-95 |
| Pedal support brake bracket | 13-25 |
| Clutch self adjuster bolt | 17-26 |
| Wheel lug nuts | 85-105 |
| Front hub nut | 17-25, back off then to 10-15 lbs |
| Manual transmission drain & filled plug | 12-22 |
| Rear differential cover bolts, 1994 to 1998 | 22 |
| Rear differential cover bolts, 1999 and up | 32 |
Valve information
| Minimum valve margin width | 1/32″ |
| Intake & exhaust valve seat angle | 45 degrees |
| Intake & exhaust valve face angle | 44 degrees |
| Intake & exhaust valve face runout limit | 0.002″ |
| Intake & exhaust valve seat width | 0.060 – 0.080 |
| Intake & exhaust valve seat runout limit | 0.003 |
| Intake stem diameter | 0.3423-0.3716 |
| Exhaust stem diameter | 0.3418-0.3411 |
| Intake valve stem to guide clearance | 0.001-0.0027 |
| Exhaust valve stem to guide clearance | 0.0015-0.0032 |
| 1983,84,85 Valve spring pressure, valve open | 215 lbs @1.29″ |
| 1983,84,85 Valve spring pressure, valve closed | 75 lbs @ 1.70″ |
| 1986 Valve spring pressure, valve open | 190 @ 1.28″ |
| 1986 Valve spring pressure, valve closed | 73 @ 1.70″ |
| Service limit (all) | 10 lbs loss |
| Valve lifter bore diameter | 0.874 |
| bore to lifter clearance std. | 0.0007 – 0.0027 |
| Service limit | 0.005″ |
Crankshaft Specifications
| Connecting rod journal diameter | 2.3103-2.3111″ |
| Connecting rod journal out-of-round | 0.0003″ |
| Connecting rod journal taper limit | 0.0003″ per inch |
| Connecting rod Bearing oil clearance desired | 0.001-0.0014″ |
| Connecting rod Bearing oil clearance allowed | 0.00086-0.0027″ |
| Connecting rod side clearance std. | 0.0047-0.0114″ |
| Connecting rod side clearance allowed | 0.014 |
| Main Bearing journal diameter | 2.519-2.5198″ |
| Main Bearing journal out-of-round | 0.0003″ |
| Main Bearing journal taper limit | 0.0003″ per inch |
| Main Bearing journal oil clearance desired | 0.001-0.0014″ |
| Main Bearing journal oil clearance allowed | 0.0005-0.0023″ |
| Crankshaft endplay | 0.004-0.008″ |
| Cylinder bore diameter | 3.810″ |
| Cylinder bore out-ofround limit | 0.002″ |
| Cylinder bore taper limit | 0.002″ |
| Piston diameter coded red | 3.8095-3.8101″ |
| Piston diameter coded blue | 3.8107-3.8113″ |
| Piston diameter coded yellow | 3.8119-3.8125″ |
| piston to bore clearance 1983 | 0.0014-0.0022 |
| piston to bore clearance 1984,5,6 | 0.0014-0.0032″ |
| Piston ring end gap compression ring | 0.010-0.020″ |
| Piston ring end gap oil ring | 0.015-0.0583″ |
| Piston ring side clearance | 0.0016-0.0037″ |
