1996 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 1996 Mustang.

Engine Basics

Year	1996
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″