Ford Mustang (1999-2004) Service Manual: Assembly

1. Install the valve stem seals.

Engine

2. Install the valves and the valve springs.

3. CAUTION: Make sure the tool is seated correctly on the valve spring. Apply a small amount of air at a time. This will prevent the tool from shifting and causing damage to the cylinder head.

Install the air-operated spring compressor on the cylinder head.

Engine

4. Compress the valve spring compressor and install the key on the valves.

Engine

5. NOTE: LH is shown, RH is similar.

Install the camshafts.

  • Lubricate the camshafts with clean engine oil.

Engine

6. Install the camshaft bearing cap assemblies.

Engine

7. Install the hydraulic lash adjusters.

Engine

8. Install the roller followers.

1. Install the special tool on the valve spring.

2. Compress the spring and install the roller follower.

Engine

9. Repeat the previous step for the remaining roller followers.

10. NOTE: LH tensioner is shown, RH tensioner is similar.

Install the tensioner.

Engine

11. CAUTION: Timing marks must be at 12 o'clock and indexed at 6 o'clock.

Install the camshaft sprockets and the chain as an assembly.

Engine

12. Install the special tool.

Engine

13. Install the camshaft spacer, washer and bolt, and hand-tighten the bolt.

Engine

14. Install the camshaft sprocket, washer and bolt, and hand-tighten the bolt.

Engine

15. Tighten the bolts in two stages:

  • Stage 1: Tighten to 40 Nm (30 lb-ft).
  • Stage 2: Tighten and additional 90 degrees.

Engine

16. Remove the special tool.

Engine

    Disassembly
    1. CAUTION: Do not place the cylinder head flat on the bench; the valves will bend. CAUTION: Before disassembly begins, mark the valve position on the face of each valve being removed. The valves mu ...

    Piston - Pin Connecting Rod, Floating Pin
    Material Item Specification SAE 5W-20 Premium Synthetic Blend Engine Oil XO-5W20-QSP WSS-M2C153- H Disassembly 1. Remove the clips. 2. Remove the piston pin from the piston ...

    Other materials:

    Piston - Ring End Gap
    CAUTION: Use care when fitting piston rings to avoid possible damage to the piston ring or the cylinder bore. CAUTION: Piston rings should not be transferred from one piston to another. NOTE: Cylinder bore must be within specification for taper and out-of ...

    Starting a gasoline engine
    When you start the engine, the idle speed increases, this helps to warm up the engine. If the engine idle speed does not slow down automatically, have your vehicle checked by an authorized dealer. Before starting the engine: • Make sure all occupants have f ...

    Removal
    WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and can ignite. Failure to follow these instructions can result in personal injury. 1. ...