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.

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

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

Install the camshafts.

  • Lubricate the camshafts with clean engine oil.

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6. Install the camshaft bearing cap assemblies.

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7. Install the hydraulic lash adjusters.

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8. Install the roller followers.

1. Install the special tool on the valve spring.

2. Compress the spring and install the roller follower.

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

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

Install the tensioner.

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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.

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12. Install the special tool.

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

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

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15. Tighten the bolts in two stages:

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

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16. Remove the special tool.

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    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:

    Symptom Chart
    Condition Possible Sources Action Incorrect/erratic direction of airflow from outlet(s) No vacuum to A/C heater function switch selector. A/C heater function selector switch leaks vacuum. Kinked/pinched vacuu ...

    Extension Housing Seal and Gasket
    Special Tool(s) Slide Hammer 100-001 (T50T-100-A) Installer, Transmission Extension Housing Fluid Seal 308-002 (T61L-7657-A) Remover, Transmission Fluid Seal 307-048 (T74P-77248-A) Removal 1. Drain the transmiss ...

    Master Cylinder - Hydro-Boost
    Removal 1. Disconnect the fluid level sensor connector. 2. Disconnect the brake tubes. 3. Remove the brake master cylinder nuts. 4. Remove the brake master cylinder (2140). Installation 1. To install, reverse the removal procedure. Bleed the brak ...