Ford Mustang (1999-2004) Service Manual: Cylinder Block Core Plug Replacement

Special Tool(s)

 Slide Hammer 100-001 (T50T-100-A)

Material

1. Use a slide hammer or tools suitable to remove the cylinder block core plug.

Cylinder Block Core Plug Replacement

2. Inspect the cylinder block plug bore for any damage that would interfere with the correct sealing of the plug. If the cylinder block plug bore is damaged, bore for the next oversize plug.

3. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug.

Coat the cylinder block core plug and bore lightly with Threadlock 262 and install the cylinder block core plug.

Cup-Type

4. CAUTION: Use care during this procedure so as not to disturb or distort the cup sealing surface.

CAUTION: When installed, the flanged edge must be below the chamfered edge of the bore to effectively seal the bore.

Use a tool suitable to seat the cup-type cylinder block core plug.

Cylinder Block Core Plug Replacement

Expansion-Type

1. CAUTION: Do not contact the crown when installing an expansion-type cylinder block core plug. This could expand the plug before seating and result in leakage.

Use tool suitable to seat the expansion-type cylinder block core plug.

Cylinder Block Core Plug Replacement

Spark Plug Hole Thread Repair

1. There is no authorized repair for spark plug hole threads. If the threads are damaged, install a new cylinder head.

    Cylinder Head - Distortion
    Special Tool(s) Straight Edge 303-D039 (D83L-4201-A) or equivalent 1. Use a straight edge and a feeler gauge to inspect the cylinder head for flatness. If the cylinder head is disto ...

    Spark Plug - Inspection
    1. Inspect the spark plug for a bridged gap. Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil or carbon fouling. Clean the spark plug. 2. Ch ...

    Other materials:

    Fuel Injectors
    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 in ...

    Mirror - Motor
    Removal 1. Push in the upper edge of the mirror glass to the maximum travel. 2. Grasp the bottom of the mirror glass, pull outward and remove the mirror glass. 3. Remove the mirror motor screws. 4. Disconnect the mirror motor electrical connector. 5. ...

    Engine Mount RH
    Special Tool(s) Lifting Bracket, Engine 303-D088 (D93P-6001-A2) Support Bar, Engine 303-290-A Removal 1. Install the special tool. 2. Install the special tools. 3. Remove the starter. For additional information, refer to Secti ...