Ford Mustang (1999-2004) Service Manual: Cylinder Heads (Installation)

Special Tool(s)

Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
Holding Tool, Crankshaft 303-448 (T93P-6303-A)
Spreader Bar 303-D089 (D93P-6001-A3)
Lifting Bracket Set, Engine 303-D074 (D91P-6001-A)
Strap Wrench 303-D055 (D85L-6000-A) or equivalent
Compressor, Valve Spring 303-567 (T97P-6565-AH)
Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)
Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)

Material

Item Specification
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA -
Silicone Gasket and Sealant F7AZ-19554-EA or equivalent WSE-M4G323- A4
Super Premium SAE 5W-20 Engine Oil XO-5W20-QSP or equivalent WSS-M2C153- H

Both cylinder heads

1. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Heads in the Removal portion of this section.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.

NOTE: RH head gasket shown; LH head gasket similar.

Install the head gasket over the dowel pins.

Cylinder Heads

2. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.

NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.

NOTE: RH head gasket shown; LH head gasket similar.

Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.

Cylinder Heads

NOTE: Position the cylinder head(s) over the dowels on the head gasket(s).

3. NOTE: LH shown, RH similar.

Tighten the bolts in six stages in the sequence shown.

  • Stage 1: Tighten to 40 Nm (30 lb-ft).
  • Stage 2: Tighten an additional 90 degrees.
  • Stage 3: Loosen the bolts a minimum of one full turn.
  • Stage 4: Tighten to 40 Nm (30 lb-ft).
  • Stage 5: Tighten an additional 90 degrees.
  • Stage 6: Tighten an additional 90 degrees.

Cylinder Heads

4. Remove the special tools from both ends of the cylinder head.

Cylinder Heads

NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.

5. Install the hydraulic lash adjusters in their original locations.

Cylinder Heads

6. CAUTION: Timing chain procedures must be followed exactly or damage to the valves and pistons will result.

NOTE: LH shown, RH similar.

Compress each tensioner plunger, using a vise.

Cylinder Heads

7. Install a retaining clip on each tensioner to hold the plunger in during installation

Cylinder Heads

8. Remove the tensioner from the vise.

9. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.

Cylinder Heads

10. Install the timing chain guides.

1. Position LH timing chain guide.

2. Install and tighten the bolts.

3. Position the RH timing chain guide.

4. Install and tighten the RH bolts.

Cylinder Heads

11. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.

Cylinder Heads

12. CAUTION: When instructed to do so, rotate the crankshaft counterclockwise only.

Do not rotate past the position shown or severe piston and valve damage can occur.

NOTE: The number one cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.

Using the special tool, position the crankshaft so the number one cylinder is at TDC.

Cylinder Heads

13. Remove the special tool.

14. Install the crankshaft sprocket, making sure the flange faces forward.

Cylinder Heads

15. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

Cylinder Heads

16. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.

Cylinder Heads

17. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.

Cylinder Heads

18. Remove the retaining clip from the LH timing chain tensioner.

Cylinder Heads

19. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

Cylinder Heads

20. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.

Cylinder Heads

21. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.

Cylinder Heads

22. Remove the retaining clip from the RH timing chain tensioner.

Cylinder Heads

23. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.

Cylinder Heads

24. Install the crankshaft sensor ring on the crankshaft.

Cylinder Heads

25. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply a bead of sealant along the head-to-block surface as shown.

Cylinder Heads

26. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.

Cylinder Heads

27. Tighten the front cover fasteners in the sequence shown.

Cylinder Heads

 

Cylinder Heads

28. Loosely install the bolts, then tighten the bolts in three stages in the sequence shown.

  • Stage 1: Tighten to 2 Nm (18 lb-in).
  • Stage 2: Tighten to 20 Nm (15 lb-ft).
  • Stage 3: Tighten an additional 60 degrees

Cylinder Heads

29. Install the belt idler pulleys.

Cylinder Heads

30. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.

Cylinder Heads

31. Using the special tool, install the front oil seal.

Cylinder Heads

32. Install the coolant pump pulley and bolts.

Cylinder Heads

33. NOTE: The crankshaft pulley must be installed within four minutes of applying the sealant.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

Cylinder Heads

34. Using the special tool, install the crankshaft pulley.

Cylinder Heads

35. NOTE: Use special tool 303-009 or a suitable strap wrench to hold the crankshaft pulley.

Install the washer and the bolt. Tighten the bolt in four stages.

  • Stage 1: Tighten to 90 Nm (66 lb-ft).
  • Stage 2: Loosen one full turn.
  • Stage 3: Tighten to 50 Nm (37 lb-ft).
  • Stage 4: Tighten an additional 90 degrees.

Cylinder Heads

36. Install the RH engine mount.

Cylinder Heads

37. NOTE: Only three bolts are required for installation.

Install the power steering pump bolts.

  • Position the power steering pump.
  • Install the bolts.

Cylinder Heads

38. Install the special tool between the valve spring coils to prevent valve stem seal damage.

Cylinder Heads

39. NOTE: Lubricate the camshaft roller followers using clean engine oil.

NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.

Install the camshaft roller followers.

1. Install the special tool.

2. Compress the valve spring.

3. Install the camshaft roller followers in their original locations.

Cylinder Heads

40. Remove the special tool.

Cylinder Heads

41. NOTE: One spark plug shown, others similar.

Install the spark plugs.

Cylinder Heads

42. NOTE: RH side shown, LH side similar.

NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant in the locations shown.

Cylinder Heads

43. NOTE: RH valve cover shown, LH similar.

Install the valve covers.

Cylinder Heads

LH cylinder head

44. NOTE: Lubricate the O-ring seal with clean engine oil.

Install a new O-ring.

LH cylinder head

45. Install the oil level indicator tube.

LH cylinder head

46. Install the LH exhaust manifold.

  • Install a new manifold gasket.
  • Install the LH exhaust manifold.
  • Tighten the nuts in the sequence shown.

LH cylinder head

47. Connect the lower end of the exhaust gas recirculation (EGR) tube to the LH exhaust manifold.

LH cylinder head

RH cylinder head

48. Install the RH exhaust manifold.

  • Install a new exhaust manifold gasket.
  • Install the RH exhaust manifold.
  • Tighten the nuts in the sequence shown.

RH cylinder head

Both cylinder heads

49. Inspect O-ring seals and install new O-ring seals as necessary.

Both cylinder heads

50. Install the coolant bypass tube.

1. Install the bypass tube.

2. Install the nut.

Both cylinder heads

51. Install the intake manifold and gaskets. Tighten the bolts in the sequence shown.

Both cylinder heads

52. Install the thermostat and O-ring.

  • Install a new O-ring as necessary.

Both cylinder heads

53. Install the coolant outlet adapter.

Both cylinder heads

54. Install the bolts and the generator.

Both cylinder heads

55. Install the upper generator support bracket.

Both cylinder heads

56. Position the power steering reservoir and bracket, then install the bolts.

Both cylinder heads

57. Install the accessory drive belt.

Both cylinder heads

58. Install the radio interference capacitors.

Both cylinder heads

59. Install the ignition coils and bolts.

Both cylinder heads

60. Position the throttle body and install the bolts, tightening in the sequence shown.

Both cylinder heads

61. Connect the vacuum line to the fuel pressure sensor.

Both cylinder heads

62. Install the positive crankcase ventilation (PCV) valve and hose as an assembly.

Both cylinder heads

63. Connect the PCV hose to the base of the throttle body.

Both cylinder heads

64. Connect the EGR tube to the EGR valve.

Both cylinder heads

65. Install the EGR vacuum regulator solenoid.

1. Install the vacuum lines.

2. Install the electrical connector.

3. Install the bolts.

Both cylinder heads

66. Connect the hoses from the differential pressure feedback EGR transducer.

Both cylinder heads

67. Connect the differential pressure feedback EGR electrical connector.

Both cylinder heads

68. Install the breather tube.

Both cylinder heads

69. Install the engine control sensor wiring.

Both cylinder heads

 

Both cylinder heads

Both cylinder heads

70. Install the RH and LH special tool

Both cylinder heads

71. Using the special tool, remove the engine from the stand.

Both cylinder heads

72. Install the separator plate.

Both cylinder heads

73. Install the flywheel.

Both cylinder heads

74. Install the engine. For additional information, refer to Engine in the Installation portion of this section.

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