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

Special Tool(s)

Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
Engine Lift Bracket Set 303-DS086 (D93P-6001-A)
Compressor, Valve Spring (Exhaust) 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 -

Removal

Both cylinder heads

1. Remove the engine. For additional information, refer to Engine in the Removal portion of this section.

2. Remove the flywheel.

Cylinder Heads

3. Remove the separator plate.

Cylinder Heads

4. Mount the engine on a suitable engine stand.

Cylinder Heads

5. NOTE: RH shown, LH similar.

Remove the RH and LH lifting eyes.

Cylinder Heads

6. Remove the breather tube.

Cylinder Heads

7. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) electrical connector.

Cylinder Heads

8. Disconnect the hoses from the differential pressure feedback EGR transducer.

Cylinder Heads

9. Remove the EGR vacuum regulator solenoid.

1. Remove the vacuum lines.

2. Remove the electrical connector.

3. Remove the bolts.

Cylinder Heads

10. Disconnect the EGR tube from the EGR valve.

Cylinder Heads

11. Disconnect the positive crankcase ventilation (PCV) hose from the base of the throttle body.

Cylinder Heads

12. Remove the PCV valve and hose as an assembly.

Cylinder Heads

13. Remove the engine wiring harness.

Cylinder Heads

 

Cylinder Heads

14. Disconnect the vacuum line from the fuel pressure sensor.

Cylinder Heads

15. Remove the throttle body bolts.

Cylinder Heads

16. NOTE: The gasket is reusable if not damaged.

Remove the throttle body and adapter as an assembly.

  • Inspect and clean the sealing surfaces.

Cylinder Heads

17. Remove the ignition coils.

Cylinder Heads

18. Remove the radio interference capacitors.

Cylinder Heads

19. Remove the accessory drive belt.

Cylinder Heads

20. Remove the power steering reservoir and bracket as an assembly.

1. Disconnect the supply line from the pump.

2. Remove the (3) bolts and the reservoir and bracket.

Cylinder Heads

21. Remove the upper generator support bracket.

Cylinder Heads

22. Remove the bolts and the generator.

Cylinder Heads

23. Remove the coolant outlet adapter.

Cylinder Heads

24. Remove the thermostat and O-ring.

Cylinder Heads

25. Remove the bolts in the sequence shown, and remove the intake manifold.

Cylinder Heads

26. Remove the intake manifold gaskets.

Cylinder Heads

27. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools will cause scratches and gouges which make leak paths.

Clean the sealing surfaces.

28. Remove the coolant bypass tube.

1. Remove the nut.

2. Remove the coolant bypass tube.

Cylinder Heads

29. Remove the RH engine mount.

Cylinder Heads

30. NOTE: LH shown; RH similar.

Using a suitable container, drain coolant from the engine block.

  • Install the drain plugs when finished.

Cylinder Heads

31. Remove the four bolts and the power steering pump.

Cylinder Heads

RH cylinder head

32. Remove the RH exhaust manifold.

1. Remove the RH exhaust manifold nuts.

2. Remove the RH exhaust manifold.

3. Remove the RH exhaust manifold gasket and discard.

Cylinder Heads

LH cylinder head

33. Disconnect the EGR tube at the exhaust manifold.

LH cylinder head

34. Remove the LH exhaust manifold.

1. Remove the LH exhaust manifold nuts.

2. Remove the LH exhaust manifold.

3. Remove the LH exhaust manifold gasket and discard.

LH cylinder head

35. Remove the oil level indicator tube bolt.

LH cylinder head

36. Remove the oil level indicator tube.

LH cylinder head

Both cylinder heads

37. Clean and inspect the exhaust manifolds. For additional information, refer to Section.

38. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: The bolts are part of the valve cover and should not be removed. RH valve cover shown, LH valve cover similar.

Remove the RH and LH valve covers.

  • Fully loosen the bolts and remove the valve covers.
  • Clean the valve cover mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  • Inspect the valve cover gasket(s). If the gasket(s) is damaged, remove and discard the gasket(s). Clean the valve cover gasket groove(s) with soap and water or a suitable solvent.

Both cylinder heads

39. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.

NOTE: One spark plug shown, others are similar.

Remove the spark plugs.

Both cylinder heads

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

Both cylinder heads

41. NOTE: Rotate the camshaft to see the base circle of the camshaft's lobe before removing the followers. Keep roller followers in order when removing.

Use the special tool to compress the valve springs and remove the 16 camshaft roller followers.

Rotate the camshaft and crankshaft as necessary.

Both cylinder heads

42. Remove the crankshaft pulley bolt.

Both cylinder heads

43. Using the special tool, remove the crankshaft pulley.

Both cylinder heads

44. Remove the coolant pump pulley.

1. Remove the coolant pump pulley bolts.

2. Remove the coolant pump pulley.

Both cylinder heads

45. Remove the bolts and belt idler pulleys.

Both cylinder heads

46. Using the special tool, remove the engine front cover seal.

Both cylinder heads

47. Remove the bolts.

Both cylinder heads

48. Remove the bolts, the studs, and the engine front cover.

  • Discard the gaskets, clean and inspect the sealing surfaces.

Both cylinder heads

CAUTION: Since the engine is not free-wheeling, if the crankshaft or the camshafts are moved in any manner during removal and installation, the crankshaft and the camshafts must be re-synchronized.

49. Remove the crankshaft sensor ring from the crankshaft.

Both cylinder heads

50. Position the crankshaft with the keyway at the 12 o'clock position.

Both cylinder heads

51. Remove the RH and LH timing chain tensioning system from both timing chains.

1. Remove the bolts.

2. Remove the timing chain tensioners.

3. Remove the timing chain tensioner arms.

Both cylinder heads

52. Remove the LH and RH timing chains and the crankshaft sprocket.

  • Remove the RH timing chain from camshaft sprocket.
  • Remove the RH timing chain from the crankshaft sprocket.
  • Remove the LH timing chain from the camshaft sprocket.
  • Remove the LH timing chain and crankshaft sprocket.

Both cylinder heads

53. NOTE: LH shown; RH similar.

Remove the bolts and the timing chain guides.

Both cylinder heads

54. NOTE: LH shown; RH similar.

Install the lifting handles to the RH and LH cylinder heads.

Both cylinder heads

55. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.

Remove the hydraulic lash adjusters.

Both cylinder heads

RH cylinder head

56. CAUTION: The cylinder head must be cool before removing it from the engine.

Cylinder head warpage can result if a warm or hot cylinder head is removed.

CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Remove the bolts and the RH cylinder head.

  • Discard the cylinder head gasket.
  • Discard the cylinder head bolts.

RH cylinder head

LH cylinder head

57. CAUTION: The cylinder head must be cool before removing it from the engine.

Cylinder head warpage can result if a warm or hot cylinder head is removed.

CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

Remove the bolts and the LH cylinder head.

  • Discard the cylinder head gasket.
  • Discard the cylinder head bolts.

LH cylinder head

Both cylinder heads

58. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.

1. Remove any large deposits of silicone or gasket material with a plastic scraper.

2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.

3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

59. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.

Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in) .

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