Ford Mustang (1999-2004) Service Manual: Engine
- Engine System - General Information
- Engine (Diagnosis and Testing)
- Sprockets
- Rocker Arms - Inspection
- Push Rods - Inspection
- Camshaft Journal - Clearance, Plastigage Method
- Camshaft End Play - Push Rod Engines
- Camshaft End Play - OHC Engines
- Camshaft Lobe Lift
- Camshaft Runout
- Crankshaft Main Bearing Journal - Clearance
- Crankshaft End Play
- Crankshaft Runout
- Crankshaft - Connecting Rod Journal Taper, Out of Round
- Piston Inspection
- Piston - Pin to Bore Diameter
- Piston - Selection
- Piston - Ring End Gap
- Piston - Ring-to-Groove Clearance
- Piston - Pin Diameter
- Connecting Rod - Bushing Diameter
- Connecting Rod - Twist
- Connecting Rod - Bearing Journal Clearance
- Connecting Rod - Side Clearance
- Valve Stem to Valve Guide Clearance
- Valve Spring Strength
- Valve - Seat Inspection
- Cylinder Head - Distortion
- Cylinder Block Core Plug Replacement
- Spark Plug - Inspection
- Exhaust Manifold - Inspection
- Engine - 3.8L
- Engine Component View
- Upper Intake Manifold
- Lower Intake Manifold
- Valve Cover - LH
- Valve Cover RH
- Crankshaft Pulley
- Crankshaft Front Seal
- Engine Front Cover
- Rocker Arm
- Push Rod
- Valve Springs
- Valve Tappets
- Camshaft
- Engine Dynamic Balance Shaft
- Timing Chain
- Exhaust Manifold - LH
- Exhaust Manifold RH
- Cylinder Head LH
- Cylinder Head RH
- Oil Level Indicator and Tube
- Oil Pan
- Oil Pan Baffle
- Oil Pump Screen and Pickup Tube
- Flexplate
- Crankshaft Rear Seal
- Engine Support Insulators
- Engine (Removal)
- Engine (Disassembly)
- Cylinder Head
- Piston
- Engine (Assembly)
- Engine (Installation)
- Engine - 4.6L (2V)
- Engine
- Intake Manifold
- Valve Cover RH
- Valve Cover LH
- Crankshaft Pulley
- Crankshaft Front Oil Seal
- Engine Front Cover
- Timing Drive Components
- Valve Seals
- Hydraulic Lash Adjuster
- Camshaft Roller Follower
- Camshaft
- Exhaust Manifold RH
- Exhaust Manifold LH
- Oil Filter Adapter
- Oil Level Indicator and Tube
- Oil Pan
- Flywheel
- Flexplate
- Engine Mount RH
- Engine Mount LH
- Cylinder Heads (Removal)
- Engine (Removal)
- Engine (Disassembly)
- Cylinder Head (Disassembly and Assembly of Subassemblies)
- Piston
- Engine (Assembly)
- Cylinder Heads (Installation)
- Engine (Installation)
- Engine - Mach I 4.6L (4V)
- Engine
- Intake Manifold - Upper
- Intake Manifold - Lower
- Valve Cover RH
- Valve Cover LH
- Engine Front Cover
- Timing Drive Components
- Valve - Springs, Retainer and Valve Stem Seal
- Hydraulic Lash Adjusters
- Roller Followers
- Camshaft
- Exhaust Manifold RH
- Exhaust Manifold LH
- Oil Filter Adapter
- Oil Level Indicator and Tube
- Oil Pan
- Crankshaft Rear Oil Seal
- Engine Mount
- Engine (Removal)
- Engine (Disassembly)
- Cylinder Head
- Piston - Pin Connecting Rod, Floating Pin
- Engine (Assembly)
- Engine (Installation)
- Engine Cooling
- Engine Cooling (Description and Operation)
- Engine Cooling (Diagnosis and Testing)
- Cooling System Draining, Filling and Bleeding
- Engine and Radiator Flushing
- Heater Core Backflushing
- Thermostat - 3.8L
- Thermostat - 4.6L(2V)
- Thermostat - 4.6L(4V)
- Bypass Tube - 3.8L
- Bypass Tube - Cobra
- Bypass Tube - Mach I
- Water Pump - 3.8L
- Water Pump - 4.6L(2V) and 4.6L(4V)
- Radiator
- Cooling Fan Motor and Shroud
- Water Bypass Hose - 3.8L
- Degas Bottle - 4.6L(2V) and 4.6L(4V)
- Supercharger Cooling
- Supercharger Cooling (Description and Operation)
- Supercharger Cooling (Diagnosis and Testing)
- Supercharger Cooling System Draining, Filling and Bleeding
- Supercharger Cooling System Flushing
- Water Pump
- Radiator
- Degas Bottle
- Fuel Charging and Controls - 3.8L
- Fuel Charging and Controls - 4.6L (2V)
- Fuel Charging And Controls
- Throttle Body
- Fuel Injectors
- Fuel Charging Wiring Harness
- Fuel Injection Supply Manifold
- Fuel Charging and Controls - Cobra 4.6L (4V)
- Fuel Charging and Controls - Mach I 4.6L (4V)
- Accessory Drive
- Accessory Drive (Description and Operation)
- Accessory Drive - Cobra
- Accessory Drive (Diagnosis and Testing)
- Accessory Drive Belt - 3.8L
- Accessory Drive Belt - 4.6L (2V) and (4V)
- Supercharger Belt
- Accessory Drive Belt Tensioner - 3.8L
- Accessory Drive Belt Tensioner - 4.6L (2V) and (4V)
- Supercharger Belt Tensioner
- Accessory Drive Belt Idler Pulley - 3.8L
- Accessory Drive Belt Idler Pulley - 4.6L (2V) and (4V)
- Supercharger Belt Idler Pulley
- Starting System
- Starting System (Description and Operation)
- Starting System (Diagnosis and Testing)
- Starter Drive and Flywheel Ring Gear Inspection
- Relay Switch
- Starter Motor - 3.8L
- Starter Motor - 4.6L
- Engine Ignition - 3.8L
- Engine Ignition - 4.6L (2V)
- Engine Ignition - 4.6L (4V)
- Engine Emission Control
- Engine Emission Control (Description and Operation)
- Exhaust Gas Recirculation (EGR) Valve
- Exhaust Gas Recirculation (EGR) Valve - Cobra
- Exhaust Gas Recirculation (EGR) Valve - Mach I
- Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube
- Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube - Cobra
- Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube - Mach I
- Differential Pressure Feedback Exhaust Gas Recirculation (EGR) System
- Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid
- Positive Crankcase Ventilation (PCV) Hose
- Intake Air Distribution and Filtering
- Intake Air Distribution and Filtering - Supercharger, Charge Air Cooler
- Air Cleaner Outlet Pipe - 3.8L
- Air Cleaner Outlet Pipe - 4.6L (4V)
- Air Cleaner - 3.8L
- Air Cleaner - 4.6L (2V) and 4.6L (4V)
- Air Cleaner Element - 3.8L
- Air Cleaner Element - 4.6L (2V)
- Air Intake Scoop
- Air Intake Scoop Bracket
- Charge Air Cooler
- Evaporative Emissions
- Evaporative Emissions (Description and Operation)
- Evaporative Emissions (Diagnosis and Testing)
- Canister Vent Solenoid Closing Procedure
- Evaporative Emission System Leak Test
- Evaporative Emission Repair Verification Drive Cycle
- Evaporative Emission Canister
- Evaporative Emission Canister Purge Valve
- Fuel Vapor Control Tube Assembly Valve
- Evaporative Emission Test Port
- Electronic Engine Controls
- Electronic Engine Controls (Description and Operation)
- Electronic Engine Controls - Cobra
- Temperature and Manifold Absolute Pressure (T-MAP) Sensor - Cobra
- Camshaft Position (CMP) Sensor - 3.8L
- Camshaft Position (CMP) Sensor - 4.6L
- Intake Manifold Runner Control (IMRC) Actuator - 3.8L
- Crankshaft Position (CKP) Sensor - 3.8L
- Crankshaft Position (CKP) Sensor - 4.6L
- Powertrain Control Module (PCM)
- Throttle Position (TP) Sensor
- Idle Air Control (IAC) Valve - 3.8L
- Idle Air Control (IAC) Valve - 4.6L (2V)
- Idle Air Control (IAC) Valve - Cobra
- Idle Air Control (IAC) Valve - Mach I
- Cylinder Head Temperature (CHT) Sensor - 3.8L
- Engine Coolant Temperature (ECT) Sensor - 4.6L (2V)
- Engine Coolant Temperature (ECT) Sensor - Cobra
- Engine Coolant Temperature (ECT) Sensor - Mach I
- Mass Air Flow (MAF) Sensor - 3.8L
- Mass Air Flow (MAF) Sensor - 4.6L (2V)
- Mass Air Flow (MAF) Sensor - Cobra
- Mass Air Flow (MAF) Sensor - Mach I
- Heated Oxygen Sensor (HO2S)
- Catalyst Monitor Sensor
- Clutch Pedal Position (CPP) Switch
- Fuel Pressure Sensor
- Supercharger Bypass Vacuum Solenoid - Actuator
Key Release Button
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1. Insert the ignition key into the ignition switch lock cylinder and
turn to RUN position.
2. ...
Engine System - General Information
General Specifications
Engine
NOTE: This section contains information, steps and procedures that may
not be specific to your
engine.
This section covers general procedures and diagnosis and testin ...
Other materials:
Installation
NOTE: Do not use a fiber disc to clean the surfaces. Fibers from
the disc can get into the oil pan and
oil and clog the oil bypass valve.
1. Clean and inspect the cylinder head for flatness.
2. Install a new head gasket on the cylinder block with the sm ...
Installation
1. NOTE: The LH side is shown, and the RH is similar.
Install the supply manifold and tighten the four bolts.
2. Connect the EGR vacuum line.
3. Install the EGR to exhaust manifold tube. For additional information,
refer to Section.
4. NOTE: The eng ...
Spark Plugs
Special Tool(s)
Remover, Spark Plug Wire
303-106 (T74P-6666A)
Material
Item
Specification
Silicone Brake Caliper Grease
and Dielectric Compound
D7AZ-19A331-A or equivalent
ESE-M1C171-
A
Removal and Installation
CAUTION: ...
