Ford Mustang (1999-2004) Service Manual: Engine (Assembly)

Special Tool(s)

Slide Hammer 307-005 (T59L-100-B)
Remover Adapter, Vibration Damper 303-176 (T82L-6316-B)
Installer, Crankshaft Front Seal 303-474 (T94P-6701-AH)
Replacer, Steering Pump Pulley 211-009 (T65P-3A733-C)
Engine Lift Bracket Set 303-D095 (D94L-6001-A)
Replacer, Rear Crankshaft Seal 303-516 (T95P-6701-BH)
Spacer, Rear Crank Seal Replacer 303-561 (T96T-6701-B)
Adapter, Crankshaft Rear Seal (Use only the adapter retaining bolts) 303-518 (T95P-6701-DH)
Adapter, Crankshaft Rear Seal (Use only the adapter and the center jack screw) 303-S560 (T96T-6701-A)
Spreader Bar 303-D089 (D93P-6001-A3)

Material

Item Specification
Metal Surface Cleaner F4AZ-19A536-RA or equivalent WSE-M5B392- A
Silicone Gasket and Sealant F7AZ-19554-EA or equivalent WSE-M4G323- A4
SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent WSS-M2C153- H
Pipe Sealant with Teflon XW7Z-19554-AA WSK-M2G350- A2

CAUTION: The moving components must be lubricated with clean engine oil before assembly.

CAUTION: The components with oil holes must be correctly aligned with the oil feed holes.

1. If necessary, install the following:

1. the cylinder block dowels.

2. the oil gallery plugs.

3. the water jacket plugs.

Engine

2. If equipped, install the engine coolant heater.

3. Using the camshaft bearing service set, install the engine dynamic balance shaft bearings.

Engine

4. Using the camshaft bearing service set, install the camshaft bearings.

Engine

5. Install the following:

1. the engine dynamic balance shaft bearing cover.

2. the camshaft bearing cover.

Engine

6. CAUTION: Do not damage the camshaft lobes when installing the camshaft.

Install the camshaft and the camshaft spacer.

Engine

7. Install the camshaft thrust plate.

1. Position the camshaft thrust plate.

2. Install the bolts.

Engine

8. Turn the camshaft so that the timing mark is at 12 o'clock and install the engine dynamic balance shaft assembly into the cylinder block. Turn the engine balance shaft driven gear so that the timing mark aligns up with the timing mark on the engine balance shaft drive gear.

Engine

9. NOTE: If correctly aligned, the engine dynamic balance shaft keyway will be at 12 o'clock and the camshaft keyway will be at 6 o'clock on the camshaft.

Install the bolts.

Engine

10. CAUTION: Make sure the components are installed in the correct location.

NOTE: Lubricate the crankshaft main bearings prior to installation.

Install the crankshaft upper main bearings and the crankshaft upper thrust main bearing.

Engine

11. CAUTION: The crankshaft journals must be protected from damage when installing the crankshaft.

Position the crankshaft.

Engine

CAUTION: The main bearings are precision selective fit. Inspect the bearing clearance.

12. NOTE: If the rear main bearing cap 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.

Clean the rear main bearing cap sealing area with metal surface cleaner. Apply silicone gasket and sealant to the rear main bearing cap-to-cylinder block parting line.

Engine

13. Install the main bearing caps. Tighten the bolts in two stages:

  • Stage 1: Tighten to 50 Nm (37 lb-ft).
  • Stage 2: Rotate an additional 120 degrees.

Engine

14. Compress the piston rings.

Engine

15. CAUTION: Inspect the piston clearance.

CAUTION: Do not damage the cylinder wall with the sharp edges of the connecting rod.

Install the piston with the arrow on the piston face pointing toward the front of the engine.

Engine

16. CAUTION: Inspect the connecting rod bearing clearance.

CAUTION: The connecting rod cap will fit only one way.

Position the connecting lower rod bearing and the connecting rod cap on the connecting rod and the crankshaft journal.

Engine

17. Install the rod caps. Tighten the bolts in three stages:

  • Stage 1: Tighten to 25 Nm (18 lb-ft).
  • Stage 2: Tighten to 45 Nm (33 lb-ft).
  • Stage 3: Tighten an additional 105 degrees.

Engine

18. Install the remaining pistons and the connecting rods.

19. Install the oil pan bridge and baffle assembly.

Engine

20. Using a new gasket, install the oil pump screen cover and tube.

Engine

21. Install the timing chain tensioner.

1. Position the timing chain tensioner.

2. Install the bolts.

Engine

22. Retract the tensioner pad retracting mechanism.

1. Compress the tensioner pad retracting mechanism.

2. Insert a retaining pin.

Engine

23. Rotate the crankshaft so the number one piston is at top dead center (TDC) and the key is at the 12 o'clock position.

Engine

24. Turn the camshaft sprocket so that the keyway is on the bottom of the camshaft.

Engine

25. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.

Engine

26. Make sure the timing marks and the keyways are aligned.

Engine

27. Install the camshaft position sensor drive gear and retaining bolt.

Engine

28. Remove the retaining pin.

Engine

CAUTION: The components removed should be marked for location. Make sure the used parts are installed in the correct location.

29. NOTE: Install the new cylinder head gaskets with the small hole to the front of the engine.

Using new gaskets, install the RH and the LH cylinder heads.

Engine

30. CAUTION: Always use new bolts.

NOTE: Lubricate the bolts with clean engine oil prior to installation.

Position the new bolts.

1. Position the new long bolts.

2. Position the new short bolts.

Engine

31. Tighten the bolts in three stages in the sequence shown:

  • Stage 1: Tighten to 20 Nm (15 lb-ft).
  • Stage 2: Tighten to 40 Nm (30 lb-ft).
  • Stage 3: Tighten to 50 Nm (37 lb-ft).

Engine

32. CAUTION: Do not loosen all of the bolts at one time. Each bolt must be loosened and tightened prior to working on the next bolt in the sequence.

Tighten the bolts in four stages in the sequence shown: short bolts numbered 2, 4, 6 and 8:

  • Stage 1: Tighten to 25 Nm (18 lb-ft).
  • Stage 2: Tighten an additional 180 degrees.

    Long bolts numbered 1, 3, 5 and 7:

  • Stage 3: Tighten to 45 Nm (33 lb-ft).
  • Stage 4: Tighten an additional 180 degrees.

Engine

33. NOTE: Lubricate the valve tappets with clean engine oil prior to installing.

Install the valve tappets.

  • Install the valve tappets.
  • Install the tappet guide plates and retainers.
  • Install the bolts.

Engine

34. NOTE: Lubricate the push rods with clean engine oil prior to installation.

Install the 12 push rods.

Engine

35. Install the 12 rocker arms. For additional information, refer to Rocker Arm in this section.

36. NOTE: Use pipe sealant with Teflon on studs No. 4 and 6, and bolt No. 12.

Using a new gasket, install the engine front cover. Tighten the nuts and the bolts in the sequence shown.

  • Install a 135.5 mm (5.42 in) stud at location No. 5 and tighten to 7 Nm (62 lb-in).
  • Install a 137 mm (5.48 in) stud at locations No. 4, 6, 7 and 10, and tighten to 7 Nm (62 lbin).
  • Using a new gasket, install the water pump.
  • Tighten bolt No. 12 to 10 Nm (89 lb-in). All other nuts and bolts are to be tightened to 28 Nm (21 lb-ft).

Engine

37. NOTE: Lubricate the parts with clean engine oil before assembly.

Using the special tool, install the front crankshaft seal.

Engine

38. Install the crankshaft position sensor.

Engine

39. Apply a bead of silicone gasket and sealant to the keyway in the crankshaft damper. Using the special tool, position and install the crankshaft damper.

Engine

40. Install the crankshaft pulley bolt.

Engine

41. Install the camshaft synchronizer. 42. Install the water pump pulley and the retaining bolts.

Engine

43. NOTE: If the oil pan 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.

Clean and apply the sealant to the oil pan sealing areas shown and install the oil pan rear seal.

1. Apply silicone gasket and sealant to the rear main bearing cap.

2. Install the oil pan rear seal.

3. Clean the oil pan mating surfaces with metal surface cleaner and apply silicone gasket and sealant to the oil pan mating surface.

Engine

44. Tighten the oil pan bolts in the sequence shown.

Engine

45. Install the RH valve cover.

Engine

46. Install the LH valve cover.

Engine

47. Install the generator mounting bracket.

Engine

48. Install the power steering pump bracket.

Engine

49. Using the special tool, install the power steering pump pulley.

Engine

50. Install the A/C compressor bracket and the bolts.

Engine

51. Install the accessory drive belt.

Engine

52. Refer to the illustration for intake manifold sealing components.

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Engine

Engine

53. NOTE: If the lower intake manifold 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.

Install the lower intake manifold front and rear end seals.

1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear end seal mounting points as indicated.

2. Install the lower intake manifold front and rear end seals.

Engine

54. Install the intake manifold gaskets.

Engine

55. NOTE: If the lower intake manifold 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.

Position the lower intake manifold.

1. Apply a bead of silicone gasket and sealant to the lower intake manifold mounting at the points indicated.

2. Position the lower intake manifold.

Engine

56. Install the lower intake manifold bolts.

  • Install the six long bolts.
  • Install the eight short bolts.

Engine

57. Tighten the bolts in two stages in the sequence shown.

1. Stage 1: Tighten to 5 Nm (44 lb-in).

2. Stage 2: Tighten to 10 Nm (89 lb-in).

Engine

58. Install the heater water outlet tube.

Engine

59. Install the stud bolt.

Engine

60. Position the engine wire harness.

Engine

61. Connect the crankshaft position sensor electrical connector.

Engine

62. Install the pin-type retainer.

Engine

63. Connect the engine oil pressure sender electrical connector.

Engine

64. Connect the camshaft position (CMP) sensor electrical connector.

Engine

65. Connect the cylinder head temperature (CHT) sensor.

Engine

66. Install the fuel injectors and the fuel injection supply manifold as an assembly.

67. Install a new upper intake manifold gasket.

Engine

68. NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct location.

Install the upper intake manifold. Tighten the bolts in two stages in the sequence shown.

  • Stage 1: Tighten to 10 Nm (89 lb-in).
  • Stage 2: Rotate an additional 90 degrees.

Engine

69. Connect the exhaust gas recirculation (EGR) vacuum regulator solenoid electrical and vacuum connections.

Engine

70. Connect the differential pressure feedback EGR system electrical and vacuum connections.

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71. Connect the vacuum hoses.

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72. Install the positive crankcase ventilation (PCV) tube.

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73. Connect the ignition coil and the radio interference capacitor electrical connectors.

Engine

74. Position and connect the LH spark plug wires.

Engine

75. Position and connect the RH spark plug wires.

Engine

76. Connect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.

Engine

77. Install the RH exhaust manifold.

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

Engine

78. Install the exhaust gas recirculation (EGR) tube.

Engine

79. Connect the EGR valve nut.

Engine

80. Using a new gasket, install the LH exhaust manifold. Tighten the nuts in the sequence shown.

Engine

81. NOTE: Install a new O-ring seal.

Install the oil level indicator and tube and retaining bolt.

Engine

82. Install the special tool.

Engine

83. Install the special tool.

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84. Install the RH engine support insulator.

Engine

85. Install the LH engine support insulator.

Engine

86. Remove the engine from the stand.

87. NOTE: Lubricate the crankshaft rear seal lips with clean engine oil prior to installation.

Assemble the special tools and the crankshaft rear seal.

Engine

88. Install the special tools on the rear of the crankshaft.

Engine

89. Install the crankshaft rear seal. Tighten the center jack screw (303-S560) until the spacer (303- 561) contacts the engine block.

Engine

    Piston
    Special Tool(s) Piston Pin Tool or equivalent 303-D034 (D81L-6135-A) Material Item Specification SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent ...

    Engine (Installation)
    Special Tool(s) Heavy Duty Floor Crane 014-00071 or equivalent Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Material Item Specification SAE 5W-20 Pre ...

    Other materials:

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    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 distorted, install a new cylinder head. Cylinder Bore -Cleaning ...

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