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

Special Tool(s)

Guides, Connecting Rod 303-442 (T93P-6136-A)
Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH)
Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH)
Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH)
Impact Slide Hammer 100-001 (T50T-100-A)
Spreader Bar 303-D089 (D93P-6001-A3)
Lifting Bracket, Engine 303-D087 (D93P-6001-A1)
Lifting Bracket, Engine 303-D088 (D93P-6001-A2)
Lifting Bracket Set, Engine 303-D074 (D91P-6001-A)
Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
Holding Tool, Crankshaft 303-448 (T93P-6303-A)
Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
Compressor, Valve Spring 303-576 (T97P-6565-AH)
Strap Wrench 303-D055 (D85L-6000-A) or equialent
Crankshaft Seal Installer 303-635

Material

Item Specification
Silicone Gasket and Sealant F7AZ-19554-EA or equivalent WSE-M4G323- A4
Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent WSS-M2C153-H

Assembly

NOTE: During engine assembly, it may by necessary to check bearing clearances and end play. For additional information, refer to Section.

1. Record the main bearing code found on the front of the engine block.

Engine

2. Record the main bearing code found on the back of the crankshaft.

Engine

3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart determine the required bearing grade for each main bearing.

  • Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
  • Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing.
  • As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is "2."
  • Repeat this process for the remaining four main bearings.

Engine

4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearing Chart to determine the required grade for each main bearing.

Engine

NOTE: Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

5. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.

6. NOTE: Do not install the upper thrust washer until the crankshaft is installed. Refer to Step 3.

NOTE: Do not install the upper thrust washer until the crankshaft (6303) is installed. Refer to Step 3.

Install the crankshaft onto the upper main bearings.

Engine

7. NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the crankshaft surface).

Push the crankshaft rearward and install the crankshaft upper thrust washer at the rear of the No. 5 main boss.

8. NOTE: Rotate the jackscrews into the bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps.

Install the lower main bearings into the main bearing caps and lubricate them with clean engine oil.

9. Install the rear main bearing cap.

Engine

10. Install the remaining main bearing caps on the cylinder block and tap into place using a plastic or dead-blow hammer.

Engine

11. Install the vertical main bearing cap fasteners and tighten in the sequence shown.

  • Tighten to 40 Nm (30 lb-ft).
  • Tighten an additional 85-95 degrees.

Engine

12. Back out the jackscrews against the cylinder block in sequence shown.

  • Tighten to 5 Nm (44 lb-in).
  • Tighten to 10 Nm (89 lb-in).

Engine

13. Install the side bolts and tighten them in the sequence shown.

Engine

14. Check the crankshaft end play. For additional information, refer to Section.

15. Check the piston to cylinder block and piston ring clearances.

16. Install the piston rings.

Engine

17. Make sure the ring gaps (oil spacer [A], oil ring [B], and compression ring [C]) are properly spaced around the circumference of the piston.

Engine

18. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.

NOTE: Only one piston and connecting rod shown, others similar.

NOTE: Make sure the crankshaft is facing forward.

NOTE: Lubricate the piston rings, cylinder walls and connecting rod bearings with clean engine oil.

Install the upper bearings in the connecting rod as shown.

Engine

19. NOTE: The piston grade number will face the rear of the engine.

Check that the piston/connecting rod assembly is oriented with the identification marks facing the front of the engine.

Engine

20. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.

NOTE: Make sure the crankshaft is at TDC.

NOTE: Only one connecting rod assembly shown, others similar.

Using the special tool install the piston and connecting rod assembly by pushing the pistons through the top of the cylinder block.

Engine

21. NOTE: These bolts are torque-to-yield. Install new bolts each time they are serviced.

Install the connecting rod bearing caps and bolts and tighten in three stages.

  • Stage 1: Tighten to 25Nm (18 lb-ft).
  • Stage 2: Tighten to 40Nm (30 lb-ft).
  • Stage 3: Tighten an additional 90 degrees.

Engine

22. Rotate the crankshaft and install the remaining piston and connecting rod assemblies.

23. Check the connecting rod bearing clearance. For additional information, refer to Section.

24. Install the oil pump and tighten the bolts.

Engine

25. NOTE: Install a new O-ring if necessary.

Install the oil pump screen cover and tube.

Engine

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

If the retainer plate was removed, apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.                                                  

Engine

27. Install the rear main seal retainer plate. Tighten the bolts in the sequence shown.

  • Tighten bolts 1-6 to 10 Nm (89 lb-in).
  • Hand-tighten bolts 7 and 8.
  • Tighten bolts 7 and 8 to 20 Nm (15 lb-ft).
  • Tighten bolts 7 and 8 an additional 60 degrees.

28. Install the oil pan and gasket and loosely install the bolts.

Engine

29. Tighten the bolts in the sequence shown.

  • Tighten to 20 Nm (15 lb-ft).
  • Rotate an additional 60 degrees.

Engine

30. Install the cylinder head gaskets.

Engine

31. CAUTION: Cylinder head to cylinder block pre-assembly must be followed exactly or damage to valves and pistons can result.

CAUTION: Camshaft keyways must maintain a 90 degree clocked position relative to the valve cover rail.

CAUTION: To prevent piston crown and valve damage the crankshaft keyway must be clocked at 270 (45 BTDC) before the installation of the cylinder head assembly.

NOTE: Crankshaft must be rotated clockwise only.

Align the keyways as shown.

Engine

32. NOTE: Position the RH and the LH cylinder heads over the dowels on the cylinder head gaskets.

NOTE: The LH is shown the RH is 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.

Engine

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

Using a vise, compress the tensioner plunger.

Engine

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

Engine

35. Remove the tensioner from the vise.

36. NOTE: There are 58 links in each timing chain.

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

Engine

37. Install the timing chain guides.

1. Position the LH timing chain guide.

2. Install and tighten the LH bolts.

3. Position the RH timing chain guide.

4. Install and tighten the RH bolts.

Engine

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

Engine

39. 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.

Engine

40. CAUTION: Unless otherwise instructed, do not rotate either the crankshaft or the camshafts, when the timing chains are removed and the cylinder heads are installed.

Severe piston and valve damage will occur.

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.

Engine

41. Remove the special tool.

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

Engine

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

Engine

44. 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.

Engine

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

Engine

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

Engine

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

Engine

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

Engine

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

Engine

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

Engine

51. NOTE: Sensor ring teeth must face forward.

Position the crankshaft sensor ring on the crankshaft.

Engine

52. NOTE: The front cover must be installed within four minutes of applying sealant.

Apply silicone gasket and sealant in the locations shown.

Engine

53. Install a new engine front cover gasket on the engine front cover.

54. Install the engine front cover.

Engine

 

Engine

Engine

55. Tighten the four oil pan bolts in the sequence shown in three stages.

  • 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.

Engine

56. Install the belt idler pulleys.

Engine

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

Engine

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

Engine

59. Install the water pump pulley and bolts.

Engine

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

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

Engine

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

Engine

62. 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.

Engine

63. Install the LH engine mount.

Engine

64. Install the RH engine mount.

Engine

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

Install the power steering pump.

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

Engine

66. Lubricate the O-ring seal with PAG compressor oil, YN-12C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B.

Install the A/C compressor.

Engine

67. Install the oil filter adapter.

Engine

68. Install the camshaft roller followers.

1. Install the special tool.

2. Compress the valve spring.

3. Install the camshaft follower

Engine

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

Install spark plugs.

Engine

70. NOTE: The RH side is shown, the LH side is similar.

Apply an eight millimeter bead of silicone gasket and sealant at the intersection of the engine front cover and the cylinder head.

Engine

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

Install the valve covers.

Engine

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

Install a new O-ring.

Engine

73. Install the tube.

Engine

74. NOTE: RH exhaust manifold shown, LH similar. Tighten the bolts in the sequence shown.

Install the LH exhaust manifold.

Engine

75. Connect the lower end of the EGR tube to the LH exhaust manifold.

Engine

76. Inspect the O-ring seals and install new O-ring seals as necessary.

Engine

77. Install the water bypass tube.

1. Instal the bypass tube.

2. Install the nut.

Engine

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

Engine

79. NOTE: The O-ring is to be installed on top of the thermostat.

Install the water thermostat and O-ring.

  • Install a new O-ring as necessary.

Engine

80. Install the water outlet connector.

Engine

81. Install the bolts and the generator.

Engine

82. Install the generator support brace.

Engine

83. Install the accessory drive belt. For additional information, refer to Section

Engine

84. Install the radio interference capacitors.

Engine

85. Install the ignition coils and bolts.

Engine

86. Position the throttle body and install the bolts, tighten in the sequence shown.

Engine

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

Engine

88. Connect the PCV hose.

Engine

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

Engine

90. Connect the EGR tube to the EGR valve.

Engine

91. Install the EGR vacuum regulator solenoid.

1. Install the vacuum hoses.

2. Install the electrical connector.

3. Install the bolts.

Engine

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

Engine

93. Connect the differential pressure feedback EGR electrical connector.

Engine

94. Install the breather tube.

Engine

95. Install the engine control sensor wiring.

Engine

 

Engine

Engine

96. Install the RH and LH special tools.

Engine

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

Engine

98. Using the special tool, install the crankshaft rear main seal.

  • Lubricate the oil seal using clean engine oil.

Engine

99. Using the special tools, install the crankshaft rear oil slinger.

Engine

100. Install the separator plate.

Engine

101. Install the flywheel.

Engine

    Piston
    Material Item Specification Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP or equivalent WSS-M2C153- H Disassembly 1. Press the piston pin out of the connecting rod and piston a ...

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