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

Special Tool(s)

Guides, Connecting Rod 303-442 (T93P-6136-A)

Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH)
Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH)
Compressor, Valve Spring (Intake) 303-452 (T93P-6565-AR)
Compressor, Valve Spring (Exhaust) 303-567 (T97P-6565-AH)
Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH)
Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
Holding Tool, Crankshaft 303-448 (T93P-6303-A)

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
Super Premium SAE 5W-20 Engine Oil XO-5W20-QSP or equivalent WSS-M2C153- H
Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) (yellow color) WSS-M97B51- A1

Assembly

All vehicles

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 upper main bearings into the cylinder block and the lower main bearing into the crankshaft main bearing caps. Lubricate the main bearings with clean engine oil.

6. Install the crankshaft into the cylinder block.

Engine

7. CAUTION: Make sure the coated side of the thrust washer with the 5-mm wide oil grooves faces the crankshaft thrust surface.

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

Engine

8. Loosely install the main bearing caps and the bolts.

Engine

9. Push the crankshaft forward to seat the crankshaft thrust washer and hold the crankshaft in the forward position.

Engine

10. Tighten bolts 1-20 in sequence shown in four stages.

  • Stage 1: tighten to 10 Nm (89 lb-in).
  • Stage 2: tighten to 25 Nm (18 lb-ft).
  • Stage 3: tighten to 40 Nm (30 lb-ft).
  • Stage 4: tighten an additional 90 degrees.

Engine

11. Install and tighten the cross-mounted bolts in two stages.

  • Stage 1: tighten to 40 Nm (30 lb-ft).
  • Stage 2: tighten an additional 90 degrees.

Engine

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

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

NOTE: Make sure that the piston arrow is facing forward.

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

Using the special tool push the pistons through the top of the cylinder block.

Engine

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

NOTE: Make sure the crankshaft is at T.D.C.

Using the special tool, install the connecting rod assemblies.

Engine

15. NOTE: The rod bearing cap 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 25 Nm (18 lb-ft).
  • Stage 2: tighten to 45 Nm (33 lb-ft).
  • Stage 3: tighten an additional 90 degrees.

Engine

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

17. Install the LH engine mount.

Engine

18. Install the RH engine mount.

Engine

19. Install the nuts and the windage tray.

Engine

20. Install and tighten the oil pump screen spacer.

Engine

21. Position the oil pump and tighten the bolts in the sequence shown.

Engine

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

Install the oil pump screen cover and tube.

Engine

23. Install the cylinder head gaskets.

Engine

24. CAUTION: The camshafts must be positioned so the camshaft keyway is 90 degrees from the valve cover gasket surface to avoid damage to valves and pistons during timing procedures.

Make sure the camshaft timing sprockets are positioned correctly.

Engine

25. NOTE: The LH is shown; the RH is similar.

NOTE: Lubricate the bolt heads and threads. Use clean engine oil.

Install the LH and RH cylinder heads and 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

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

Compress the tensioner plunger, using a vise.

Engine

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

Engine

28. Remove the tensioner from the vise.

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

Engine

30. Install the timing chain guides.

Engine

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

Engine

32. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated.

Severe piston and valve damage will occur.

CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and/or valve damage will occur.

Using the special tool, position the crankshaft.

Remove the special tool.

Engine

33. Install the crankshaft sprocket with the flange facing forward.

Engine

34. Install the LH and RH timing chain onto the crankshaft sprocket, aligning the one copper (or marked) link on the timing chain with the slot on the crankshaft sprocket.

Engine

35. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.

Position the RH timing chain on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark.

36. As a post-check, verify correct alignment of all timing marks.

Engine

37. Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the bolts.

Engine

38. Remove the retaining clips from the timing chain tensioners.

Engine

39. Position the crankshaft sensor ring on the crankshaft.

Engine

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

Engine

41. Tighten the bolts in the sequence shown.

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

Engine

42. Install the drain plugs

Engine

43. 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 result in future oil leakage.

Apply silicone gasket and sealant in the locations shown.

Engine

44. Install the engine front cover.

Engine

 

Engine

Engine

45. Tighten the four oil pan bolts 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.

Engine

46. Install oil filter adapter.

1. Position the gasket.

2. Position the oil filter adapter.

3. Tighten the bolts.

4. Install a new oil filter.

Engine

47. Using the special tool, install the 32 roller followers.

Engine

48. NOTE: If the valve 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 result in future oil leakage.

Apply silicone gasket and sealant in the locations shown.

Engine

49. NOTE: The RH is shown; the LH is similar.

Install the valve covers and tighten the bolts in the sequence shown.

Engine

50. Install the belt idler pulleys.

Engine

51. Lubricate the front oil seal and the engine front cover with clean engine oil.

Engine

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

Engine

53. Apply silicone gasket and sealant to the woodruff key on the crankshaft pulley.

Engine

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

Engine

55. Install the crankshaft pulley and tighten the bolt in four stages.

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

Engine

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

Install the coolant pump.

Engine

57. NOTE: The RH is shown; the LH is similar. Use new gaskets when installing the exhaust manifolds.

Install the exhaust manifold.

Engine

58. Install the knock sensors.

Engine

59. Install the knock sensor wiring harness.

1. LH knock sensor electrical connector

2. RH knock sensor electrical connector

3. Engine control sensor electrical connector

4. Fuel injector electrical connector

5. A/C compressor electrical connector

6. CKP sensor electrical connector

Engine

60. Install the lower intake manifold.

  • Position the gaskets.
  • Install the intake manifold and tighten the bolts in the sequence shown.

Engine

61. Install the generator.

Engine

62. Install the upper generator support bracket and coolant bypass tube.

  • Install the upper generator support bracket.
  • Install the coolant bypass tube.
  • Install the bolts.

Engine

63. Install the eight ignition coils.

Engine

64. Connect the eight ignition coils.

Engine

65. Connect the engine coolant temperature (ECT) sensor.

Engine

66. Connect the eight fuel injectors.

Engine

67. Install the RH ignition coil cover.

Engine

68. NOTE: The fastener at location five is a stud.

Install the gasket and the upper intake.

Engine

69. Connect the throttle position (TP) sensor electrical connector.

Engine

70. Connect the idle air control (IAC) valve electrical connector.

Engine

71. Connect the generator wiring.

Engine

72. Install the LH coil cover.

Engine

73. Connect the EGR vacuum regulator (EVR) electrical connector.

Engine

74. Connect the fuel pressure sensor electrical connector.

Engine

75. Connect the EGR tube to the exhaust manifold.

Engine

76. Connect the EGR tube to the EGR valve.

Engine

77. Install the PCV valve hose and connect the electical connector.

Engine

78. Connect the PCV valve tube to the upper intake manifold.

Engine

79. Install the special tool.

Engine

80. Remove the engine from the stand.

Engine

81. NOTE: If 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 result in future oil leakage.

Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer plate sealing surface. Also apply a bead of silicone gasket and sealant at the junction where the cylinder block, oil pan and rear oil seal retainer plate meet.

Engine

82. Install the rear oil seal retainer plate. Tighten the bolts in the sequence shown.

  • Tighten the bolts to 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.

Engine

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

Engine

84. Using the special tools, install the crankshaft oil slinger.

Engine

Automatic transmission vehicles

85. Install the flexplate and install the bolts in the sequence shown.

Engine

Manual transmission vehicles

86. Install the flywheel and the bolts in the sequence shown.

Engine

87. Install the clutch and pressure plate. For additional information, refer to Section.

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