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

Special Tool(s)

Impact Slide Hammer 100-001 (T50T-100-A)
Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
Installer, Connecting Rod 303-442 (T93P-6136-A)
Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
Engine Lift Bracket Set 303-DS086- (D93P-6001-EA)
Cylinder Ridge Reamer 303-016 (T64L-6011-EA)
Compressor, Valve Spring (Exhaust) 303-567 (T97L-6565-AH)
Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)

1. Remove the flywheel.

Engine

2. Remove the separator plate.

Engine

3. Using the special tools, remove the crankshaft rear oil slinger.

Engine

4. Using the special tools, remove the rear main seal.

Engine

5. Remove the rear seal retainer plate.

6. Mount the engine on a work stand.

Engine

7. NOTE: RH shown, LH similar.

Remove the RH and LH lifting eyes.

Engine

8. Remove the breather tube.

Engine

9. Disconnect the differential pressure feedback EGR electrical connector.

Engine

10. Disconnect the hoses from the differential pressure feedback EGR transducer (9J434).

Engine

11. Remove the EGR vacuum regulator solenoid.

1. Remove the vacuum hoses.

2. Remove the electrical connector.

3. Remove the bolts.

Engine

12. Disconnect the exhaust gas recirculation (EGR) tube from the EGR valve.

Engine

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

Engine

14. Disconnect the PCV valve hose.

Engine

15. Remove the engine wiring harness.

Engine

 

Engine

16. Disconnect the vacuum line to the fuel pressure sensor.

Engine

17. Remove the throttle body bolts.

Engine

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

Remove the throttle body and adapter as an assembly.

  • Inspect and clean the sealing surfaces.

Engine

19. Remove the ignition coils.

Engine

20. Remove the radio interference capacitors.

Engine

21. Rotate the belt tensioner and remove the accessory drive belt.

Engine

22. Remove the power steering reservoir bracket as an assembly.

1. Disconnect the supply line from the pump.

2. Remove the three bolts and reservoir.

Engine

23. Remove the upper generator support bracket.

Engine

24. Remove the bolts and the generator.

25. Remove the water outlet connector.

Engine

26. Remove the water thermostat and O-ring.

Engine

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

Engine

28. Remove the intake manifold gaskets.

Engine

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

Remove the water bypass tube.

1. Remove the nut.

2. Remove the water bypass tube.

Engine

30. NOTE: RH shown, LH similar.

Remove the RH and the LH engine mount.

Engine

31. NOTE: One side shown, other side similar.

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

  • Install the drain plugs when finished.

Engine

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

Engine

33. Remove the compressor.

1. Remove the bolts.

2. Remove the compressor.

Engine

34. Remove the oil filter adapter.

1. Remove the oil bypass filter.

2. Remove the bolts.

3. Remove the oil filter adapter.

4. Clean and inspect the sealing surfaces.

Engine

35. Remove the LH exhaust manifold.

1. Remove the exhaust manifold nuts.

2. Remove the exhaust manifold.

3. Remove the exhaust manifold gasket and discard.

Engine

36. Disconnect the exhaust recirculation (EGR) tube (9D477) at the exhaust manifold.

Engine

37. Remove the RH exhaust manifold.

1. Remove the exhaust manifold nuts.

2. Remove the exhaust manifold.

3. Remove the exhaust manifold gasket and discard.

Engine

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

39. Remove the oil level indicator tube bolt.

Engine

40. Remove the bolt and the oil level indicator tube.

Engine

41. Remove valve cover.

  • Remove the fasteners.
  • Remove the valve cover.

Engine

42. Remove valve cover.

  • Remove the fasteners.
  • Remove the valve cover.

Engine

43. NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs (12405).

NOTE: One spark plug is shown; others are similar.

Remove the spark plugs.

Engine

44. NOTE: Rotate the camshaft to the base circle of the camshaft lobe before removing followers.

Keep roller followers in order when removing.

Use special tool to compress the valve springs (6513) and remove the 16 camshaft roller followers.

  • Rotate the camshaft and the crankshaft as necessary.

Engine

45. Remove the crankshaft pulley bolt.

Engine

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

Engine

47. Remove the water pump pulley.

1. Remove the water pump pulley bolts.

2. Remove the water pump pulley.

Engine

48. Remove the bolts and belt idler pulleys.

Engine

49. NOTE: The gasket can be reused if not damaged.

Remove the oil pan.

  • Remove the bolts.
  • Remove the oil pan.

Engine

50. Using the special tool, remove the front cover seal.

Engine

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

  • Discard the gaskets. Clean and inspect the sealing surfaces.

Engine

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.

52. Remove the crankshaft sensor ring from the crankshaft.

Engine

53. Remove the RH and LH timing chain tensioner (RH shown, LH similar).

1. Remove the bolts.

2. Remove the timing chain tensioners.

3. Remove the timing chain tensioner arms.

Engine

54. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage can occur.

CAUTION: Do not remove the special tool from the camshafts.

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

  • Remove the RH timing chain from the 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 from the crankshaft sprocket.

Engine

55. NOTE: The LH is shown and the RH is similar.

Remove the bolts and the timing chain guides.

Engine

56. NOTE: One side shown, other side similar.

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

Engine

57. CAUTION: New cylinder head bolts must be installed. They are tighten-to-yield designed and cannot be reused.

CAUTION: Place cylinder head on cardboard or wood surface to prevent damage to the joint face.

Remove the RH and LH cylinder heads.

1. Remove the bolts.

2. Remove the cylinder heads.

Engine

58. CAUTION: Do not use metal scrappers, wire brushes, power abrasive discs or other abrasive means to clean gasket surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scrapping tool to remove all traces of the head gasket (6051).

Clean and inspect all of the sealing surfaces. For additional information, refer to Section.

59. Remove the oil pump screen cover and tube, and the spacer.

Engine

60. Remove the oil pump.

Engine

61. CAUTION: Do not stamp the top of pistons, as ring land damage can occur.

NOTE: Connecting rods and rod caps should be numbered to retain correct orientation.

Remove the connecting rod caps for piston numbers 1 and 6.

  • Discard the bolts.

Engine

 

Engine

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

NOTE: Before removing pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer following the manufacturer's instructions.

Remove the piston removing pistons number 1 and 6 through the top of the cylinder block.

Engine

63. Repeat the previous two steps to remove the remaining pistons, rotating the crankshaft 90 degrees between piston pairs 3 and 5, 4 and 7, 2 and 8.

64. Remove the piston rings.

Engine

65. Clean and inspect pistons. For additional information, refer to Section.

66. Remove the crankshaft bearing cap fasteners.

1. Remove and discard the cross-mounted main cap bolts.

2. Loosen the jackscrews.

3. Remove and discard the main cap bolts.

Engine

67. Remove the main bearing cap and the crankshaft main bearings from the cylinder block.

Engine

68. Remove the crankshaft, crankshaft main bearings and the thrust washer.

Engine

    Engine (Removal)
    Special Tool(s) Special Tool(s) Support Bracket, Engine 303-639 Spreader Bar 303-D089 (D93P-6001-A3) Lifting Bracket Set, Engine 303-D074 (D91P-6001-A) Re ...

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    Other materials:

    Valve Cover RH
    Removal and Installation 1. Remove the throttle body. For additional information, refer to Section. 2. Disconnect the crankcase vent hose. 3. Remove the differential feedback exhaust gas recirculation (EGR) system vacuum hoses and the bracket bolts. Po ...

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    Auxiliary input jack
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