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

Special Tool(s)

Impact Slide Hammer 100-001 (T50T-100-A)

Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
Holding Tool, Crankshaft 303-448 (T93P-6303-A)
Guides, Connecting Rod 303-442 (T93P-6136-A)
Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
Compressor, Valve Spring (Intake) 303-452 (T93P-6565-AR)
Compressor, Valve Spring (Exhaust) 303-567 (T97P-6565-AH)
Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)

Disassembly

Manual transmission vehicles

1. Remove the clutch and pressure plate. For additional information, refer to Section.

2. Remove the flywheel.

Engine

Automatic transmission vehicles

3. Remove the flexplate. For additional information, refer to Flexplate in this section.

Engine

All vehicles

4. Using the special tool, remove the rear oil slinger.

Engine

5. Using the special tool, remove the rear main seal.

Engine

6. Remove the rear seal retainer plate.

Engine

7. Mount the engine on a work stand.

Engine

8. Remove the special tools.

Engine

9. Disconnect the positive crankcase ventilation (PCV) tube.

Engine

10. Remove the PCV valve tube and electrical connector.

Engine

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

Engine

12. Disconnect the EGR tube from the exhaust manifold.

Engine

13. Disconnect the fuel pressure damper electrical connector.

Engine

14. Disconnect the EGR vacuum regulator electrical connector.

Engine

15. Disconnect the four LH fuel injector electrical connectors.

Engine

16. Remove the LH coil cover.

Engine

17. Disconnect the generator.

Engine

18. Disconnect the idle air control (IAC) valve electrical connector.

Engine

19. Disconnect the throttle position (TP) sensor electrical connector.

Engine

20. Remove the bolts and the upper intake manifold.

Engine

21. Remove the upper intake manifold gasket.

  • Clean and inspect the sealing surfaces.

Engine

22. Remove the RH coil cover.

Engine

23. Disconnect the LH ignition coils.

Engine

24. Disconnect the four RH fuel injector electrical connectors.

Engine

25. Disconnect the engine coolant temperature (ECT) sensor.

Engine

26. Disconnect the RH ignition coils.

Engine

27. Remove the eight ignition coils.

Engine

28. Remove the bracket from the accessory drive belt tensioner.

29. Remove the accessory drive belt.

30. Remove the coolant bypass tube and upper generator support bracket.

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

Engine

31. Remove the generator.

Engine

32. Remove the eight bolts and the two studs in the sequence shown. Remove the lower intake manifold.

Engine

33. Remove the bolts and the coolant pump pulley.

Engine

34. Remove the coolant pump from the cylinder block.

  • Remove the bolts.
  • Inspect and clean the sealing surfaces.

Engine

35. Remove the bolt.

Engine

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

Engine

37. Using the special tool, remove the crankshaft front seal.

Engine

38. Remove the belt idler pulleys.

Engine

39. Remove the bolts and the LH valve cover.

Engine

40. Remove the bolts and the RH valve cover.

Engine

41. Remove 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. Crankshaft position sensor (CKP) electrical connector.

Engine

42. Remove the knock sensors.

Engine

43. NOTE: LH side is shown; RH side is similar.

Remove the exhaust manifolds.

1. Remove the nuts.

2. Remove the LH and RH exhaust manifolds.

3. Remove the exhaust manifold gaskets.

Engine

44. Remove the four bolts.

Engine

45. Remove the engine front cover.

Engine

 

Engine

46. NOTE: Be careful when removing the gasket. It is reusable if not damaged.

Remove the oil pan and the gasket.

Engine

47. Remove the CKP sensor pulse wheel.

Engine

48. Using the special tool, remove the 32 roller followers.

Engine

49. Remove the bolts and the RH and LH timing chain tensioners

Engine

50. Remove the RH and LH timing chain tensioner arms.

Engine

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

Engine

52. Remove the RH and LH timing chain guides.

Engine

53. Remove the RH and LH cylinder heads.

Engine

54. Remove the oil filter adapter.

1. Remove the oil filter.

2. Remove the bolts.

3. Remove the oil filter adapter.

4. Remove the gasket.

Engine

55. Clean and inspect the oil filter adapter.

  • Flush the adapter with parts cleaner. If metal particles are present, install a new oil filter adapter.

56. Remove the bolts and the oil pump screen and pickup tube.

Engine

57. Remove the oil pump screen and pickup tube spacer.

Engine

58. Remove the nuts and the windage tray.

Engine

59. Remove the LH engine mount.

Engine

60. Remove the RH engine mount.

Engine

61. Remove the bolts and the oil pump.

Engine

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

NOTE: Connecting rods and rod caps should be numbered to keep the correct orientation in the following sequence.

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

  • Discard the bolts.

Engine

63. CAUTION: Do not scratch the 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 manufacturer's instructions.

Using the special tool, push pistons number 1 and 6 through the top of the cylinder block.

Engine

64. To remove pistons 3 and 5, 4 and 7, 2 and 8, turn crankshaft 90 degrees and repeat the previous two steps.

65. Remove the side main bearing cap bolts.

Engine

66. Remove and discard the main bearing cap bolts.

Engine

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

Engine

68. Remove the crankshaft, the crankshaft thrust washer, and the crankshaft upper main bearings from the cylinder block.

Engine

    Engine (Removal)
    Special Tool(s) Lifting Bracket, Engine 303-D087 (D93P-6001-A1) Lifting Bracket, Engine 303-D088 (D93P-6001-A2) Spreader Bar 303-D089 (D93P-6001-A3) Rem ...

    Cylinder Head
    Special Tool(s) Compressor, Valve Spring (Exhaust Side) 303-567 (T97P-6565-AH) Compressor, Valve Spring (Intake Side) 303-452 (T93P-6565-AR) Holding Tool, ...

    Other materials:

    Installation
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    Removal
    WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited, possibly resulting in personal injury. WARNING: Fuel supply lines ...

    Assembly
    1. Install the valve stem seals. 2. Install the valves and the valve springs. 3. CAUTION: Make sure the tool is seated correctly on the valve spring. Apply a small amount of air at a time. This will prevent the tool from shifting and causing damage to the ...