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

Special Tool(s)

Spreader Bar 303-D089 (D93P-6001-A3)
Support Bracket, Engine 303-639
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)

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
Premium Engine Coolant E2FZ-19549-AA (In Canada CXC-10; In Oregon F5FZ- 19549-CC) or equivalent ESE-M97B44- A

1. NOTE: Adjust the transmission support jack as necessary to aid in the installation of the engine.

Using the special tool, install the engine.

Engine

2. Connect the transmission wiring to the bracket during installation.

Engine

3. Remove the special tool.

Engine

4. Install the special tool.

Engine

5. NOTE: This step will allow the installation of the exhaust manifold through the bottom and access for the removal of the engine lift brackets.

Using a suitable floor crane raise the engine.

Engine

6. Remove the RH and LH special tool.

Engine

7. Install new gaskets and the exhaust manifolds, tighten the nuts in the sequence shown.

Engine

8. Lower the engine, remove the special tool.

Engine

9. Install the generator. For additional information, refer to Section.

10. Raise the vehicle. for additional information, refer to Section.

11. Install the power steering pump. For additional information, refer to Section.

12. Install the bolt and the body ground.

Engine

13. Install the nine bell housing bolts.

Engine

14. Install the starter. For additional information, refer to Section.

15. NOTE: This will need to be done as the H-pipe is being positioned.

Connect the LH heated oxygen sensor.

Engine

16. NOTE: This will need to be done as the H-pipe is being positioned.

Connect the RH heated oxygen sensor.

Engine

17. Re-position the H-pipe and install the four exhaust flange to manifold nuts.

Engine

18. Lower the vehicle.

19. NOTE: The O-ring seal must be inspected and cleaned before installation. For additional information, refer to Section.

Install the A/C line and tighten the nut.

Engine

20. NOTE: The O-ring seal must be inspected and cleaned before installation. For additional information, refer to Section.

Connect the line to the evaporator core.

Engine

21. Install the safety clip.

Engine

22. NOTE: The O-ring seal must be inspected and cleaned before installation. For additional information, refer to Section.

Connect the line to the receiver drier.

Engine

23. Install the safety clip.

Engine

24. Connect the degas sensor lead to the battery tray.

Engine

25. Connect the connector.

Engine

26. Install the battery leads.

Engine

27. Position the access cover.

Engine

28. Connect the ground connector

Engine

29. Connect the connector.

Engine

30. Connect the fuse link.

Engine

31. Install and tighten the body ground.

Engine

32. Connect the power steering line.

Engine

33. NOTE: The O-ring seal must be inspected and cleaned before installation. For additional information, refer to Section.

Install the A/C line.

Engine

34. Connect the A/C pressure cycle switch.

Engine

35. NOTE: The O-ring seal must be inspected and cleaned before installation. For additional information, refer to Section.

Connect the A/C manifold suction line.

Engine

36. Install the safety clip to the manifold suction line.

Engine

37. Connect the electrical connector.

Engine

38. Connect the harness in three locations.

Engine

39. Connect the engine bulkhead connector.

Engine

40. Connect the heater water hoses.

Engine

41. Connect the climate control vacuum supply lines.

Engine

42. Position the cables and install the bracket.

Engine

43. Connect the throttle cable, speed control actuator cable and the return spring.

Engine

44. Connect the upper radiator hose from the water outlet adapter.

Engine

45. Connect the fuel lines. For additional information, refer to Section.

46. Install the battery. For additional information, refer to Section.

47. Install the air cleaner and outlet tube. For additional information, refer to Section.

48. Install the degas bottle.

49. Fill the fluids to the correct levels.

50. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.

51. Recharge the A/C system. For additional information, refer to Section.

52. Install the hood.

    Cylinder Heads (Installation)
    Special Tool(s) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Holding Tool, Crankshaft 3 ...

    Other materials:

    Driveline Angle Inspection
    Special Tool(s) Anglemaster II Driveline Inclinometer 164-R2402 or equivalent NOTE: An incorrect driveline angle can cause a vibration or shudder. 1. Check the vehicle for evidence or overload or sagging. Check for specified air pressures in ...

    Pinpoint Tests
    The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the s ...

    Bulb
    Removal and Installation 1. Remove the floor console. For additional information, refer to Section. 2. Remove the bolts, then position the bezel upward. 3. Remove the bulb socket from the bezel. 4. Remove the bulb. 5. To install, reverse the removal ...