Ford Mustang (1999-2004) Service Manual: Installation

NOTE: Do not use a fiber disc to clean the surfaces. Fibers from the disc can get into the oil pan and oil and clog the oil bypass valve.

1. Clean and inspect the cylinder head for flatness. 2. Install a new head gasket on the cylinder block with the small hole to the front of the engine and position the cylinder head.

Cylinder Head RH

3. CAUTION: Always use new bolts.

NOTE: Lubricate the bolts with clean engine oil.

Install new bolts. Refer to the location note made during removal and make sure the bolts are installed the correct location.

1. Install the new long bolts.

2. Install the new short bolts.

Cylinder Head RH

4. Tighten the bolts in three stages in the sequence shown.

  • Stage 1: Tighten to 20 Nm (15 lb-ft).
  • Stage 2: Tighten to 40 Nm (30 lb-ft).
  • Stage 3: Tighten to 50 Nm (37 lb-ft).

Cylinder Head RH

5. CAUTION: Do not loosen all of the bolts at one time. Each bolt must be loosened and final-tightened prior to working on the next bolt in the sequence.

NOTE: The short bolts are numbered 2, 4, 6 and 8 and the long bolts are numbered 1, 3, 5 and 7.

Loosen, then tighten the bolts in the sequence shown:

  • Tighten short bolts to 25 Nm (18 lb-ft), then tighten an additional 180 degrees.
  • Tighten long bolts to 45 Nm (33 lb-ft), then tighten an additional 180 degrees.

Cylinder Head RH

6. Install the three studs.

Cylinder Head RH

7. Install the bracket and bolts.

Cylinder Head RH

8. Connect the A/C compressor clutch electrical connector.

Cylinder Head RH

9. Connect the A/C manifold and tube assembly.

10. Install the accessory drive belt.

11. Install the push rods. For additional information, refer to Push Rod in this section.

12. Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in this section.

13. Install the RH exhaust manifold. For additional information, refer to Exhaust Manifold RH in this section.

14. Connect the battery ground cable.

15. CAUTION: Correct cooling system bleeding is critical for correct engine cooling.

Fill and bleed the engine cooling system.

16. Recharge the A/C refrigerant system.

    Removal
    1. Disconnect the battery negative cable. 2. Drain the engine cooling system. 3. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold RH in this section. 4. Remo ...

    Oil Level Indicator and Tube
    Removal and Installation 1. Remove the oil level indicator tube (6754). Remove the bolt. Remove the oil level indicator tube. Remove and discard the oil level indicator tube O-ring. 2. To ...

    Other materials:

    Torque Converter (Description and Operation)
    The torque converter transmits and multiplies torque. The torque converter is a four-element device: impeller assembly turbine assembly reactor assembly clutch and damper assembly The standard torque converter components operate as follo ...

    Removal
    1. CAUTION: The vehicle must be on level ground and at curb height. Mark the rear shock absorbers relative to their protective sleeve. During installation, raise the suspension to this reference mark before tightening the suspension component fasteners. ...

    Engine - 3.8L
    General Specifications a - 20-200 seconds to leakdown 3.18 mm (0.125 in) with 225 Newtons (50 pounds) load and tappet filled with leak-down fluid. Torque Specifications a - Refer to the procedure in this section b - Advance one-half turn aft ...