Ford Mustang (1999-2004) Service Manual: Installation

All vehicles

1. Position the engine front cover gasket on the engine front cover.

Engine Front Cover

2. 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 cause future oil leakage.

Apply the silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface.

Engine Front Cover

3. Install the engine front cover and tighten the bolts and studs in sequence shown.

Engine Front Cover

 

Engine Front Cover

Engine Front Cover

4. Install the idler pulleys.

Engine Front Cover

5. Connect the camshaft position (CMP) sensor electrical connector.

Engine Front Cover

6. Position the power steering reservoir and bracket assembly and install the bolts.

Engine Front Cover

7. Install the coolant pump pulley and the bolts.

Engine Front Cover

8. Install the LH valve cover and loosely install the bolts.

Engine Front Cover

9. Tighten the LH valve cover bolts in the sequence shown.

Engine Front Cover

10. Raise and support the vehicle. For additional information, refer to Section.

Manual transmission vehicles

11. Connect the clutch release cable to the clutch release fork.

Engine Front Cover

12. Install the clutch release cable shield and the bolt.

Engine Front Cover

All vehicles

13. Loosely install the four oil pan bolts. Tighten the bolts in three stages, and in the sequence shown.

1. Stage 1: Tighten the bolts to 2 Nm (18 lb-in).

2. Stage 2: Tighten the bolts to 20 Nm (15 lb-ft).

3. Stage 3: Tighten the bolts an additional 90 degrees (1/4 turn).

Engine Front Cover

14. Position the wiring harness and install the nuts.

Engine Front Cover

15. Connect the crankshaft position (CKP) sensor electrical connector.

Engine Front Cover

16. Position the A/C compressor, A/C muffler, and the hose. Install the bolts.

Engine Front Cover

17. Install the A/C muffler bracket nut.

Engine Front Cover

18. Position the power steering pump and install the bolts.

Engine Front Cover

19. Install the crankshaft front oil seal. For additional information, refer to Crankshaft Front Oil Seal in this section.

20. Position the cooling fan and shroud in the installed position.

Engine Front Cover

21. Install the RH cooling fan bolt.

Engine Front Cover

22. Install the LH cooling fan bolt.

Engine Front Cover

23. Attach the cooling fan wiring harness to the fan shroud.

Engine Front Cover

24. Connect the cooling fan electrical connector.

Engine Front Cover

25. Connect the lower radiator hose to the bypass tube.

Engine Front Cover

26. Connect the upper radiator hose to the bypass tube.

Engine Front Cover

27. Install the degas bottle and the nuts.

Engine Front Cover

28. Connect the degas bottle return hose.

Engine Front Cover

29. Connect the degas bottle vent hose.

Engine Front Cover

30. Connect the wiring harness anchor to the valve cover.

Engine Front Cover

31. Install the positive crankcase ventilation (PCV) valve hose and connect the electrical connector.

Engine Front Cover

32. Position the oil level indicator tube and install the bolt.

Engine Front Cover

33. Install the LH ignition coils.

Engine Front Cover

34. Connect the LH ignition coil electrical connectors.

Engine Front Cover

35. Install the LH coil cover and install the bolts.

Engine Front Cover

Manual transmission vehicles

36. Install the clutch release cable screws.

Engine Front Cover

All vehicles

37. Install the RH valve cover. For additional information, refer to Valve Cover RH in this section.

38. Install the Hydro-Boost brake booster. For additional information, refer to Section.

39. Install the air intake scoop bracket. For additional information, refer to Section.

40. Fill the crankcase with clean engine oil.

    Removal
    All vehicles 1. Remove the air intake scoop bracket. For additional information, refer to Section. 2. Remove the RH valve cover. For additional information, refer to Valve Cover RH in this section. ...

    Timing Drive Components
    Special Tool(s) Holding Tool, Crankshaft 303-448 (T93P-6303-A) ...

    Other materials:

    Hydraulic System
      Fluid Pump   The transmission uses a gerotor-type design front pump support and gear. The pump provides the volume of fluid needed to charge the torque converter, main control assembly, cooling system and lube system. Pump pressure is regu ...

    Master Cylinder Priming - 4.6L
    1. CAUTION: Use only bleed screws on the engine side of the brake master cylinder (2140). The hydro-boost bleed screw, located near the dash on the hydro-booster casting, is for the booster cavity filled with power steering fluid, not brake fluid. ...

    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 ...