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.

3. Position the cylinder head.

Cylinder Head LH

4. 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 LH

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

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

Cylinder Head LH

6. 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 numbered 1, 3, 5 and 7.

Loosen, then tighten the bolts in two stages in the sequence shown.

  • Stage 1: Tighten short bolts to 25 Nm (18 lb-ft), then tighten an additional 180 degrees.
  • Stage 1: Tighten long bolts to 45 Nm (33 lb-ft), then tighten an additional 180 degrees.

Cylinder Head LH

7. Install the exhaust manifold studs.

Cylinder Head LH

8. Install the bracket and bolts.

Cylinder Head LH

9. Install the support bracket.

Cylinder Head LH

10. Using the special tool, install the power steering pump pulley.

Cylinder Head LH

11. Install the drive belt.

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

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

14. Install the LH exhaust manifold. For additional information, refer to Exhaust Manifold-LH in this section.

15. Connect the battery ground cable.

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

Fill and bleed the engine cooling system.

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

    Cylinder Head RH
    Material ...

    Other materials:

    Starter Drive and Flywheel Ring Gear Inspection
    1. Remove the starter motor. For additional information, refer to Starter Motor-3.8L or Starter Motor-4.6L in this section. 2. Check the wear patterns on the starter drive gear and the flywheel ring gear . If the wear pattern is normal, install the sta ...

    Throttle Body
    Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and can ignite. Failure to follow these instructions can result in personal in ...

    Ignition Switch Lock Cylinder - Non-Functional
    Removal and Installation 1. NOTE: Make sure the front wheels are in the straight-ahead position. Disconnect the battery ground cable (14301) and wait at least one minute to allow the depletion of the restraint system backup power supply. 2. WARNING: To avo ...