Section 03-01A: Engine, 2.3L
1993 Mustang Workshop Manual
REMOVAL AND INSTALLATION

 CAUTION: Do not oil threads that require oil resistant or water resistant sealer.

When installing nuts or bolts, oil the threads with light-weight engine oil.

Cylinder Head

Tools Required:

 

Removal

  1. Drain cooling system.
  1. Remove air cleaner assembly.
  1. Remove engine and generator wiring harnesses.
  1. Remove ignition wires (spark plug wires). Remove spark plugs.
  1. Disconnect required vacuum hoses.
  1. Remove dipstick, disconnect dipstick tube from bracket.
  1. Remove upper intake manifold, throttle body assembly and EGR tube, as outlined.
  1. Remove rocker cover retaining bolts and remove cover.
  1. Remove intake manifold retaining bolts.
  1. Remove belt tensioner. Loosen generator retaining bolt and swing generator aside. Remove ribbed belt.
  1. Disconnect upper radiator hose at both ends. Remove from vehicle.
  1. Remove timing belt cover retaining bolt and remove cover.
  1. Loosen timing belt idler retaining bolts. Position idler in the unloaded position and tighten the retaining bolts.
  1. Remove timing belt from the cam pulley and auxiliary pulley.
  1. Remove the eight exhaust manifold retaining bolts.
  1. Remove timing belt idler and two bracket bolts.
  1. Remove timing belt idler spring stop from the cylinder head.
  1. Remove cylinder head retaining bolts.
  1. Remove the cylinder head.
  1. Clean cylinder head gasket surface at the block.
  1. Clean intake manifold gasket surface at the intake manifold.
  1. Clean exhaust manifold gasket surface at the exhaust manifold.
  1. Clean exhaust manifold gasket surface at the cylinder head.
  1. Clean cylinder head gasket surface at the cylinder head.
  1. Clean intake manifold gasket surface at the cylinder head.
  1. Blow oil out of the cylinder head bolt block holes.
  1. Clean rocker cover gasket surface on the head.
  1. Check gasket surfaces for flatness. Refer to Specifications.


Installation




  1. Position head gasket on the block.
  1. Clean rocker arm cover (cam cover).

     CAUTION: Position camshaft as shown in illustration.

  1. Position cylinder head to block.
  1. Install new cylinder head retaining bolts. Tighten in sequence in three steps: tighten to 70 Nm (52 lb-ft), retighten to 70 Nm (52 lb-ft) minimum in sequence, then tighten 90 ± 10 degrees in sequence.
  1. Install rocker arm cover and gasket. Tighten retaining bolts to 7-11 Nm (62-97 lb-in).
  1. Install intake manifold. Tighten retaining nuts/bolts in sequence to 26-38 Nm (19-28 lb-ft).
  1. Install cam belt tensioner spring stop to the cylinder head.
  1. Position cam belt tensioner and tensioner spring to cylinder head, and install retaining bolts. Rotate tensioner against spring with Camshaft Belt Tensioner Tool T74P-6254-A and temporarily tighten.
  1. Install the eight exhaust manifold retaining bolts. Tighten the bolts in sequence in two steps: 20-23 Nm (178-203 lb-in), then 27-41 Nm (20-30 lb-ft).
  1. Align cam sprocket with pointer.
  1. Align crank pulley (TDC) with pointer on cam belt cover.
  1. Install cam belt over sprockets.
  1. Loosen tensioner retaining bolts, rotate engine by hand one complete revolution and check timing alignment.
  1. Tighten tensioner retaining bolts to specification.
  1. Install cam belt cover and retaining bolt. Tighten to 8-12 Nm (6-9 lb-ft).
  1. Install upper intake manifold throttle body and EGR tube assembly as outlined.
  1. Connect upper radiator hose to engine and radiator. Connect vacuum hoses. Install automatic belt tensioner.
  1. Position generator and install retaining bolt.
  1. Position ribbed belt on pulleys.
  1. Install dipstick tube and bracket.
  1. Install spark plugs.
  1. Install dipstick.
  1. Position and connect engine and generator wiring harnesses. Install ignition wires.
  1. Fill cooling system. Refer to Section 03-03.
  1. Install hose from air cleaner to throttle body.
  1. Start engine and check for leaks.