1996-1998 Mustang GT 4.6L or 2001-2004 Romeo– Installing 1999-2000 Windsor Heads/Cam/Intake for PI Headswap
Reuse your camshafts and PI Intake. They will fit.
Parts Checklist:
99-00 PI Windsor Heads – 2L1Z-6049-DA (bare, no cams) and with cams is 2L3Z-6049-BA (RH) and 2L3Z-6049-DA (LH) - (1 of each)
99+ PI Individual Cams - 1L2Z-6250-AA (RH) and 1L2Z-6250-DA (LH) - (1 each) - If you have camless heads.
01+ PI Intake Manifold Assembly – 1W7Z-9424-AB – (1 assembly)
99-00 PI Head Gaskets - FC2Z-6051-AA – (RH) and 4C2Z-6051-BA – (LH) – (1 each)
99-00 Intake Manifold Gasket - YL3Z-9429-BA - (1 each for a total of 2)
Cam/Valve Cover - 2L3Z-6582-BA and 2L3Z-6582-DA - (1 each)
Cam/Valve Cover Gasket - 2L3Z-6584-AA (LH) and 2L3Z-6584-BA (RH) – (1 each)
Cam/Valve Cover Bolts – 4C3Z-6C519-AA (Pack of 4 bolt/grommets) - Need 27 new/used windsor valve cover bolts/grommets.
Windsor Head Bolts - 3L3Z-6065-AA - (20 bolts)
Alternator Bracket - F8AZ-10153-EA – 96-98 with PI Intake/Al. Crossover - (1 bracket)
Coolant Tube - XR3Z-18B402-AA - (1 tube)
Coolant Nipple - F75Z-8555-AA - (1 nipple)
Timing Cover/Front Cover Gasket - F1AZ-6020-A - (1 gasket)
Timing Cover/Front Cover Gasket - F6AZ-6020-BB - (1 gasket)
Timing Cover/Front Cover Gasket - F1AZ-6020-C - (1 gasket)
Exhaust Manifold Gaskets - YC2Z-9448-CA (4 gaskets)
Crankshaft Seal - F5AZ-6700-A – (1 seal)
Crankshaft Bolt – F5RZ-6A340-B aka: F1AZ-6A340-A – (1 bolt) or ARP-156-2501
Oil Dipstick or Lokar Oil Dipstick - XR3Z-6754-BA or LOK-ED-5014 (1 dipstick)
Upper Plenum O-Ring - XR3Z-9L437-BA - (1 o-ring)
Thermostat O-Ring - F1VY-8255-A - (1 o-ring)
Water Pump O-Ring - F1VY-8507-A- (1 o-ring)
Timing Cover Bolt - N808142-S437 – M10 - (Comes in Pack of 4, washers included)
Timing Cover Stud - N808140-S309 - M10 - (Comes in Pack of 4, washers included)
Timing Cover Stud - N808529-S309 -M10X1 5X1 - (Comes in Pack of 4)
Header Down-Pipe Gasket – XR3Z-9450-AA – (1 gasket)
Stock or 180* Thermostat – 3L3Z-8575-AC (192*) or XL3Z-8575-AA (180*)- (1 t-stat)
Spark Plug Wires – F8PZ-12259-HA – (1 kit)
Spark Plugs – SP-505 – 192* (8 plugs): Motorcraft AGSF-22C's gapped at .048 to .050
(our stock gap if you are running stock compression like you) for normal street use or AWSFA-12C's for street/strip. The 12C's are 2 steps colder than stock and if you are going to run it hard it might be a better option.
* - Windsor valve cover bolts come with grommets that attach to the windsor bolts and Romeo valve cover bolts are separate from the grommets.
More Windsor Head Swap Information:
Windsor Heads/Valve Covers has 13 (driver side) and 14 bolts (passenger side), and Romeo has 11 bolts.
If using Windsor heads (99-00), you will need 99-00 Valve Covers and extra valve cover bolts, Four 10mm bolts and 4 10mm studs (Romeos need 8mm) that put the timing cover to the head for a total of 8 with 4 on each side. Drill out heater tube bracket at the back of the head and get bigger bolt (10mm x 1.5 and 20/25mm) to hold down the bracket.
If you want to piece together the extra timing cover bolts and studs (mentioned above in the parts checklist), here are the sizes:
(A) 5 long double studs (10x1.5 thread both studs, 18mm Hex) that go into the top 4 holes of the T.C. and 1 goes in the outside lower Driver side.
(B) 1 shorter double stud (10x1.5 / 6x1.00 thread, 18mm hex) that goes in the Pass. side outside lower hole.
(C) 2 Standard Timing Cover bolts (10x1.5 thread, 13mm hex) these go in the inside lower holes of both banks.
Windsor heads have separate cam journals and Romeo heads have two bridge style caps,
but the camshafts will work on either.
Windsor cam gears are press fit and not bolt-on like 96-98 and 01-04.
I hope this is a start for you. Technically you can reuse a lot of the gaskets if you are trying to save some money. Headgaskets need to be replaced without a doubt though.
I have had good luck with the FRPP headchanging kit:
The head changing kit can save you some money. It includes head gaskets (older gen. 7 style), head bolts, exhaust manifold gaskets, oil dipstick tube, and head bolt bushings that help you install the heads in the engine bay. It keeps the head bolts from protruding past the bottom of the head while installing. Easily removed and easier to use. Keep in mind, the oil dipstick tube that comes with this kit does not line up to the head bracket area, but it can work in a pinch with some customizing. I had no issues with it. It is part number FMS-M-6067-D46 for a little over $100.
http://store.summitracing.com/partdetail.asp?part=FMS-M-6067-D46&autoview=sku
Good Luck!
