Ford Thunderbird Manual page 77

03·01A-38
IN-VEHICLE SERVICE (Continued)
CAUTION: As piston is tapped into bore with
3.
a hammer handle, guide connecting rod onto
crankshaft journal to avoid damage to
bearing surfaces.
NOTE: Install pistons in the same cylinders from
which they were removed or to which they were
fitted. If a connecting rod is transposed from one
cylinder blocks or cylinder to another, new
connecting rod bearings (62 1 1) should be fitted
and connecting rod should be numbered to
correspond with new cylinder number.
Install piston with notch in piston dome facing the
front of engine, using Piston Ring Compressor
08 1 L -6002·C or equivalent.
4. Check connecting rod bearing clearances. Refer
to Section 03..()().
5. Lubricate bearing surfaces with Engine Assembly
Lubricant 09AZ· 1 9579-D or equivalent meeting
Ford specification ESR-M99C8Q-A.
Piston and Connecting Rod
CYLIN DER BLOC K
PISTON
6010
6108
NOTE: PISTON TO BORE CLEARANCE.
PISTON AND LOCATION SPECIFIED ON
CYLINDER BLOCK - 0.018-0.044 mm
(0.00071-0.00173 INCH)
1 1 . Install cylinder heads as described.
12. Install lower intake manifold and upper intake
manifold as described.
13. Fill crankcase with the correct amount of clean
engine oil meeting Ford specification
WSS-M2C 1 53-F.
Engine, 3.8L
NOTE: PISTON TO DECK CLEARANCE
TO BE 0.27 mm (0.01 1 INCH) BELOW
DECK TO 0.25 mm (0.010 INCH) ABOVE
DECK WHEN MEASURED AT PISTON T.D.C.
PARALLEL TO CRANKSHAFT ON
TRUE CENTERLINE OF PISTON.
(AVERAGE OF TWO READINGS)
NOTE: ARROW TOWARDS FRONT
OF ENGINE (AS SHOWN)
VIEW
A
NOTE: PREVENT
TO DAMAGE TO
PISTONS AFTER ASSEMBLY,
SO
CRANKSHAFT KEYWAY ALL
PISTONS ARE BELOW DECK
6. Make sure connecting rod is seated on
crankshaft journal. Install connecting rod cap and
tighten retaining bolts as follows:
•
Tighten to 20·25 N·m ( 1 5- 1 8 1b-ft).
•
Tighten to 40·45 N·m (3Q-33 1b-ft).
•
Rotate an additionai 9Q- 1 20 degrees.
7. If necessary, check connecting rod side
clearance as described in Section 03-oo.
8. Install oil pump screen cover and tube (6622) with
a new oil pump inlet tube gasket (6626) and
tighten retainers as follows:
•
Tighten oil pump screen cover and tube
cylinder block bolts to 2Q-30 N·m ( 1 5·22 1b-ft).
•
Tighten oil pump screen cover and tube
support bracket retaining nut to 4Q-55 N·m
(3Q-40 lb-ft).
9. Install oil pan as described.
10. Check piston deck clearance and bore clearance
as shown.
CONNECTING ROD BEARING
VERTICAL ASSEMBI.ED CLEARANCE TO
POSITION
BE 0.022 ..0 .069 mm (0.0009-0 . 0027 1
14. Fill cooling system with the specified engine
coolant. Refer to Section 03.03.
1 5. Start engine and check for oil and coolant leaks.
03·01A·38
NOTE: LETTERS FOR
CAP ORIENTATION
IN THIS AREA
1 .5 mm (O.G59 1NCH)
NO
DISTORTION
OF PARTING
SURFACE
PERMITTE D
- 1 1-­
CONNEcnNG ROD TO
CRANKSHAFT SIDE
CLEARANCE 0.11..0.29 mm
(0.0047-G.01 14 1NCH)
VIEW A
8211 N
CH)
AA1007·A
1997 Thunderbird, Cougar July 1996