Ford Thunderbird Manual page 87

03-01 A-48
REMOVAL AND INSTALLATION (Continued)
c. Tighten an additional 9Q- 1 20 degrees.
14. Install timing chain and engine front cover with
water pump as described.
15. Install camshaft position sensor (CMP
sensor)(6B288) as described in Section 03- 1 4.
16. Install oil pan as described.
17. Install engine rear plate and flywheel as
described.
18. Install spark plugs. Refer to Section 03-07 A.
19. Connect ignition wires to spark plugs. Refer to
Section 03-07 A.
20. Install engine in the vehicle as described.
DISASSEMBLY AND ASSEMBLY
Engine
SPECIAL SERVICE TOOL(S) REQUIRED
Description
Crankshaft Damper Remover
Front Cover Seal Replacer
Spark Plug Wire Remover
Damper I Front Cover Seal Replacer
Vibration Damper Remover Adapter
Cylinder Ridge Reamer
Disassembly
Before starting disassembly, remove accessories and
any emission control equipment which is not directly
attached to the engine.
1 . Remove flywheel (6375) and engine rear plate
(7007).
2. Remove intake manifolds (9424).
3. NOTE: When LH exhaust manifold (9430) is
removed, note location of oil level indicator tube
support bracket.
Remove LH and RH exhaust manifolds.
4. Disconnect front evaporative emission hose and
remove the following positive crankcase
ventilation system components:
•
Front and rear crankcase ventilation tube
(6758).
•
Positive crankcase ventilation valve (PCV
valve)(6A666).
5.
Disconnect water bypass tube (8548) and water
bypass hose (8597) at lower intake manifold.
Remove heater water outlet tube retaining bolts
and heater water outlet tube ( 1 8663) from water
pump (850 1).
Engine, 3.8L
6.
7.
8.
Tool Number
T58P-6316-D
T70P-6B070-B
T7 4P-6666-A
T82L-631 6-A
T82L-631 6-B
T64L-601 1 -EA
9.
10. Remove valve covers (6582).
1 1 . CAUTION: Do not damage machined sealing
1 2. Remove spark plugs.
1 3. Remove rocker arms (6564) and push rods
NOTE: When removing an ignition wire from a
spark plug ( 1 2405), use Spark Plug Wire
Remover T7 4P-6666-A. Grasp and twist boot
back and forth on spark plug insulator to free
boot. Use tool to pull boot from spark plug. Do not
pull on ignition wire directly or it may become
separated from connector inside boot.
Disconnect ignition wires from spark plugs. Refer
to Section 03-07 A.
Remove the following components:
•
throttle body (9E926) and throttle body gasket
(TB gasket)(9E936)
•
EGR valve (EGR valve)(9D475)
•
upper intake manifold and intake manifold
upper gasket (9H486)
•
fuel injectors (9F593) and fuel injection supply
manifold (9F792)
NOTE: If the crankshaft pulley and vibration
damper have to be separated, mark the damper
and pulley so that they may be reassembled in
the same relative position. This is important as
the damper and pulley are initially balanced as an
assembly.
NOTE: If the crankshaft damper is being
replaced, check if the original damper has
balance pins installed. If so, new balance pins
(EOSZ-6A328-A or equivalent) must be installed
on the new damper in the same position as the
original damper. The crankshaft pulley (new or
original) must also be installed in the same
relative position as originally installed.
Remove crankshaft pulley and vibration damper.
Use Crankshaft Damper Remover T58P-63 1 6-D
and Vibration Damper Remover Adapter
T82L -63 1 6-B to remove vibration damper.
Remove hold-down clamp ( 1 2270) and camshaft
position sensor (CMP sensor)(6B288) and
housing.
surfaces or possible leakage may occur.
NOTE: Before attempting to remove lower intake
manifold, break seal between lower intake
manifold and cylinder blocks (60 1 0). Wedge a
large prybar between lower intake manifold and
cylinder blocks. Pry downward on prybar using
lug on water pump as a leverage point.
Remove lower intake manifold and intake
manifold gasket (9439). Discard intake intake
manifold gasket and end seals.
(6565). The location of each rocker arm, push
rod and rocker arm seat (6A528) should be
noted. When engine is assembled, each
component should be installed in its original
position.
1997 Thunderbird, Cougar July 1996
03-01A-48