Ford Thunderbird Manual page 95

03·01 A·56
DISASSEMBLY AND ASSEMBLY
5. Remove valve spring retainer (65 1 4), val�e stem
seal (657 1) and valve. Discard valve stem seals
and identify all valve parts from the disassembled
cylinder and note whether they are intake or
exhaust.
Part
Item Number
1 6507
2 6505
3 69536
4 657 1
5 65 13
6 6514
7 65 18
8 6049
6. Clean, inspect and service cylinder head (6049)
as required or prepare to transfer all usable parts
to a new cylinder head.
Assembly
All valves, valve stem seals and valve guides are to be
lubricated with Engine Assembly Lubricant
D9AZ- 19579-D or equivalent meeting Ford
specification ESR-M99C80-A. Apply Multi-Purpose
Grease DOAZ- 1 9584-AA or equivalent meeting Ford
specification ESB-M 1 C93-A and ESR-M 1 C 1 59-A to
valve tips before installation.
1 . Install each valve in port from which it was
removed or to which it was fitted.
Engine, 3.8L
(Continued)
A6719-E
Description
Intake Valve
Exhaust Valve
Lower Valve Spring Retainer
Valve Stem Seal
Valve Spring
Upper Valve Spring Retainer
Valve Spring Retainer Key
Cylinder Head
2. NOTE: Due to different leakage rates between
intake and exhaust valve stems, valve stem seals
must not be interchanged.
Install exhaust valve stem seal. Make sure valve
stem seal is bottomed on guide.
3. Install intake valve stem seal. Valve stem seal
must be bottomed on guide.
Install lower valve spring retainer.
4.
Install valve spring over valve and then install
5.
upper valve spring retainer. Compress valve
spring and install valve spring retainer keys.
6. CAUTION: Do not install the spacers unless
necessary. Use of spacers in excess of
recommendations will result in
over-stressing valve springs and overloading
camshaft lobes which could lead to valve
spring breakage and/ or worn camshaft
lobes.
Measure assembled height of valve spring from
top of lower valve spring retainer to underside of
upper valve spring retainer with dividers. Check
dividers against a scale. If assembled height is
greater than specificati n, install necessary 0. 79
mm (0.030 inch) thick s
cylinder head spring pad nd lower valve spring
retainer to bring assem ed height to
recommended speci
7. CAUTION: Do not tighten bolts. The bolts
must be loose enough to allow rocker arm to
be rotated to side.
Position rocker arms and rocker arm seats on
cylinder heads and install rocker arm seat
retaining bolts.
8. Install exhaust manifold, if removed, and spark
plugs.
Pistons, Piston Pins and Rings
SPECIAL SERVICE TOOL(S) REQUIRED
Description
Piston Pin Remover I Replacer
Disassembly
Remove connecting rod bearings (62 1 1) from
1 .
connecting rod (6290) and cap.
2. Remove piston rings using a suitable piston ring
expander.
3. Mark piston (6 1 08) to ensure assembly with
same connecting rod and installation in same
cylinders from which they were removed.
03-01 A-56
cer(s) between
tion.
Tool Number
T68P·6 135-A
1 997 Thunderbird, Cougar July 1996