Ford Thunderbird Manual page 97

03-01 A-58
DISASSEMBLY AND ASSEMBLY (Continued)
Inspection
1 .
Thoroughly clean pressure relief valve bore and
pressure relief valve to remove any metal chips
which may have entered bore as a result of
drilling operation.
2. Inspect pressure relief valve and valve bore for
wear, scoring or galling. If inspection determines
part(s) to be unserviceable, replace pressure
relief valve and I or oil pump and filter body.
3. Check clearance between pressure relief valve
and bore. The valve should slip into bore without
side play or binding.
4. Check spring for signs of fatigue or collapse.
Installation
1 . Lubricate pressure relief valve with clean engine
oil and install in bore. The end with smaller
diameter goes in first.
2. Position spring in bore.
Install a new plug. The plug can be tapped into
3.
bore using a plastic-tipped hammer. Make sure
plug is Q-0.25 mm (O-Q.0 1 0 inch) below machined
surtace.
Oil Pump Intermediate Shaft
Removal
1 .
Remove camshaft position sensor (CMP
sensor)( 1 2 1 26) and camshaft position sensor
housing as described in Section 03- 1 4.
2. Separate oil pump intermediate shaft (6A6 1 8)
from camshaft position sensor housing shaft.
Installation
1 . Push lock ring end of oil pump intermediate shaft
into camshaft position sensor housing shaft.
2. NOTE: Install camshaft position sensor housing
and oil pump intermediate shaft as an assembly,
making sure that end of oil pump intermediate
shaft is seated in oil pump drive gear.
Install oil pump intermediate shaft and camshaft
position sensor as described in Section 03- 1 4.
3. Install hold-down clamp ( 1 2270). lighten to
20-30 N·m ( 1 5-22 lb-ft).
Cylinder Block Assembly
Disassembly
1 . Mount the engine in a workstand and remove all
parts not furnished with the new cylinder blocks
(60 1 0) following the procedures in Removal and
Installation.
Engine, 3.8L
2. Remove the cylinder head to block dowels
(6A008) and the cylinder block drain plugs.
3. Remove the used cylinder blocks from the
workstand.
Assembly
1 . Clean the gasket and seal surtaces of all
serviceable parts and assemblies.
2. Position the new cylinder blocks in a work stand
and install the cylinder head to block dowels and
cylinder block drain plugs.
3. Transfer all serviceable parts removed from the
used cylinder blocks.
4. Check all assembly clearances and correct as
necessary.
Cylinder Block, Bare
Before replacing a cylinder blocks, determine if it is
serviceable. If so, make the necessary service. Refer
to Section 03-00.
Disassembly
1 . Completely disassemble the used engine
·
following the procedures in Removal and
Installation.
2. Remember to ridge ream the cylinder bores
before removing pistons.
3. Remove the cylinder head to block dowels and
the cylinder block drain plugs.
Assembly
1 . Clean the gasket and seal surtaces of all
serviceable parts and assemblies.
2. Position the new cylinder blocks in a work stand
and install the cylinder head to block dowels and
the cylinder block drain plugs.
3. Transfer all serviceable parts removed from the
used cylinder blocks following the procedures in
Removal and Installation.
4. Check all assembly clearances and correct as
necessary.
03-01A-58
1997 Thunderbird, Cougar July 1996