Ford COUGAR 1968 Shop Manual page 321

PART 8-2
-
170 And 200 Six
THERMACTOR CHECK
VALVE REPLACEMENT
I. Disconnect the air supply hose
at the valve. Remove the check valve
assembly (the valve has a standard,
right-hand pipe thread).
2. Clean the threads on the air
manifold adapter with a wire brush.
Install the check valve and torque it
to specifications. Connect the air
supply hose.
THERMACTOR AIR MANIFOLD
REMOVAL
1. Disconnect the air supply hose
a t the check valve and position the
hose out of the way.
2. Loosen all of the air manifold
to cylinder head tube coupling nuts
(compression fittings). Then unscrew
each one until it is free of the cylin-
der head. Grasp the air manifold at
each end and pull it away from the
cylinder head.
INSTALLATION
1. Position the air manifold(s) on
the cylinder head. Be sure all the tube
coupling nuts are aligned with the
cylinder head. Screw each coupling
nut into the cylinder head I to 2
threads. Tighten the tube coupling
nuts.
2. Connect the air supply hose to
the air manifold.
THERMACTOR AIR SUPPLY
TUBE REPLACEMENT
Normally, air supply tubes would
be replaced as necessary during cyl-
inder head overhaul. An air supply
tube may be replaced without re-
moving the cylinder head by remov-
ing the air manifold and using a
hooked tool to pull the tube from the
casting.
Additionally, the air tubes could
be inspected for badly eroded tips
with the aid of a mirror, when the
exhaust manifold(s) is removed.
THERMACTOR AIR P U M P
DRIVE PULLEY REPLACEMENT
1. Loosen the air supply pump
adjusting arm and mounting bolts
and nuts to relieve the belt tension.
2. Remove the drive pulley at-
taching bolts and pull the drive
pulley off the air pump shaft.
3. Position the drive pulley on the
air supply pump shaft, and install
the retaining bolts. Torque the bolts
in sequence, across from each other,
to specifications.
4. Position the drive belt and ad-
just the belt tension (Section 3) to
specifications. Tighten the adjusting
arm and mounting bolts and nuts.
THERMACTOR AIR
SUPPLY P U M P
Overhaul or rebuild of the air pump
is not recommended; therefore,
do
not disassemble it.
However, the
centrifugal filter fan is replaceable.
REMOVAL
1.
Disconnect the air outlet hoses
at the air pump.
2. Loosen the adjusting arm to
air pump and air pump to mounting
bracket bolts to relieve the drive
belt tension.
3. Disengage the drive belt. Re-
move the mounting bolts and air
P"""P.
INSTALLATION
Before installing the pump, be sure
that the correct pressure setting plug
is installed in the pressure relief
valve.
The correct pressure setting plug
for these engines should be color
coded blue.
1. Position the air pump on the
mounting bracket and install the mount-
ing bolt and nut.
2. Place the drive belt in the
pulleys and attach the adjusting arm
to the ai; pump. Adjust the drive
belt tension to specifications and
tighten the adjusting arm and mount-
ing bolts.
3. Connect the air inlet and out-
let hoses to the air pump.
THERMACTOR AIR P U M P
RELIEF VALVE
REPLACEMENT
D o not disassemble the air pump to
replace the relief valve, but remove it
from the engine.
1. Position Too T66L-9A486-D on
the air pump and remove the relief
valve with the aid of a slide ham-
mer (T59L-100-B).
2. Position the relief valve on the
pump housing and hold Tool T66L-
9A486-B on the relief valve. Use a
hammer to
tap the tool lightly
until,
the relief valve is seated.
THERMACTOR RELIEF VALVE
PRESSURE SETTING PLUG
REPLACEMENT
1. Compress the shoulders of the
pressure setting plug together and
pull the plug out of the relief valve.
2. Insert the proper plug in the
relief valve hole and press against
its center with an appropriate tool.
THERMACTOR AIR P U M P
CENTRIFUGAL FILTER
F A N REPLACEMENT
REMOVAL
1. Remove the drive pulley.
2. Pry loose and remove the outer
disc.
3. Pull the remaining portion from
the metal drive hub. It is seldom
possible to remove the filter fan with-
out damage.
Care should be taken to
prevent fragments from entering the
air intake hole.
Do not attempt to
remove the metal drive hub.
INSTALLATION
1. Position the filter fan and
the outer discon the drive hub.
2. Using the drive pulley and the
retaining screws as tools draw the
filter fan into position. Do this
evenly by alternately torquing the
retaining screws.
3.
M a k e certain that the outer
edge of the filter fan slips into the
housing.
A slight amount of inter-
ference with the housing is normal,
and some initial noise during run-in
may be expected.
EXHAUST MANIFOLD
REMOVAL
1. Remove the air cleaner and hot
air duct. Disconnect the muffler inlet
pipe from the exhaust manifold, and
remove the automatic choke hot air
tube.
2. Bend the exhaust manifold re-
taining bolt lock tabs back and re-
move the retaining bolts. Remove
the exhaust manifold.
INSTALLATION
1. Clean the mating surfaces of
the exhaust manifold and cylinder
head. Scrape the gasket material
from the mounting flange of the ex-
haust manifold and muffler inlet
pipe.
2. Apply graphite grease to the