Ford COUGAR 1968 Shop Manual page 338

GROUP8
-
Engine
19, 21 and 24 under Engine Dis-
assembly. Remove the cylinder as-
sembly from the work stand.
Clean the gasket and seal sur-
faces of all parts and assemblies.
A S S E M B L Y
Install the replacement cylinder
block assembly on a work stand.
Transfer all parts removed from the
old cylinder assembly to the new
cylinder assembly, following the
procedures in steps 1 thru 4,. 6 thru
9, 11 thru 21, 28 thru 50, 53 and
56 thru 58 under Engine Assem-
bly. Check all assembly clearances.
ENGINE DISASSEMBLY
1.
Disconnect the distributor vac-
uum line at the carburetor.
2.
Disconnect the carburetor fuel
inlet line at the fuel filter, and at the
fuel pump. Remove the fuel inlet line.
Disconnect the distributor vacuum
hose at the distributor.
3. Remove the crankcase venti-
lation system by following the pro-
cedures under Crankcase Ventila-
tion System Removal in Section 2
of this part of the manual.
On a Thermactor engine dis-
connect the air and vacuum hoses.
Remove the air supply pump, air
manifold assembly, intermediate ex-
haust air supply tube assembly, air
bypass valve, and air and vacuum
hoses and brackets. Identify the vac-
uum lines for proper replacement.
4.
Remove the automatic choke
heat tube; then remove the carbu-
retor and gasket. Remove the ex-
haust manifold.
5. Remove the coil. Remove the
distributor cap and spark plug wires
as an assembly. Remove the distribu-
tor, fuel pump. oil pressure sending
unit, oil filter and oil filter mounting
insert. Remove the spark plugs. Re-
move the distributor vacuum advance
control valve (deceleration valve).
6. Remove the valve rocker arm
cover. Remove the valve rocker arm
shaft assembly (Fig. 18) by remov-
ing the support bolts evenly and
equally 2 turns at a time.
7. Remove the valve push rods in
sequence and identify them so that
they can be installed in their original
positions (Fig. 19).
8.
Remove all cylinder head bolts.
Lift the cylinder head assembly off
the engine. D o not pry between the
head and block as the gasket sur-
faces may become damaged. Using
a magnet, remove the valve lifters
and keep them in order so they can
be installed in their original location
(Fig. 32). If the valve lifters are stuck
in their bores by excessive varnish,
etc., it may be necessary to use a claw-
type tool to remove the lifters.
On a flywheel for a manual-shift
transmission, mark the pressure plate
cover so that it can be replaced in
the same position. Remove the
clutch pressure plate and cover as-
sem bly
.
Remove the flywheel. Remove the
clutch pilot bushing (Fig. 45) and
engine rear cover plate.
9.
Remove the dipstick and the
oil pan. Discard the gasket and
seals.
10. Remove the oil pump and in-
let tube assembly. Discard the oil
pump gasket.
11. Loosen the alternator mount-
ing bolts and disconnect the alter-
nator adjusting arm at the water
pump.
12. Remove the alternator, the
water pump and the accessory drive
pulley (if so equipped). Remove the
crankshaft damper. Remove the
damper by using tool T58P-63 16-A.
13. Remove the cylinder front
cover. Discard the gasket. Check the
camshaft end play by following step
15 under Camshaft Removal. Check
timing chain deflection by following
steps 4 and 5 under Cylinder Front
Cover Removal.
14.
Remove the camshaft sprock-
et retaining bolt and washer. Slide
both sprockets and the timing chain
forward and remove them as an
assembly (Fig. 28).
15. Remove any ridges and/or
deposits from the upper end of the
cylinder bores. Remove the cylinder
ridges with a ridge cutter. Follow the
instructions furnished by the tool
manufacturer. Never cut into the
ring travel area in excess of 1/32
inch when removing ridges.
16. M a k e sure all bearing caps
(main and connecting rod) are
marked so they can be installed in
their original locations. Turn the
crankshaft until the connecting rod
being removed is down. Remove the
connecting rod cap.
17. Push the connecting rod and
piston assembly out the top of the
cylinder with the handle end of a
hammer.
Avoid damage to the crank-
pin or the cylinder wall when remov-
ing the piston and rod.
18. Remove the bearing inserts
from the connecting rods and caps.
Remove the main bearing caps.
19. Carefully lift the crankshaft
out of the cylinder block so that the
thrust bearing surfaces are not dam-
aged. Handle the crankshaft with
care to avoid possible fracture or
damage to the finished surfaces.
20. Remove the rear journal oil
seal from the block and rear main
bearing cap. Remove the main bear-
ing inserts from the block and bear-
ing caps.
21. Remove the camshaft thrust
plate. Carefully remove the camshaft
by pulling it toward the front of the
engine.
Use caution to avoid dam-
aging the journals and lobes.
22.
Remove the camshaft rear
bearing bore plug (Fig. 34).
23.
Remove the camshaft bear-
ings (Fig. 60).
24. Remove the dipstick tube
and the plug or drain.
ENGINE ASSEMBLY
Clean and inspect all parts per the
appropriate procedures in Part 8-1,
except do not disassemble the oil
pump and hydraulic valve lifters for
cleaning.
1. Install the camshaft bearings
and rear bore plug by following steps
6 and 7 ,under Camshaft Bearing
Replacement.
2. The camshaft and related parts
are shown in Fig. 31. Oil the cam-
shaft journals and apply Lubriplate
to all camshaft lobes. Carefully slide
the camshaft through the bearings.
3. Install the thrust plate. Torque
the retaining screws to specifications.
4.
The crankshaft and related
parts are shown in Fig. 54 or 55.
Be sure that the rear journal oil seal
grooves are clean. Install a new rear
journal oil seal in the block (Fig.
56) and rear main bearing cap (Fig.
38). After installation, cut the ends
of the seals flush.
5.
If the crankshaft main bearing
journals have been refinished to a
definite undersize, install the correct
undersize bearings. Be sure the bear-
ing bores are clean. Place the upper
main bearing inserts in position in
the bore with the tang fitting in the
slot provided.
6.
Install the lower main bearing
inserts in the bearing caps.
7. Carefully lower the crankshaft
into place.
Be careful not to damage
the bearing surfaces.
8.
Check the clearance of each
main bearing following steps 10 thru
13 under Main Bearing Replace-
ment. In step 10, place the Plasti-
gage on the crankshaft journal in-
stead of in the bearing cap (Fig. 57).
9. 'After the bearings have been
fitted, apply a light coat of engine
o i l to the journals and bearings.